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P-K STORM
GAS FIRED BOILER
®
w/ NURO
CONTROL SYSTEM
™
Natural Gas
ST-2500, ST-3000, ST-3500, ST-4000, ST-5000, ST-6000,
& ST-8000
Part #
2691000273
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
C.S.A Design-Certified
Complies with ANSI Z21.13/CSA 4.9
Gas-Fired Low Pressure Steam and Hot Water Boilers
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 design without notice and without incurring any obligation.
Released: February 2, 2024
Patterson-Kelley 2024: All Rights Reserved.
INSTALLATION
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MAN U A L
INSTALLATION
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INSTALLATION
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MAN U A L
INSTALLATION
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MAN U A L
INSTALLATION
& O W N E R'S
MAN U A L
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MAN U A L
INSTALLATION
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MAN U A L
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Related Manuals for Patterson-Kelley P-K STORM ST-8000
Summary of Contents for Patterson-Kelley P-K STORM ST-8000
- Page 1 Patterson-Kelley 2024: 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...
- 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, ST- maintained and checked per the 5000, ST-6000, & ST-8000 recommended schedule. Refer to All P-K STORM ®...
- 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.
- Page 5 ® P-K STORM Gas Fired Boiler Technical Service 1.877.728.5351 Overfire Hazard! Possible fire and explosion from excess gas pressure. Make sure that gas inlet pressure does not exceed 14 inches W.C. Overfire Hazard! Possible fire and explosion. Possible malfunction of regulators and/or gas safety shut off/control valves.
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Page 6: Table Of Contents
Category II Installations ....................41 Category IV Installations ....................42 Stainless Steel Venting ..................... 42 CPVC Vent System Installation..................42 Revised: February 2, 2024 Patterson-Kelley 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 Installation and Owners Manual Rev G.docx All Rights Reserved. - Page 7 ..................74 FTER EPAIRS OR AINTENANCE ....................75 EQUENCE OF PERATIONS ....................... 76 ROUBLESHOOTING Revised: February 2, 2024 Patterson-Kelley 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 Installation and Owners Manual Rev G.docx All Rights Reserved. Page vi...
- Page 8 APPENDIX C – WATER QUALITY STANDARDS QUALITY STANDARDS FOR HYDRONIC BOILERS IN MULTI-METAL SYSTEMS ................... 119 APPENDIX D – BEST PRACTICES FOR NEW & RETROFIT SYSTEMS ........120 Revised: February 2, 2024 Patterson-Kelley 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 Installation and Owners Manual Rev G.docx All Rights Reserved.
- Page 9 UPPLY ......................122 LECTRICAL OWER UPPLY .......................... 123 XHAUST ENTING ......................126 ROPYLENE LYCOL Revised: February 2, 2024 Patterson-Kelley 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 Installation and Owners Manual Rev G.docx All Rights Reserved. Page viii...
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Page 10: Introduction
Failure to do so could result in system. Patterson-Kelley cannot be responsible for the personal injury or death. design or operation of such systems and a qualified engineer or contractor must be consulted. - Page 11 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 12: 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 13: Site Preparation
électrique de la pompe. Fermer plutôt le robinet service access, increasing the d’admission de gaz à l’extérieur de l’appareil. possibility of injury. Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. -
Page 14: 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 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. -
Page 15: Location Setup
NOTE: Do NOT allow any rigging equipment to interfere with unit components as this can damage the unit Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. - Page 16 A variety of lifting equipment may be required to properly lift the unit using the channels. NOTE: Do NOT allow any lifting equipment to contact unit components as this can damage the unit Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved.
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Page 17: Foundation
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 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. -
Page 18: Clearances
** 18” required on either the left or right side. *** ST-8000 ONLY Note: Failure to provide recommended service clearances may make it difficult to perform service on the boiler(s). Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. -
Page 19: 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 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx... -
Page 20: Category Ii/Iv Flue Gas Exhaust Vent Planning
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 3.4.3... - Page 21 +0.01” to +1.0” W.C. NOTE: ST-2500-ST-4000: Total combined vent pressure not to exceed 0.44” W.C. ST-5000-ST-8000: Total combined vent pressure not to exceed 1.0” W.C. Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved.
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Page 22: Venting Materials For Flue/Exhaust Systems
It is not permissible to use material from different manufacturers within the same system Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. - Page 23 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 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved.
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Page 24: Required Clearances
Improper interconnection of venting systems may result in leakage of flue gases into occupied spaces. Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. - Page 25 ¼ po par pied (21 mm/m) entre la chaudière et l'évent; les chaudières de catégories II et IV doivent être installées de façon à empêcher l'accumulation de condensat; et si nécessaire, les chaudières de catégories II et IV doivent être pourvues de dispositifs d'évacuation du condensate. Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved.
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Page 26: Gas Piping Considerations
® 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 27: 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 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. -
Page 28: 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 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. -
Page 29: Appliance Connections (St-5000 - St-8000)
Gas Fired Boiler Technical Service 1.877.728.5351 Appliance Connections (ST-5000 - ST-8000) All connections must be in compliance with national, state, and local code requirements. Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. -
Page 30: Electrical Connections
208 VAC main voltage. Refer to Section 7.2.4 for proper wiring and configuration of the internal control transformer. Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx... - Page 31 Do not over-tighten the hot lead terminal screws. Maximum tightening torque = 13 in-lbs! NOTE: The hot lead terminals can accommodate maximum 10AWG wire. The ground terminal can accommodate maximum 8AWG wire. Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved.
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Page 32: 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 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. - Page 33 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 2024 Revised: February 2, 2024...
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Page 34: 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 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. - Page 35 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 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved.
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Page 36: Combustion Air
When air is taken from the outdoors through a horizontal duct into combustion air applications. the mechanical room, 1 square inch per 2,000 Btu per hour (1,100 /kW) of total boiler input is required. Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. -
Page 37: Air Inlet Requirements - Canada
E. When combustion air is supplied by mechanical means, an airflow-sensing device must be installed. It must be wired into the pre-ignition limit/interlock to prevent the burner from starting or to stop an operating burner in case of air supply failure. Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. -
Page 38: Direct Vent / Sealed Combustion Installations
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 39 Patterson-Kelley offers an "Air Intake Filter" accessory on the Storm Boilers. If this accessory is installed, the boiler may be run in these conditions provided that the air filter is installed and maintained properly.
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Page 40: Motorized Combustion Air Dampers
P-K Storm Gas Fired Boiler Technical Service 1.877.728.5351 Motorized Combustion Air Dampers Patterson-Kelley recommends, and most installation codes require, the use of motorized combustion air dampers with end limit switches installed in the combustion air intake ductwork upstream of each appliance. This damper isolates the combustion air supply when the appliance is in standby. - Page 41 Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx...
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Page 42: 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 43: Category Ii Or Iv Venting Installation
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 3.4.3... - Page 44 If the combustion air intake ductwork and the exhaust vent terminate on the same wall of the NOTE: 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 3.4.3...
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Page 45: 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 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. -
Page 46: 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 47: Sealed Combustion/Direct Vent Systems
This boiler may be installed with sidewall vent using room air. Exhaust Vent 36” Minimum 12” Minimum Air Inlet Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx Page 36... - Page 48 36” above nearby parapet wall 12” above expected snowline Loop/trap for condensate or rain water disposal (pipe to drain) Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx...
- Page 49 12” from sidewall Motorized combustion air damper Loop/trap for condensate or rain water disposal (pipe to drain) Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx...
- Page 50 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 3.4.3...
- Page 51 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 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved.
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Page 52: 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 53: Category Iv Installations
10” 910510CPVC ST3500-ST4000 12” 912512CPVC ST5000-ST8000 14” 912512CPVC* *Requires 14” to 12” reducer 2691000373 Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx Page 42... -
Page 54: Polypropelene Vent System Installation
10” ISSA1010 ST3500-ST4000 12” ISSA1212 ST5000-ST8000 14” ISSA1212* *Requires 14” to 12” reducer 2691000373 Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx Page 43... -
Page 55: 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 56 ® P-K Storm Gas Fired Boiler Technical Service 1.877.728.5351 Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx Page 45...
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Page 57: Removing An Existing Boiler
Faire fonctionner le brûleur principal pendant 5 min ensuite, déterminer si le coupe-tirage déborde à l'ouverture de décharge. Utiliser la flamme d'une allumette ou d'une chandelle ou la fumée d'une cigarette, d'un cigare ou d'une pipe. Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. - Page 58 être modifié pour respecter les valeurs minimales des tableaux pertinents de l'appendice F du National Fuel Gas Code, ANSI Z223.1/ NFPA 54 et (ou) les codes d'installation CAN/CSA-B149.1. Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved.
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Page 59: 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 60: Natural 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 2024 Revised: February 2, 2024... -
Page 61: 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 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. - Page 62 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.
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Page 63: Boiler Water Piping (For Installer)
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 64: Water Quality
“water quality”. For information, please refer to Patterson-Kelley Multi-Metal Systems Water Quality Standards as it appears 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 65: Pre-Start Checklist
The low water cut-off 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 2024 Revised: February 2, 2024... -
Page 66: 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 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. -
Page 67: Gas Pressure Switch Tests
Time”. Reconnect the gray plug to the forward most gas valve actuator. If 10007: “Did not Start in Allotted Time” is displayed the boiler must be manually reset by pressing “Reset Control”. Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. -
Page 68: Fuel/Air Adjustments
A combustion analyzer must be used. Combustion must be set in accordance with Recommended Combustion Settings for P-K Storm Boilers in Section 3.11.2. Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. -
Page 69: 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 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. -
Page 70: 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 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. -
Page 71: 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 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. -
Page 72: 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 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. -
Page 73: Setup Wizard
208-240 Three Less than 25 ST-8000 8,000,000 7767 7,680,000 440-480 Three Less than 15 Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx Page 62... -
Page 74: 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 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. -
Page 75: Normal Lighting And Shut-Down Procedures
See the image to the right for the locations of the Natural Gas valve. Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. -
Page 76: Maintenance
REFRACTORY LINING MATERIAL étiquetez tous les fil savant de les debrancher. Les erreurs de • This Patterson-Kelley product contains a Combustion câblage risquent de causer un fonctionnement deficient et Area lined with REFRACTORY CERAMIC FIBERS dangereux. (RCFs) similar to many other devices produced in this industry. -
Page 77: 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 ®... -
Page 78: Semi-Annually
(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 79 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 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved.
- Page 80 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 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved.
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Page 81: 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 82 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 83 Be very careful when cleaning to avoid spraying any of the electrical or control components. Water may cause a short circuit and damage circuitry. Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved.
- Page 84 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. Remove the temporary drain hose and reconnect the condensate assembly.
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Page 85: 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 86: Sequence Of Operations
“POST PURGE TIME” timer has expired. 9. When the outlet water temperature is reduced by the load on the system, a heat request is generated. The operating sequence will recycle to Step 3. Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. -
Page 87: Troubleshooting
Next, check for obstructions of the combustion air intake and/or exhaust (flue) piping. Next, check the hoses leading to the air switches are not kinked or obstructed. An error related to the air switch does not necessarily mean that the air switch is defective. Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. -
Page 88: 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 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. -
Page 89: 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 90: 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 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. -
Page 91: Terminal Block Assignments - High Voltage (Tb2) Terminal Block
External Interlock Circuit #2 (In Series w/ #1) START INTERLOCK #2 NOTE: On the ST-6000 & ST-8000 there is NO Start Interlock #2. Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. -
Page 92: Wiring Diagrams
P-K Storm Gas Fired Boiler Technical Service 1.877.728.5351 6.2 Wiring Diagrams ST-2500-ST-4000 Natural Gas 208-240 Volt Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx... - Page 93 ® P-K Storm Gas Fired Boiler Technical Service 1.877.728.5351 Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx Page 82...
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Page 94: St-2500-St-4000 Natural Gas 480 Volt
® P-K Storm Gas Fired Boiler Technical Service 1.877.728.5351 ST-2500-ST-4000 Natural Gas 480 Volt Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx Page 83... - Page 95 ® P-K Storm Gas Fired Boiler Technical Service 1.877.728.5351 Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx Page 84...
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Page 96: St-5000 Natural Gas 208-240 Volt
® P-K Storm Gas Fired Boiler Technical Service 1.877.728.5351 ST-5000 Natural Gas 208-240 Volt Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx Page 85... - Page 97 ® P-K Storm Gas Fired Boiler Technical Service 1.877.728.5351 Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx Page 86...
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Page 98: St-5000 Natural Gas 480 Volt
® P-K Storm Gas Fired Boiler Technical Service 1.877.728.5351 ST-5000 Natural Gas 480 Volt Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx Page 87... - Page 99 ® P-K Storm Gas Fired Boiler Technical Service 1.877.728.5351 Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx Page 88...
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Page 100: St-6000 - St-8000 Natural Gas 240 Volt
® P-K Storm Gas Fired Boiler Technical Service 1.877.728.5351 ST-6000 – ST-8000 Natural Gas 240 Volt Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx... - Page 101 ® P-K Storm Gas Fired Boiler Technical Service 1.877.728.5351 Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx Page 90...
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Page 102: St-6000 - St-8000 Natural Gas 480 Volt
® P-K Storm Gas Fired Boiler Technical Service 1.877.728.5351 ST-6000 – ST-8000 Natural Gas 480 Volt Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx... - Page 103 ® P-K Storm Gas Fired Boiler Technical Service 1.877.728.5351 Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx Page 92...
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Page 104: Control Transformer Diagrams
Gas Fired Boiler Technical Service 1.877.728.5351 Control Transformer Diagrams ST-2500-ST-4000 240 VAC, Three Phase, 60 Hz ST-2500-ST-4000 480 VAC, Three Phase, 60 Hz Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. - Page 105 ® P-K Storm Gas Fired Boiler Technical Service 1.877.728.5351 ST-5000 - ST-8000 240 VAC, Three Phase, 60 Hz Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx...
- Page 106 220-240V, three phase, 60Hz 440-480V, three phase, 60Hz Improper configuration of the control transformer could result in serious injury or death. Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved.
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Page 107: 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 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx... -
Page 108: 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 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx Page 97... -
Page 109: Main Boiler Assembly (St-5000)
® P-K Storm Gas Fired Boiler Technical Service 1.877.728.5351 Main Boiler Assembly (ST-5000) Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx Page 98... -
Page 110: Main Boiler Assembly (St-6000)
® P-K Storm Gas Fired Boiler Technical Service 1.877.728.5351 Main Boiler Assembly (ST-6000) Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx Page 99... -
Page 111: Main Boiler Assembly (St-8000)
® P-K Storm Gas Fired Boiler Technical Service 1.877.728.5351 Main Boiler Assembly (ST-8000) Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx Page 100... -
Page 112: Control Panel (St-2500-St-4000)
® P-K Storm Gas Fired Boiler Technical Service 1.877.728.5351 Control Panel (ST-2500-ST-4000) Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx Page 101... -
Page 113: Control Panel (St-5000)
® P-K Storm Gas Fired Boiler Technical Service 1.877.728.5351 Control Panel (ST-5000) Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx Page 102... -
Page 114: Control Panel (St-6000 & St-8000)
® P-K Storm Gas Fired Boiler Technical Service 1.877.728.5351 Control Panel (ST-6000 & ST-8000) Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx Page 103... -
Page 115: 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 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx Page 104... -
Page 116: 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 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx Page 105... -
Page 117: Heat Exchanger Assembly St-5000 - St-8000
® P-K Storm Gas Fired Boiler Technical Service 1.877.728.5351 Heat Exchanger Assembly ST-5000 - ST-8000 Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx Page 106... -
Page 118: Natural Gas Train (St-2500-St-4000)
® P-K Storm Gas Fired Boiler Technical Service 1.877.728.5351 Natural Gas Train (ST-2500-ST-4000) Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx Page 107... -
Page 119: Natural Gas Train (St-5000)
® P-K Storm Gas Fired Boiler Technical Service 1.877.728.5351 Natural Gas Train (ST-5000) Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx Page 108... -
Page 120: Natural Gas Train (St-6000)
® P-K Storm Gas Fired Boiler Technical Service 1.877.728.5351 Natural Gas Train (ST-6000) Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx Page 109... -
Page 121: Natural Gas Train (St-8000)
® P-K Storm Gas Fired Boiler Technical Service 1.877.728.5351 Natural Gas Train (ST-8000) Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx Page 110... -
Page 122: Burner/Blower Assembly (St-2500-St-4000)
® P-K Storm Gas Fired Boiler Technical Service 1.877.728.5351 Burner/Blower Assembly (ST-2500-ST-4000) Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx Page 111... -
Page 123: Burner/Blower Assembly (St-5000 & St-6000)
® P-K Storm Gas Fired Boiler Technical Service 1.877.728.5351 Burner/Blower Assembly (ST-5000 & ST-6000) Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx Page 112... -
Page 124: Burner/Blower Assembly (St-8000)
® P-K Storm Gas Fired Boiler Technical Service 1.877.728.5351 Burner/Blower Assembly (ST-8000) Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx Page 113... -
Page 125: 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 126 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 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved.
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Page 127: Boiler Fire-Test Report
Gas Fired Boiler Technical Service 1.877.728.5351 8 Boiler Fire-Test Report A copy must be returned within 30 days of startup to Patterson-Kelley Patterson-Kelley • 155 Burson Street • E. Stroudsburg, PA 18301 P) 570-476-7261 F) 570-476-7247 pkchtsupport@spx.com Patterson-Kelley 2024... -
Page 128: Appendix A - Maintenance Log
Appendix A – Maintenance Log Hi Fire / Stack Date Action Low Fire Temp Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx Page 117... -
Page 129: 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 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. -
Page 130: 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 131: 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 132 (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.
- Page 133 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 134 If the combustion air intake ductwork and the exhaust vent terminate on the same wall of the NOTE: 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 3.4.3...
- Page 135 60 °F Switch Switch Switch Switch Minimum Flow Low Fire Setting) Setting) Setting) Setting) Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx Page 124...
- Page 136 60 °F Minimum Flow Ignition Switch Setting) Switch Setting Switch Setting) Minimum Flow Low Fire Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx Page 125...
- Page 137 131.4 ft 576 GPM 56.7 ft 692 GPM 81.6 ft 922 GPM 145.1 ft Patterson-Kelley 2024 Revised: February 2, 2024 2691000403 P-K Storm ST2500-ST8000 Released: February 2, 2024 All Rights Reserved. Installation and Owners Manual Rev G.docx Page 126...