User Manuals: Patterson-Kelley STORM ST-4000 Boilers

Manuals and User Guides for Patterson-Kelley STORM ST-4000 Boilers. We have 3 Patterson-Kelley STORM ST-4000 Boilers manuals available for free PDF download: Installation And Owner's Manual, Installation & Owner's Manual

Patterson-Kelley STORM ST-4000 Installation & Owner's Manual (133 pages)

GAS FIRED BOILER w/ NURO™ CONTROL SYSTEM Natural Gas

Brand: Patterson-Kelley | Category: Boiler | Size: 12 MB

Table of Contents
6
Introduction
10
Purpose of this Document
12
Common Abbreviations
12
Site Preparation
13
Initial Inspection Upon Receiving
13
Storage Prior to Installation
13
Compliance with Codes
14
Location Setup
15
Lifting
15
Foundation
17
Clearances
18
Inlet Air and Exhaust Venting Considerations
19
Applicable Codes and Standards
19
Combustion Air Inlet Planning (United States and Canada Considerations)
19
Category II/IV Flue Gas Exhaust Vent Planning
20
Venting Materials for Flue/Exhaust Systems
22
Required Clearances
24
Gas Piping Considerations
26
Water Quality Standard
26
Installation
26
Overview
26
Appliance Connections
26
Appliance Connections (ST-2500 & ST-3000)
27
Appliance Connections (ST-3500 & ST-4000)
28
Appliance Connections (ST-5000 & ST-6000)
29
Electrical Connections
30
Power Requirements
30
Three Phase Power Supply Connection
30
High Voltage (TB2) Terminal Block
32
Low Voltage (TB1) Terminal Block
34
Combustion Air
36
Air Inlet Requirements - United States
36
Air Inlet Requirements - Canada
37
P-K STORM ™ Combustion Air Requirements
38
Direct Vent / Sealed Combustion Installations
38
Motorized Combustion Air Dampers
39
Flue Gas / Exhaust Venting
41
Category II or IV Venting Installation
41
Vent Termination
43
Venting for Multiple Boilers
44
Sealed Combustion/Direct Vent Systems
45
Inlet Duct Connection to Boiler
49
Intake Duct Materials and Sizes
49
Category II Installations
49
Category IV Installations
50
Stainless Steel Venting
50
CPVC Vent System Installation
50
Polypropelene Vent System Installation
51
Condensate Drain, Trap & Disposal
52
Removing an Existing Boiler
54
Piping
55
Gas Piping Overview
55
Natural Gas Piping
56
Pressure Testing the Gas Piping
56
Boiler Water Piping
57
Boiler Water Piping (for Installer)
59
Water Quality
60
Pre-Start Checklist
61
Safety Checks
61
Ignition Safety System Test
61
Low Water Cut-Out Test
61
Flow Switch Test
62
Manual Reset High Temperature Limit Test
62
Gas Pressure Switch Tests
63
Fuel/Air Adjustments
64
Gas Pressure Adjustment
64
Manual Control Mode for High and Low Fire Adjustment
64
Adjusting High Fire
66
Adjusting Low Fire
66
Checking Flame Signal
66
Pilot Burner Adjustments (ST-6000 Only)
67
Pilot Test Hold
67
Pilot Gas Pressure Adjustment
67
Checking Pilot Flame Signal
67
Initial Nuro Control Setup and Adjustment
68
Startup
68
Home Screen
69
Information Screen
69
Setup Wizard
70
Typical Boiler Operating Conditions
70
Operations
71
NURO Control Panel
71
NURO Touch Screen Interface
71
Factory Tests
71
Normal Lighting and Shut-Down Procedures
72
Normal Lighting Procedures
72
Normal Shut down Procedures
72
Emergency Shut-Off
72
Maintenance
73
Preventative Maintenance
73
Daily
74
Weekly
74
Monthly
74
Semi-Annually
74
Annually or 2500 Run Hours (Whichever Comes First)
75
Cleaning the Combustion Chamber
79
After Repairs or Maintenance
83
Sequence of Operations
84
Troubleshooting
85
Loss of Power
85
Loss of Water Level
85
Low Gas Pressure
85
High Gas Pressure
85
High Water Temperature
85
Low Air
85
Flame Failure
86
Flame Error
86
Flue Problem/Condensate Blockage
86
Parts/Technical Support
87
Terminal Block Assignments
88
Terminal Block Assignments - Low Voltage (TB1) Terminal Block
88
Terminal Block Assignments - High Voltage (TB2) Terminal Block
89
Wiring Diagrams
90
ST-2500-ST-4000 Natural Gas 208-240 Volt
90
ST-5000 Natural Gas 208-240 Volt
92
ST-2500-ST-4000 Natural Gas 480 Volt
94
ST-5000 Natural Gas 480 Volt
96
ST-6000 Natural Gas 240 Volt
98
ST-6000 Natural Gas 480 Volt
100
Control Transformer Diagrams
102
Boiler Parts Identification
105
Main Boiler Assembly (ST-2500 & ST-3000)
105
Main Boiler Assembly (ST-3500 & ST-4000)
106
Main Boiler Assembly (ST-5000)
107
Main Boiler Assembly (ST-6000)
108
Control Panel (ST-2500-ST-4000)
109
Control Panel (ST-5000)
110
Control Panel (ST-6000)
111
Heat Exchanger Assembly ST-2500 & ST-3000
112
Heat Exchanger Assembly ST-3500 & ST-4000
113
Heat Exchanger Assembly ST-5000 & ST-6000
114
Natural Gas Train (ST-2500-ST-4000)
115
Natural Gas Train (ST-5000)
116
Natural Gas Train (ST-6000)
117
Burner/Blower Assembly 240V (ST-2500-ST-4000)
118
Burner/Blower Assembly 480V (ST-2500-ST-4000)
119
Burner/Blower Assembly 240V (ST-5000 & ST-6000)
120
Burner/Blower Assembly 480V (ST-5000 & ST-6000)
121
K Storm Specific Limited Warranty
122
Boiler Fire-Test Report
124
Appendix A - Maintenance Log
125
Appendix B - Boiler Altitude Derate Schedule
126
Appendix C - Water Quality Standards Quality Standards for Hydronic Boilers in Multi-Metal Systems
127
Appendix D - Best Practices for New & Retrofit Systems
128
Appendix E - Installation and Quick Reference
130
Fuel/Gas Supply
130
Electrical/Power Supply
130
Exhaust Venting
130
Propylene Glycol Flow
133

Patterson-Kelley STORM ST-4000 Installation And Owner's Manual (137 pages)

Brand: Patterson-Kelley | Category: Boiler | Size: 12 MB

Table of Contents
6
1 Introduction

10
- Purpose of this Document
  12
- Common Abbreviations
  12
2 Site Preparation

13
3 Installation

26
- Overview
  26
- Appliance Connections
  26
- Electrical Connections
  30
- Combustion Air
  36
- Flue Gas / Exhaust Venting
  42
- Removing an Existing Boiler
  57
- Piping
  59
  - Gas Piping Overview
    59
  - Natural Gas Piping
    60
  - Pressure Testing the Gas Piping
    60
  - Boiler Water Piping
    61
  - Boiler Water Piping (for Installer)
    63
- Water Quality
  64
- Pre-Start Checklist
  65
- Safety Checks
  65
  - Ignition Safety System Test
    65
  - Low Water Cut-Off Test
    65
  - Flow Switch Test
    66
  - Manual Reset High Temperature Limit Test
    66
  - Gas Pressure Switch Tests
    67
- Proof of Closure Switch Test (ST6000 & ST8000 ONLY)
  67
- Fuel/Air Adjustments
  68
- Initial Nuro Control Setup and Adjustment
  71
  - Startup
    71
  - Home Screen
    72
  - Information Screen
    72
  - Setup Wizard
    73
- Typical Boiler Operating Conditions
  73
4 Operations

74
- Nuro ® Control Panel
  74
  - NURO Touch Screen Interface
    74
  - Factory Tests
    74
- Normal Lighting and Shut-Down Procedures
  75
  - Normal Lighting Procedures
    75
  - Normal Shut down Procedures
    75
- Emergency Shut-Off
  75
5 Maintenance

76
- Preventative Maintenance
  76
  - Daily
    77
  - Weekly
    77
  - Monthly
    77
  - Semi-Annually
    78
  - Annually or 2500 Run Hours (Whichever Comes First)
    78
- Cleaning the Combustion Chamber
  81
- After Repairs or Maintenance
  85
- Sequence of Operations
  86
- Troubleshooting
  87
  - Loss of Power
    87
  - Loss of Water Level
    87
  - Low Gas Pressure
    87
  - High Gas Pressure
    87
  - High Water Temperature
    87
  - Low Air
    87
  - Flame Failure
    88
  - Flame Error
    88
  - Flue Problem/Condensate Blockage
    88
6 Parts/Technical Support

89
7 K Storm ® Specific Limited Warranty

125
8 Boiler Fire-Test Report

127
Appendix A - Maintenance Log

128
Appendix B - Boiler Altitude Derate Schedule

129
Appendix C - Water Quality Standards Quality Standards for Hydronic Boilers in Multi-Metal Systems

130
Appendix D - Best Practices for New & Retrofit Systems

131

Patterson-Kelley STORM ST-4000 Installation & Owner's Manual (101 pages)

GAS FIRED BOILER W/ NURO CONTROL SYSTEM

Brand: Patterson-Kelley | Category: Boiler | Size: 3 MB

Table of Contents
5
1 Introduction

8
- Purpose of this Document
  10
- Common Abbreviations
  10
2 Site Preparation

11
3 Installation

20
- Overview
  20
- Appliance Connections
  20
  - Appliance Connections (ST-2500 & ST-3000)
    21
  - Appliance Connections (ST-3500 & ST-4000)
    22
- Electrical Connections
  23
- Combustion Air
  29
- Flue Gas / Exhaust Venting
  34
- Removing an Existing Boiler
  45
- Piping
  46
  - Gas Piping Overview
    46
  - Natural Gas Piping
    46
  - Pressure Testing the Gas Piping
    47
  - Boiler Water Piping
    48
  - Boiler Inlet and Outlet Connections
    49
  - Boiler Water Piping (for Installer)
    49
- Water Quality
  50
- Pre-Start Checklist
  51
- Safety Checks
  51
  - Ignition Safety System Test
    51
  - Low Water Cut-Out Test
    51
  - Flow Switch Test
    52
  - Manual Reset High Temperature Limit Test
    52
  - Gas Pressure Switch Tests
    53
- Fuel/Air Adjustments
  53
- Initial Nuro Control Setup and Adjustment
  56
  - Startup
    56
  - Home Screen
    57
  - Information Screen
    57
  - Setup Wizard
    58
- Typical Boiler Operating Conditions
  58
4 Operations

59
- NURO Control Panel
  59
  - NURO Touch Screen Interface
    59
  - Factory Tests
    59
- Normal Lighting and Shut-Down Procedures
  60
  - Normal Lighting Procedures
    60
  - Normal Shut down Procedures
    60
- Emergency Shut-Off
  60
5 Maintenance

61
- Preventative Maintenance
  61
  - Daily
    62
  - Weekly
    62
  - Monthly
    62
  - Semi-Annually
    62
  - Annually or 2500 Run Hours (Whichever Comes First)
    63
- Cleaning the Combustion Chamber
  66
- After Repairs or Maintenance
  70
- Sequence of Operations
  71
- Troubleshooting
  71
  - Loss of Power
    72
  - Loss of Water Level
    72
  - Low Gas Pressure
    72
  - High Gas Pressure
    72
  - High Water Temperature
    72
  - Low Air
    72
  - Flame Failure
    73
  - Flame Error
    73
  - Flue Problem/Condensate Blockage
    73
6 Parts/Technical Support

74
7 K Storm Specific Limited Warranty

91
8 Boiler Fire-Test Report

93
Appendix A - Maintenance Log

94
Appendix B - Boiler Altitude Derate Schedule

95
Appendix C - Water Quality Standards Quality Standards for Hydronic Boilers in Multi-Metal Systems

96
Appendix D - Best Practices for New & Retrofit Systems

97
Appendix E - Installation and Quick Reference

99
- Fuel/Gas Supply
  99
- Electrical/Power Supply
  99
- Exhaust Venting
  99
- Propylene Glycol Flow
  101

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User Manuals: Patterson-Kelley STORM ST-4000 Boilers

Patterson-Kelley STORM ST-4000 Installation & Owner's Manual (133 pages)

Table of Contents

Patterson-Kelley STORM ST-4000 Installation And Owner's Manual (137 pages)

Table of Contents

1 Introduction

2 Site Preparation

3 Installation

4 Operations

5 Maintenance

6 Parts/Technical Support

7 K Storm ® Specific Limited Warranty

8 Boiler Fire-Test Report

Appendix A - Maintenance Log

Appendix B - Boiler Altitude Derate Schedule

Appendix C - Water Quality Standards Quality Standards for Hydronic Boilers in Multi-Metal Systems

Appendix D - Best Practices for New & Retrofit Systems

Patterson-Kelley STORM ST-4000 Installation & Owner's Manual (101 pages)

Table of Contents

1 Introduction

2 Site Preparation

3 Installation

4 Operations

5 Maintenance

6 Parts/Technical Support

7 K Storm Specific Limited Warranty

8 Boiler Fire-Test Report

Appendix A - Maintenance Log

Appendix B - Boiler Altitude Derate Schedule

Appendix C - Water Quality Standards Quality Standards for Hydronic Boilers in Multi-Metal Systems

Appendix D - Best Practices for New & Retrofit Systems

Appendix E - Installation and Quick Reference

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