Patterson-Kelley Thermific Operating instructions

PATTERSON-KELLEY

THERMIFIC®

GAS-FIRED BOILER

Installation Date: _______________________

100 Burson Street, P.O. Box 458,

East Stroudsburg, PA 18301

elephone: (877) 728-5351, Facsimile: (570) 476-7247

www.pkboilers.com

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

OWNER’S

MANUAL

INSTALLATION

OWNER’S

MANUAL

INSTALLATION

OWNER’S

MANUAL

INSTALLATION

OWNER’S

MANUAL

INSTALLATION

OWNER’S

MANUAL

INSTALLATION

OWNER’S

MANUAL

INSTALLATION

OWNER’S

MANUAL

INSTALLATION

OWNER’S

MANUAL

TBIG-02

Thermific®Gas-Fired Boiler Table of Contents

1.0 INTRODUCTION ................................. 1

2.0 SAFETY............................................... 1

2.1 General ......................................................1

2.2 Training......................................................1

2.3 Safety Features..........................................1

2.4 Safety Labels .............................................2

2.5 Safety Precautions.....................................2

2.5.1 Electrical Hazards .............................2

2.5.2 Burn, Fire, and Explosion Hazards ...2

2.5.3 Crush Hazards ..................................3

2.5.4 Chemical Hazards.............................3

2.5.5 Pressure Hazards .............................4

2.5.6 Slip, Fall Hazards..............................4

3.0 INSTALLATION ................................... 5

3.1 Receiving and Storage ..............................5

3.1.1 Initial Inspection ................................5

3.1.2 Storage Prior to Installation...............5

3.2 Compliance with Codes .............................5

3.3 Setup .........................................................5

3.3.1 Foundation ........................................5

3.3.2 Placement .........................................5

3.3.3 Clearances........................................6

3.4 Electrical Connections ...............................6

3.5 Combustion Air ..........................................7

3.6 Flue Venting...............................................7

3.6.1 Vent Elbows ......................................8

3.6.2 Barometric Damper...........................8

3.6.3 Barometric Damper Location ............8

3.6.4 Flue Connection................................8

3.6.5 Vent Termination...............................9

3.6.6 Removing an Existing Boiler .............9

3.7 Gas Piping .................................................9

3.7.1 Gas Supply Piping by Installer ........11

3.7.2 Gas Bleeds and Vents ....................11

3.8 Boiler Water Piping..................................11

3.8.1 Piping Design..................................11

3.8.2 Boiler Inlet and Outlet Connections 12

3.8.3 Boiler Water Piping by Installer.......12

3.8.4 Flushing and Filling.........................13

3.9 Burner and Ignition System .....................13

3.9.1 Inspection .......................................13

3.10 Pre-Start Check List...............................13

3.11 Safety Checks........................................13

3.11.1 Test of Ignition Safety System ......13

3.11.2 Test of Low Water Cut-off.............14

3.11.3 Test of High-Limit Control .............14

3.11.4 Test of Gas Pressure Switch ........14

3.12 Initial Adjustments..................................15

3.12.1 Operating Temperature Controller for

Lo-Hi-Lo Thermific®.............................15

3.12.2 Gas Pressure Adjustment.............16

3.12.3 Air Flow Adjustments ....................16

4.0 OPERATION ..................................... 19

4.1 General....................................................19

4.1.1 Control Panel Front.........................19

4.1.2 Tests ...............................................19

4.2 Lighting and Shut-Down Procedures.......19

4.2.1 Lighting Procedures........................19

4.2.2 Normal Shut Down Procedures ......20

4.2.3 Emergency Shut Off .......................20

4.3 Typical Boiler Operating Conditions ........20

5.0 MAINTENANCE ................................ 21

5.1 Maintenance and Inspection Schedule....21

5.1.1 Daily................................................21

5.1.2 Weekly ............................................21

5.1.3 Monthly (During Operation) ............21

5.1.4 Semi-Annually.................................21

5.1.5 Annually ..........................................22

Thermific®Gas-Fired Boiler Table of Contents

5.2 Cleaning the Burner.................................22

5.2.1 Semi-Annual Cleaning ....................22

5.2.2 Annual Cleaning .............................22

5.3 Removing the Exchanger ........................23

5.4 After All Repairs or Maintenance .............23

5.5 Sequence Of Operation ...........................23

5.6 Troubleshooting .......................................24

6.0 PARTS/TECHNICAL SUPPORT .......26

6.1 Wiring Diagrams ......................................27

6.1.1 On-Off .............................................28

6.1.1a On-Off IRI .....................................30

6.1.2 Lo-Hi-Lo ..........................................32

6.1.2a Lo-Hi-Lo IRI ..................................34

6.1.3 Water Cut-Off.................................. 36

6.2 Boiler Parts List ....................................... 38

6.2.1 Main Assembly ...............................38

6.2.2 Control Panel.................................. 39

6.2.3 Gas Train........................................ 40

6.2.4 Cabinet ...........................................41

7.0 LIMITED WARRANTY ....................... 42

7.1 Express Warranty .................................... 42

7.2 Warranty Disclaimer ................................42

Reorder No. 6020-V2WHPK

Improper use may

result in fire or injury.

Read instructions/safety

manual before installing,

operating or servicing boiler.

WARNING

1998 HCS, Inc. 800-748-0241

WARNING!

It is essential to read, understand, and follow the rec-

ommendations of this manual before installing, operat-

ing, or servicing this equipment. Failure to do so could

result in fire or explosion and serious injury, death,

and/or property damage.

The same features which permit this boiler to achieve

high-efficiency performance make it unlike most other

boilers of this general size, so it is important to under-

stand how this boiler operates.

Do not store or use gasoline or other flammable vapors

or liquids in the vicinity of this or any other appliance.

WARNING!

Installation and service must be performed by a quali-

fied installer, service agency, or gas supplier.

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. Immedi-

ately 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.

Thermific® Gas-Fired Boiler Introduction/Safety

Page 1

1.0 INTRODUCTION

The P-K Thermific®Gas-Fired Boiler combines a ra-

dial pre-mix fan-assisted burner with a compact, fin-

ned-tube heat exchanger to provide maximum effi-

ciency in a minimum of space. The high-quality mate-

rials and thoroughly tested design of the boiler should

provide years of trouble-free, hot-water service, if the

instructions in this manual are followed carefully.

This manual covers installation of P-K Thermific®

Boiler Series 700, 1000, 1200, 1500, 1700, and 2000.

The model numbers may be followed by a prefix or

suffix letter in some cases to indicate special features

or different options.

While details may differ slightly, basic operation is the

same for all models. Boilers may be built to operate

with natural gas or liquefied petroleum gas (propane).

Check the rating plate for correct fuel usage and gas

pressures.

The boiler is only a part of the complete heating sys-

tem. This boiler may be fully operational and yet be-

cause of poor circulation, control or other operating

characteristics, not deliver heat to the desired location.

Additional equipment such as temperature sensors,

pumps, flow switches, balancing valves and check

valves will be required for satisfactory operation of

any system. Patterson-Kelley cannot be responsible

for the design or operation of such systems and a

qualified engineer or contractor must be consulted.

2.0 SAFETY

2.1 GENERAL

The Thermificgas-fired boiler must be:

•Installed by qualified personnel in accordance with

designs prepared by qualified facility engineers in-

cluding: structural, mechanical, electrical, and

other applicable disciplines.

•Operated and serviced in accordance with a com-

prehensive safety program determined and estab-

lished by the customer. Do not attempt to operate

or service until such a program has been estab-

lished.

•Operated and serviced by qualified, properly

trained personnel in accordance with all applicable

codes, laws, and regulations.

2.2 TRAINING

Reorder No. 6020-V2WHPK

Improper use may

result in fire or injury.

Read instructions/safety

manual before installing,

operating or servicing boiler.

WARNING

1998 HCS, Inc. 800-748-0241

It is essential to read, understand, and follow the rec-

ommendations of this manual before installing, operat-

ing, or servicing this equipment. Failure to do so

could result in serious injury, death, and/or property

damage.

Proper training is the best protection against accidents.

Operating and service personnel must be thoroughly

familiar with the basic construction of the Thermific

boiler, the use and locations of the controls, the opera-

tion of the boiler, adjustment of its various mecha-

nisms, and all applicable safety precautions. If any of

the provisions of this manual are not fully and com-

pletely understood, contact the Patterson-Kelley Sales

Department toll-free at (877) 728-5351 for assistance.

2.3 SAFETY FEATURES

It is the responsibility of the customer to maintain the

safety features of this machine, such as: guards, safety

labels, safety controls, interlocks, lockout devices, etc.,

in place and operable.

Thermific® Gas-Fired Boiler Safety

Page 2

2.4 SAFETY LABELS

NOTE

Make sure this union is

tight before closing cabinet

cover after servicing boiler.

Reorder No. 8032-02NHAK

1998 HCS, Inc. 800-748-0241

NOTE

Reorder No. 8032-01NHPK

When opening leak test valves,

always follow instructions in

operation and safety manual.

1998 HCS, Inc. 800-748-0241

Reorder No. 6020-V2WHPK

Improper use may

result in fire or injury.

Read instructions/safety

manual before installing,

operating or servicing boiler.

WARNING

1998 HCS, Inc. 800-748-0241

WARNING

C 1998 HCS, Inc. 800-748-0241

Reorder No. 5025-V1WHPK

Follow lockout/tagout

procedure when

servicing this boiler.

Electrical hazard.

The safety labels shown above are affixed to your

boiler. Although the labels are of high quality, they

may become dislodged or unreadable over time. Con-

tact Patterson-Kelley toll-free at (877) 728-5351 for

replacement labels.

2.5 SAFETY PRECAUTIONS

Provide a suitable location for the boiler, away from

normal personnel traffic, with adequate working space,

adequate clearances, proper ventilation and lighting,

with a structure sufficiently strong and rigid to support

the weight of the boiler, all piping, and accessories.

2.5.1 Electrical Hazards

WARNING

C 1998 HCS, Inc. 800-748-0241

Reorder No. 5025-V1WHPK

Follow lockout/tagout

procedure when

servicing this boiler.

Electrical hazard.

•Shock hazard! Properly lockout/tagout the electri-

cal service and all other energy sources before

working on or near the machine.

•Shock hazard! Boiler is not rated for wash-down

service.

2.5.2 Burn, Fire, and Explosion Hazards

General Warning

Hot Surface

Reorder No. 6020-V2WHPK

Improper use may

result in fire or injury.

Read instructions/safety

manual before installing,

operating or servicing boiler.

WARNING

1998 HCS, Inc. 800-748-0241

NOTE

Make sure this union is

tight before closing cabinet

cover after servicing boiler.

Reorder No. 8032-02NHAK

1998 HCS, Inc. 800-748-0241

NOTE

Reorder No. 8032-01NHPK

When opening leak test valves,

always follow instructions in

operation and safety manual.

1998 HCS, Inc. 800-748-0241

•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/CGA B.149. Install all required

ventlines for gas devices. Refer to Section 3.7.2

below.

•Hazard from incorrect fuels! Possible fire, explo-

sion, overheating, and damage. Do not use any

fuels except the design fuel for the unit.

•Overfire hazards! High pressure in gas or propane

supply could result in overfiring of other devices

supplied from the same source.

•Fire and explosion hazards! Close the main gas

shutoff before servicing boiler.

Thermific® Gas-Fired Boiler Safety

Page 3

•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. Use only factory

recommended vent components.

•Burn hazard! Hot fluids. Use caution when ser-

vicing or draining boiler.

•Fire and explosion hazards! Use caution when

servicing burner. Propane (LPG) is heavier than

air and may linger in the combustion chamber,

vent lines, or elsewhere.

•Gas leak hazard! Make sure all connections to

main burner are tight when reassembling the

burner. These connections cannot be tested after

the burner is assembled.

•Gas leak hazard! All threaded gas connections

must be made using a pipe compound that is resis-

tant to liquefied petroleum. Do not use Teflon

tape on threaded gas piping.

•Gas leak hazard! Check entire gas train for leaks

after installation. If there is a smell of gas, shut

down the boiler and obtain immediate assistance

from trained service personnel and/or your local

fire department.

•Overfire hazard! Possible fire and explosion from

excess gas pressure. Make sure that gas inlet pres-

sure does not exceed 14 inches W.C. to the regula-

tor.

•Overfire hazard! Possible fire and explosion.

Possible malfunction of regulators and/or motor-

ized gas valves. Maintain all gas train components

in good condition. Do not alter wiring connec-

tions. Annual inspection by factory-trained per-

sonnel for proper set-up and operation is recom-

mended.

•Overfire and underfire hazards! Possible fire, ex-

plosion, overheating, and component failure. Do

not attempt to adjust firing rate of the boiler. The

firing rate must be adjusted only by factory trained

personnel.

2.5.3 Crush Hazards

General Warning

•Lifting hazards! Use properly rated lifting equip-

ment to lift and position the boiler. The load is

unbalanced. Test balance before lifting 3 ft. above

the floor. Do not allow personnel beneath the

lifted load. Refer to approximate weights in the

table below:

Boiler Size Weight in Pounds

700,000 Btu 595

1,000,000 Btu 595

1,200,000 Btu 685

1,500,000 Btu 990

1,700,000 Btu 985

2,000,000 Btu 1,025

•Bump hazard from overhead piping. Install piping

with adequate vertical clearance.

2.5.4 Chemical Hazards

•Environmental hazard! The motorized gas valves

may contain hydraulic oil. Use safe procedures

for the disposal of all lubricants.

•Chemical hazards from cleaning products. Use

caution when cleaning the system. The use of pro-

fessional assistance is recommended. Use safe

procedures for the disposal of all cleaning solu-

tions.

Thermific® Gas-Fired Boiler Safety

Page 4

2.5.5 Pressure Hazards

Improper use may

result in fire or injury.

Read instructions/safety

manual before installing,

operating or servicing boiler.

WARNING

1998 HCS, Inc. 800-748-0241

•Pressure hazard! Hot fluids. Install isolation

valves on boiler water inlet and outlet. Make sure

isolation valves are closed before servicing boiler.

•Pressure hazard! Hot fluids. Annually test safety

relief valve for proper operation. Do not operate

boiler with faulty relief valve.

2.5.6 Slip, Fall Hazards

Improper use may

result in fire or injury.

Read instructions/safety

manual before installing,

operating or servicing boiler.

WARNING

1998 HCS, Inc. 800-748-0241

•Tripping hazard! Do not install piping on floor

surfaces. Maintain clear path around boiler.

•Slip and fall hazard! Use drip pan to catch water

while draining the boiler. Maintain dry floor sur-

faces.

•Slip and fall hazard! Do not locate intake or ex-

haust terminations directly above a walkway;

dripping of condensation can cause icing of the

walking surface.

Thermific® Gas-Fired Boiler Installation

Page 5

3.0 INSTALLATION

3.1 RECEIVING AND STORAGE

3.1.1 Initial Inspection

Upon receiving the boiler, inspect it for signs of ship-

ping damage. Pay particular attention to the control

panel on the top of the boiler and the components

mounted on the back, which may show damage from

mishandling.

The exterior cabinet must be reasonably air-tight for

the burner to operate correctly. Leaks caused by dents

in the sheet metal or panels out of position may cause

the limit controls to show Low Air. Check to be sure

that the mixer core in the top burner is centered and

has not moved in shipment; (see Section 5.2, "Clean-

ing the Burner" for proper location). Verify that the

total number of pieces shown on the packing slip

agrees with those actually received.

Important: Note any damage or shortage on the

freight bill and immediately notify the carrier. File

all claims for shortage or damage with the carrier.

3.1.2 Storage Prior to Installation

If the boiler is not installed immediately, it must be

stored in a location adequately protected from the

weather, preferably indoors. If this is not possible,

then it should remain in the shipping container and be

covered by a tarpaulin or other waterproof covering.

Note: Controls and other equipment that are damaged

or fail due to weather exposure are not covered by

warranty.

3.2 COMPLIANCE WITH CODES

The P-K Thermific®Boiler with standard components

and many options complies with American National

Standard/CSA Standard ANSI Z21.13/CSA 4.9, latest

edition, Gas-Fired Low Pressure Steam and Hot Water

Boilers. The heat exchanger is constructed and

stamped in accordance with ASME Boiler and Pres-

sure Vessel Code, Section IV for 160 psig maximum

operating pressure and/or 250º F maximum operating

temperature. Other codes or approvals which apply

will be labeled on the boiler.

Installation of the boiler must conform to all the re-

quirements of all national, state and local codes estab-

lished by the authorities having jurisdiction or, in the

absence of such requirements, in the U.S. to the Na-

tional Fuel Gas Code, ANSI Z223.1/NFPA 54, latest

edition. In Canada, the equipment shall be installed in

accordance with the current Installation Code for Gas

Burning Appliances and Equipment, CAN/CGA-

B.149, and applicable Provincial Regulations for the

class, which should be carefully followed in all cases.

Authorities having jurisdiction should be consulted

before installations are made.

Where required by local codes, the installation must

conform to American Society of Mechanical Engi-

neers Safety Code for Controls and Safety Devices for

Automatically Fired Boilers (ASME CSD-1).

3.3 SETUP

3.3.1 Foundation

Provide a firm, level foundation, preferably of con-

crete.

Note: The boiler may be installed on a combustible

floor; however, the boiler must never be installed on

carpeting.

3.3.2 Placement

The boiler must be level to function properly. To as-

sist in leveling the boiler, the four (4) leg bolts (1/2"-

NC) holding the boiler to the shipping skid must be

reinstalled in the threaded legs on the bottom. The

adjustable legs are also necessary to provide adequate

floor clearance and prevent distortion on the cabinet,

(twisting, etc.) in addition to leveling.

Thermific® Gas-Fired Boiler Installation

Page 6

Adjustable Legs for Leveling and Floor Clearance

3.3.3 Clearances

If the boiler is to be installed near combustible sur-

faces, the minimum clearances shown in the table be-

low must be maintained.

Failure to provide for the service access clearances,

even with non-combustible surfaces, may cause future

problems servicing the boiler.

The boiler must be installed in a space large in com-

parison to the boiler as described in Section 6.3 of the

National Fuel Gas Code, ANSI Z223.1, latest edition.

No pipes,

ducts, etc.

in this area.

Minimum Clearances from Adjacent Walls, Ceiling, and

Obstructions

Dimensions (inches)

Type of Surface

A B C† D

Combustible Surfaces 30 24 24 24

Non-combustible Sur-

faces

30 24* 24 24**

† "C" dimension includes clearance to remove the

burner. Do not put pipes, ducts, etc. in this area above

the boiler.

* CSA minimum. Actual clearance depends upon

stacking requirements.

** Service access need be only on one side of a boiler

or row of boilers. Boilers may be installed immedi-

ately adjacent to each other. However, P-K recom-

mends this clearance between each boiler when there

is insufficient access at the rear to allow for service

and adjustment.

In Canada: The boilers are approved for installation

with zero clearance to combustible surfaces, but 24

inch service clearances are recommended.

3.4 ELECTRICAL CONNECTIONS

The boiler is wired for 120 volts, single phase, 60

hertz. The total operating amperage is indicated on the

rating nameplate. The 700 and 1000 series require less

than 8 amps; the 1200 series less than 9 amps; the

1500, 1700, 2000 series less than 12 amps. Before

Table of contents

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