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MOD-04
PATTERSON-KELLEY
®
THERMIFIC
MODU-FIRE® GAS-FIRED BOILER
Installation and Owner's Manual
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. B
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® Modu-Fire Gas-Fired Boiler Table of Contents 1.0 INTRODUCTION ........................................1 3.8.1 Piping Design......................................11 3.8.2 Boiler Inlet and Outlet Connections ....12 2.0 SAFETY......................................................1 3.8.3 Boiler Water Piping by Installer...........12 2.1 General ....................................................... 1 3.8.4 Flushing and Filling .............................13 2.2 Training.....
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® Modu-Fire Gas-Fired Boiler Table of Contents 5.3 Removing the Exchanger ......................... 26 IRI Unit - Local Control - Logic Diagram .......36 5.4 After All Repairs or Maintenance.............. 26 IRI Unit - Remote Control - Logic Diagram ...37 5.5 Sequence of Operation.............................. 27 IRI Unit - Local & Remote Control - Logic Diagram ..................................................38 5.5.1 Standard Modulating .......................... 27 IRI Unit
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® Modu-Fire Gas-Fired Boiler Introduction/Safety • Operated and serviced in accordance with a 1.0 INTRODUCTION comprehensive safety program determined and established by the customer. Do not attempt to ® The P-K MODU-FIRE Gas Fired Boiler is a revo- operate or service until such a program has been lutionary advance; Patterson-Kelley now combines established. full-modulation burner control with our time-tested • Operated and serviced by qualified, factory- modular hot water bo
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® Modu-Fire Gas-Fired Boiler Safety 2.4 SAFETY LABELS • Shock hazard! Properly lockout/tagout the elec- trical service and all other energy sources before working on or near the machine. NOTE Make sure this union is • Shock hazard! Boiler is not rated for wash- tight before closing cabinet cover after servicing boiler. down service. c 1998 HCS, Inc. 800-748-0241 Reorder No. 8032-02NHAK NOTE When opening leak test valves, always follow instructions in operation and safety ma
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® Modu-Fire Gas-Fired Boiler Safety • Fire and explosion hazards! Do not store or use 2.5.3 Crush Hazards gasoline or other flammable vapors or liquids in the vicinity of this or any other gas fired appli- ance. • Burn hazard! Possible hot surfaces. Do not touch gas vent during firing operation. Use only General Warning factory recommended vent components. • Lifting hazards! Use properly rated lifting • Burn hazard! Hot fluids. Use caution when equipment to lift and
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® Modu-Fire 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. operating or servicing boiler. c c 1998 HCS, Inc. 800-748-0241 1998 HCS, Inc. 800-748-0241 • Pressure hazard! Hot fluids. Install isolation • Tripping haz
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® Modu-Fire Gas-Fired Boiler Installation temperature. Other codes or approvals which apply 3.0 INSTALLATION will be labeled on the boiler. Installation of the boiler must conform to all the re- 3.1 RECEIVING AND STORAGE 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- 3.1.1 Initial Inspection tional Fuel Gas Code, ANSI Z223.1/NFPA 54, latest edition. In Can
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® Modu-Fire Gas-Fired Boiler Installation DD 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- A B C† D faces, the minimum clearances shown in the table be- Combustible Surfaces 30 24 30 24 low must be maintained. Non-combustible Sur- 30 24* 30 24** Failure to provide for the service access cl
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® Modu-Fire Gas-Fired Boiler Installation is wired for 120 volts, single phase, 60 hertz. The total If air is taken directly from outside the building, each operating amperage is indicated on the rating name- opening should have a net free area of 1 square inch plate. The 1000 series require less than 9 amps; the for each 4,000 Btu per hour of total boiler input. For 1500 and 2000 series less than 12 amps. Before start- instance, 300 square inches (2-1/12 square feet) are ing the bo
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® Modu-Fire Gas-Fired Boiler Installation tee. The condensate drain must be routed to a sewer WARNING! drain trap or pump in accordance with local codes. This boiler should not be installed with an automatic Refer to diagram under Vent Elbows. damper on the flue. Damper failure could create an explosion hazard. 3.6.2 Barometric Damper In Canada, the boiler is certified for installation with a “Power Venter” by the Canadian Gas Association This boiler is certified for opera
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® Modu-Fire Gas-Fired Boiler Installation 4. Place the appliance being inspected in operation. Follow the lighting instructions. Adjust the ther- mostat so that the appliance will operate continu- ously. 5. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle or smoke from a ciga- rette, cigar or pipe. Incorrect Correct Listed Termination Termination 6. After it has been determined that each applianc
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® Modu-Fire Gas-Fired Boiler Installation on the boiler. Gas piping should be installed in accor- By Installer dance with National Fuel Gas Code, ANSI Z223.1, Remote Gas latest edition, and any other local codes which may Shutoff (not apply; in Canada see CAN/CGA-B 149. supplied) Note: See chart below for required pipe size, based on overall length of pipe from meter plus equivalent length of all fittings. Approximate sizing may be based Union on 1 cubic foot of natural gas p
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® Modu-Fire Gas-Fired Boiler Installation in accordance with the National Fuel Gas Code 3.7.1 Gas Supply Piping by Installer (NFPA 54), ANSI Z223.1, which states: The boiler and all gas piping connections should be pressure-tested and must be checked for leaks be- “In the case of vents leading outdoors, means shall fore being placed into service. Test with com- be employed to prevent water from entering this pressed air or inert gas if possible. piping and also to prevent blockage
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® Modu-Fire Gas-Fired Boiler Installation Consideration must be given to all possible condi- Note: Pipe unions and isolating valves must be tions and their consequences. installed in both water connections for ease of service. Piping With Refrigeration Machines The bottom connection to the boiler is the INLET When used with a refrigeration system, the boiler and must be used for the return from the system. shall be installed so that chilled medium is piped in parallel with the boi
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® Modu-Fire Gas-Fired Boiler Installation treated make-up water can cause premature failure WARNING! due to buildup of scale. Such failure is not covered Never install a valve that can isolate the low water by warranty. cutoff from the boiler. Scale can also reduce efficiency. For example, a scale thickness of 1/16" will result in a 12.5% loss Drain Valve and Piping of efficiency. The boiler is not provided with external drain con- The water quality should be within th
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® Modu-Fire Gas-Fired Boiler Installation 2. Gas connection has been made, pressure tested 2. With the main gas cock (inlet manual gas valve) for leakage, and the line purged of air. Make open and the pilot gas cock open, the burner sure all required bleeds and vents have been in- should be cycled on. After all the safety limits stalled. on gas pressure, water flow and temperature are satisfied, the blower will run and pre-purge the 3. Water connections are complete, and the boile
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® Modu-Fire Gas-Fired Boiler Installation the main burner shuts off (the green "Heat" indicator 3.12 INITIAL ADJUSTMENTS will go out). The high-limit switch must be manu- ally reset after testing. This same check should also be made for the "Operating Temperature" control. 3.12.1A – Configuring the Local Controller After completion of these tests, readjust thermostats (Applies to models furnished with programmable to desired operating temperature and set high-limit tempera
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® Modu-Fire Gas-Fired Boiler Installation For example, assume the following settings: Item Display Value Setpoint 1 SP1 160 Low Temp Differential HyS1 -5 High Temp Differential HyS3 12 Low Temp Setpoint SPL 150 High Temp Setpoint SPH 195 o The boiler will modulate to try to maintain 160 F. The setpoint of the boiler is controlled by an out- o If the temperature increases to 172 F which is Set- door temperature sensor. As the outdoor tempera- point 1 (SP1) 160 + High Te
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® Modu-Fire Gas-Fired Boiler Installation Analog Input Direct Drive PARAMETER level, and the The firing rate of the boiler is controlled by an ex- CONFIGURATION level. ternal analog signal, usually from a multiple boiler The following table indicates the menu options control. The boiler turns on and off as directed by available from each level. The options available the external control. depend on the operating mode of the boiler. An operating limit control ensures that the
