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Patterson-Kelley MOD-04 manual

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  • Page 1

    PATTERSON-KELLEY THERMIFIC ® MODU-FIRE® GAS-FIRED BOILER Installation and Owner's Manual Installation Date : _______________ ________ 100 Burson Street, P.O. Box 458, East Stroudsburg, PA 18301 Telephone: (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 Pressur[...]

  • Page 2

    Modu-Fire ® Gas-Fired Boiler Table of Contents 1.0 INTRODUCTION ........................................ 1 2.0 SAFETY ...................................................... 1 2.1 Gene ral ....................................................... 1 2.2 Training ....................................................... 1 2.3 Safety Features ............[...]

  • Page 3

    Modu-Fire ® Gas-Fired Boiler Table of Contents 5.3 Removing the Exchanger ......................... 26 5.4 After All Repairs or Maintenance .............. 26 5.5 Sequence of Operation .............................. 27 5.5.1 Standard Modulating .......................... 27 5.5.2 IRI M odulating .................................... 28 5.6 Troubles [...]

  • Page 4

    Modu-Fire ® Gas-Fired Boiler Introduction/Safety 1 1.0 INTRODUCTION The P-K MODU-FIRE ® Gas Fired Boiler is a revo- lutionary advance; Patterson-Kelley now combines full-modulation burner control with our t ime-tested modular hot water boiler design. The result is “modular full-modulation”- Modu-Fire! This new hybrid boiler combines the best [...]

  • Page 5

    Modu-Fire ® Gas-Fired Boiler Safety 2 2.4 S A FETY L AB E LS NOTE Make sure this union is tight before closing cab inet cover after servicing boiler . Reorder No. 8032-02NHAK c 1998 HCS, Inc. 800-748 -0241 NOTE Reorder No. 80 32-01NHPK c When opening leak test valves, always follow instruc tions in operation and safety manual. 1998 HCS, Inc . 800-[...]

  • Page 6

    Modu-Fire ® Gas-Fired Boiler Safety 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 appli- ance. • Burn hazard! Possible hot surfaces. Do not touch gas vent during firing operation. Use only factory recommended vent components. • Burn hazard! Ho[...]

  • Page 7

    Modu-Fire ® Gas-Fired Boiler Safety 4 2.5.5 Pressure Hazards Improper u se may result in fire or injury . Read instr uctions/saf ety manua l before insta lling, operating or s ervicing boile r . c ! W ARNING 1998 HCS , Inc. 800- 748-0241 • Pressure hazard! Hot fluids. Install isolation valves on boiler water inlet and outlet. Make sure isolation[...]

  • Page 8

    Modu-Fire ® Gas-Fired Boiler Installation 5 3.0 INST ALLA TION 3.1 R ECEIVING AND S TORAGE 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 com ponents mounted on the back, which ma y show damage from mishandling. The exteri[...]

  • Page 9

    Modu-Fire ® Gas-Fired Boiler Installation 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 [...]

  • Page 10

    Modu-Fire ® Gas-Fired Boiler Installation 7 is wired for 120 volts, single phase, 60 hertz. The total operating amperage is indicated on the rating name- plate. The 1000 series require less than 9 amps; the 1500 and 2000 series less than 12 amps. Before start- ing the boiler, check to ensu re that the proper voltage and amperage are connected to t[...]

  • Page 11

    Modu-Fire ® Gas-Fired Boiler Installation 8 WARNING! This boiler should not be installed with an automatic damper on the flue. Damper failure coul d create an explosion hazard. In Canada, the boiler is certified for installation with a “Power Venter” by the Canadian Gas Association when installed with the “listed accessories.” Consult your[...]

  • Page 12

    Modu-Fire ® Gas-Fired Boiler Installation 9 Vent Termination The vent must be provided with a weather cap of ap- proved design and adequate capacity. 3.6.6 Removing an Existing Boiler (from a common venting system) When an existing boiler is removed from a common venting system, the common venting s ystem is likely to be too large for proper venti[...]

  • Page 13

    Modu-Fire ® Gas-Fired Boiler Installation 10 Gas Piping Note: Install a sediment trap (drip leg) and a union connection ahead of the primary manual shutoff valve on the boiler. Gas piping should be installed in accor- dance with National Fuel Gas Code, ANSI Z223.1, latest edition, and any other local codes which may apply; in Canada see CAN/CGA-B [...]

  • Page 14

    Modu-Fire ® Gas-Fired Boiler Installation 11 3.7.1 Gas Supply Piping by Installer The boiler and all gas piping connections should be pressure-tested and must be checked for leaks be- fore being placed into service. Test with com- pressed air or inert gas if possible. The boiler must be disconnected at the boiler man- ual shut-off valve (located a[...]

  • Page 15

    Modu-Fire ® Gas-Fired Boiler Installation 12 Consideration must be given to all possible condi- tions and their consequences. Piping With Refrigeration Machines When used with a refrigeration system, the boiler shall be installed so that chilled medium is piped in parallel with the boiler. Valves should be installed to prevent chilled water from e[...]

  • Page 16

    Modu-Fire ® Gas-Fired Boiler Installation 13 WARNING! Never install a valve that can isolate the low wate r cutoff from the boiler. Drain Valve and Piping The boiler is not provided with external drain con- nections. A drain valve should be installed near the inlet (system return) connection to the boiler and piped to a suitable floor drain. The b[...]

  • Page 17

    Modu-Fire ® Gas-Fired Boiler Installation 14 2. Gas connection has been made, pressure tested for leakage, and the line purged of air. Make sure all required bleeds and vents have been in- stalled. 3. Water connections are complete, and the boiler and system have been filled and purged of air. 4. The boiler must be connected to a 120 volt / 60 Hz [...]

  • Page 18

    Modu-Fire ® Gas-Fired Boiler Installation 15 the main burner shuts off (the green "Heat" indicator 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. After completion of these tests, readjust thermostats to desired operating te[...]

  • Page 19

    Modu-Fire ® Gas-Fired Boiler Installation 16 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 The boiler will modulate to try to maintain 160 o F. If the temperature increases to 172 o F which is Set- p[...]

  • Page 20

    Modu-Fire ® Gas-Fired Boiler Installation 17 Analog Input Direct Drive The firing rate of the boiler is controlled b y an ex- ternal analog signal, usually from a multiple boiler control. The boiler turns on and off as directed by the external control. An operating limit control ensures that the boiler temperature does not exceed the set value. Re[...]

  • Page 21

    Modu-Fire ® Gas-Fired Boiler Installation 18  To change to manual operation press EXIT for 5 seconds.  The LED above the hand symbol lights up.  Change the firing rate of the boiler with  or  .  The firing rate increases as long as  is pressed.  The firing rate decreases as long as  is pressed. LED's on the control [...]

  • Page 22

    Modu-Fire ® Gas-Fired Boiler Installation 19 Table 1 - Table of Parameters[...]

  • Page 23

    Modu-Fire ® Gas-Fired Boiler Installation 20 Configuration Level The configuration level is used to set up the control for the sensors used, and the functioning of the alarm relay. The configuration level must be ad- justed by factory-trained personnel only. 3.12.1B Optional Remote Control This option is used when the firing rate of the boiler is [...]

  • Page 24

    Modu-Fire ® Gas-Fired Boiler Installation 21 3.12.3 Gas Pressure Adjustment See r ati ng p lat e for the min imu m and max imu m gas pressure of the boiler. Each boiler is furnished with two plugged taps in the gas manifold for test gauge connections. One tap is located at the main gas cock for measuring the gas supply pressure (1/4” IPS). The s[...]

  • Page 25

    Modu-Fire ® Gas-Fired Boiler Operation 22 4.0 OPERA TION 4.1 G ENERAL 4.1.1 Control Panel Front The front of the control panel shows Operating In- structions and a series of illuminated indicator lights which show the condition of the boiler. 4.2 L IGHTING A ND S HUT -D OWN P ROCEDURES Do not use this boiler if any part has been under wa- ter. Imm[...]

  • Page 26

    Modu-Fire ® Gas-Fired Boiler Operation 23 4. Turn power switch on. If a red warning indica- tor is illuminated, see call for factory-trained personnel to troubleshoot the problem and im- plement corrective action. Wait five minutes before attempting to reset boiler. 4.2.2 Normal Shut Down Procedures 1. Close all manual gas valves. 2. Turn off elec[...]

  • Page 27

    Modu-Fire ® Gas-Fired Boiler Maintenance 24 5.0 MAINTENANCE General Lock out / Tag out procedure must be em- ployed when servicing unit. Hazard analysis should be performed by end user to insure safety of their employees and/or service tech- nicians. In addition to the requirements of Section 2.1, main- tenance performed on the Siemens gas valve r[...]

  • Page 28

    Modu-Fire ® Gas-Fired Boiler Maintenance 25 3. Inspect burner for any signs of deterioration or corrosion. Replace immediately if deterioration or corrosion is evident. The blower motor is permanently lubricated and does not require periodic lubrication. This work should be performed by factory-trained personnel. 5.1.5 Annually In addition to the [...]

  • Page 29

    Modu-Fire ® Gas-Fired Boiler Maintenance 26 8. Before re-installing the burner, check the cleanliness of the heat exchanger and the condi- tion of the combustion cham ber. If corrosion or leaks are noticed, (green or otherwise, please call the factory for assistance) 9. Install the burner and mixer core. Reconnect the pilot tube, main gas union, 4[...]

  • Page 30

    Modu-Fire ® Gas-Fired Boiler Maintenance 27 5.5 S EQUENCE OF O PERATION 5.5.1 Standard Modulating 1. When the On/Off (Main power) switch is turned on, the switch illuminates. Power is provided to the flame safeguard control, the temperature control, and through normally closed contacts of relays 2 and 3 to the damper close terminal. Power is also [...]

  • Page 31

    Modu-Fire ® Gas-Fired Boiler Maintenance 28 14. When the load is below the low fire rating of the boiler the boiler will continue firing and the out- let water temperature will rise until it reaches the set point + hysterises value. At this point the operating control switch opens and the com- bustion control is de-energized at Terminal 6 and the [...]

  • Page 32

    Modu-Fire ® Gas-Fired Boiler Maintenance 29 minal 9 of the Combustion Control is energized. This opens the main gas valve and energizes the air gas ratio control. The 15 second "Main Flame Establishing” period begins. If pilot flame has not been established, the unit will lock out on pilot flame failure. 13. After the 15 second “Main Flam[...]

  • Page 33

    Modu-Fire ® Gas-Fired Boiler Maintenance 30 • Check the cabinet pressure for a minimum of 0.3" w.c. • Check burner is clean (refer to Section 5.2). Ignition Failure In the event the pilot flam e is not detected by the UV scanner during the 10 second trial-for-ignition period (Step 9), the pilot gas valve and spark igni- tion are de-energi[...]

  • Page 34

    Modu-Fire ® Gas-Fired Boiler Parts/Technical Support 31 6.0 P ARTS/TECHNICAL SUPPORT Spare parts and replacement parts can be ordered from your local representative or Patterson-Kelley by calling (570) 476-7261 or Toll Free (877) 7 28- 5351. The fax number is (570) 4 76-7247. Refer to the parts list shown on the assembly drawing pro- vided with th[...]

  • Page 35

    Modu-Fire ® Gas-Fired Boiler Parts/Technical Support 32 # 2 START INTER LOCK FLAME SAFEY ALARM # 1 START INTER LOCK CUSTOMER CONNECTIONS Standard Unit - Local Control - Logic Diagram[...]

  • Page 36

    Modu-Fire ® Gas-Fired Boiler Parts/Technical Support 33 CUSTOMER CONNECTIONS # 2 START INTERLOCK FLAME SAFEY ALARM # 1 START INTERLOCK ANALOG INPUT -- + Standard Unit - Remote Control - Logic Diagram[...]

  • Page 37

    Modu-Fire ® Gas-Fired Boiler Parts/Technical Support 34 CUSTOMER CONNECTIONS # 2 START INTERL OCK FLAME SAFEY ALARM # 1 START INTERL OCK ANALOG INPUT -- + Standard Unit - Local & Remote Control - Logic Diagram[...]

  • Page 38

    Modu-Fire ® Gas-Fired Boiler Parts/Technical Support 35 CUSTOM ER CONNECTIONS # 2 START INTERLOCK FLAME SAFEY ALARM # 1 START INTERLOCK ALTERNATE SETPOINT OUTDOOR AIR TEMPERATURE +mA ANALOG INPUT SETPOINT +V (c) ALL LIMIT POINTS ALARM PUMP DELAY SETPOINT RANGE ALAR M ANALOG INPUT -- + Standard Unit - Local & Remote Control w Options - Logic Di[...]

  • Page 39

    Modu-Fire ® Gas-Fired Boiler Parts/Technical Support 36 FLAME SAFETY ALARM # 1 START INTERLOCK # 2 START INTERLOCK 1 2 0 /1 /6 0 CUSTOMER CONNECTIONS IRI Unit - Local Control - Logic Diagram[...]

  • Page 40

    Modu-Fire ® Gas-Fired Boiler Parts/Technical Support 37 ANALOG INPUT -- + CUSTO MER CONNECTION S 120/ 1/ 60 FLAME SAFETY ALARM # 1 START INTERLOCK # 2 START INTERLOCK IRI Unit - Remote Control - Logic Diagram[...]

  • Page 41

    Modu-Fire ® Gas-Fired Boiler Parts/Technical Support 38 ANALOG INPUT -- + CUSTOMER CONNECTIONS 120/ 1/ 60 FLAME SAFETY ALARM # 1 START INTERLOCK # 2 START INTERLOCK IRI Unit - Local & Remote Control - Logic Diagram[...]

  • Page 42

    Modu-Fire ® Gas-Fired Boiler Parts/Technical Support 39 1 2 0 /1 /6 0 ANALOG INPUT -- + ANALOG INPUT SETPOINT +mA +V (c) OUTDOOR AIR TEMPER ATURE ALTERNATE SETPOINT SETPOINT RANGE ALARM ALL LIMIT POINTS ALARM PUMP DELAY CUSTOMER CONNECTIONS FLAME SAFETY ALARM # 1 START INTERLOCK # 2 START INTERLOCK IRI Unit - Local & Remote Control w Options -[...]

  • Page 43

    Modu-Fire ® Gas-Fired Boiler Parts/Technical Support 40 Standard Unit – Panel Layout[...]

  • Page 44

    Modu-Fire ® Gas-Fired Boiler Parts/Technical Support 41 IRI Unit – Panel Layout[...]

  • Page 45

    Modu-Fire ® Gas-Fired Boiler Parts/Technical Support 42 6.2 B OILER P ART S L IST 6.2.1 Main Assembly No. P a r t 1. Mixer Core, Burner (Inside Cabinet) 2. Burner Orifice (Inside Cabinet) 3. Spark Igniter Electrode 4. UV Scanner 5. Thermowell w/Clamp 6. Electrode Assembly w/Mica (Inside Cabi- net) 7. Pilot Tube (Inside Cabinet) 8. Burner (Inside C[...]

  • Page 46

    Modu-Fire ® Gas-Fired Boiler Parts/Technical Support 43 6.2.2 Control Panel No. Part 1. Thermostat (Manual Re- set) 2. Thermostat (Oper. Temp) 3. Air Flow Switch 4. Motor Start Relay 5. Terminal Block, Neutral 6. Terminal Block, Power No. Part 7. Flame Safeguard Pro- grammer 7a. Am plifier (UV Scanner) 7b. Timing Card, 30 sec. 8. Programmer, Sub-B[...]

  • Page 47

    Modu-Fire ® Gas-Fired Boiler Parts/Technical Support 44 No. Part 1. Thermostat (Manual Re- set) 2. Thermostat (Oper. Temp) 3. Air Flow Switch 4. Motor Start Relay 5. Terminal Block, Neutral 6. Terminal Block, Power No. Part 7. Flame Safeguard Pro- grammer 7a. Am plifier (UV Scanner) 7b. Timing Card, 30 sec. 8. Programmer, Sub-Base 9. Switch, On/Of[...]

  • Page 48

    Modu-Fire ® Gas-Fired Boiler Parts/Technical Support 45 6.2.3 Gas Trains 6.2.3.1 Standard Gas Train - 1000 No. Part 1. Main Gas Shutoff Cock 2. Main Gas Valve Actuator 3. Main Gas Valve 4. Air/Gas Ratio Control 5. Low Gas Pressure Switch 6. High Gas Pressure Switch 7. Leak Test Valve 8. Pilot Gas Cock 9. Vent Filter 4 3 1 6 5 2 7 8 9[...]

  • Page 49

    Modu-Fire ® Gas-Fired Boiler Parts/Technical Support 46 6.2.3.2 Standard Gas Train - 1500 & 2000 No. Part 1. Main Gas Shutoff Cock 2. Main Gas Valve Actuator 3. Main Gas Valve 4. Air/Gas Ratio Control 5. Low Gas Pressure Switch 6. High Gas Pressure Switch 7. Leak Test Valve 8. Pilot Gas Cock 9. Vent Filter 4 3 1 6 5 2 7 8 9[...]

  • Page 50

    Modu-Fire ® Gas-Fired Boiler Parts/Technical Support 47 6.2.3.3 IRI Gas Train - 1000 No. Part 1. Main Gas Shutoff Cock 2. Main Gas Valve Actuator 3. Main Gas Valve 4. Air/Gas Ratio Control 5. Low Gas Pressure Switch 6. High Gas Pressure Switch 7. Leak Test Valve 8. Normally Open Vent Valve 9. Pilot Gas Cock 10. Vent Filter 4 3 1 6 5 2 7 8 9 10[...]

  • Page 51

    Modu-Fire ® Gas-Fired Boiler Parts/Technical Support 48 6.2.3.4 IRI Gas Train - 1500 & 2000 No. Part 1. Main Gas Shutoff Cock 2. Main Gas Valve Actuator 3. Main Gas Valve 4. Air/Gas Ratio Control 5. Low Gas Pressure Switch 6. High Gas Pressure Switch 7. Leak Test Valve 8. Normally Open Vent Valve 9. Pilot Gas Cock 10. Vent Filter 6 4 1 3 5 2 7[...]

  • Page 52

    Modu-Fire ® Gas-Fired Boiler Parts/Technical Support 49 6.2.4 Cabinet IC EC EC No. Part 1. Exterior Cabinet, Assy. 2. Exterior Cabinet, Door 3. Exterior Cabinet, Top 4. Sight Glass 5. Sight Glass Bezel 6. Combustion Chamber, Assy. 7. Combustion Chamber, Door 8. Combustion Cham ber, Top 9. Control Panel, Label 10. Control Panel, Cover 11. Control P[...]

  • Page 53

    Modu-Fire ® Gas-Fired Boiler Limited Warranty 50 7.0 LIMITED W A RRANTY Subject to the terms and conditions herein and except as pro- vided below with respect to products or parts no t manufactured by Patterson - Kelley Co., Seller warrants to the original owner at the original installation site that products manufactur ed by Seller ("Product[...]

  • Page 54

    BOILER SERIAL # ___________________________ MODEL # _________________ DATE_________________ INSTALLATION: Name: __________________________________________________ City: _________________________ State: ______ Zip: __________ Installer Name: ____________________ Type of Installation: _________________(Hotel, School, Etc) 1. Factory Fire-Test: (copy [...]