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Patterson-Kelley Thermific, Installation & Owner'S Manual

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Patterson-Kelley Thermific Installation & Owner'S Manual Download Page 1

 

 

 

 

 
 
 
 

PATTERSON-KELLEY 

 

THERMIFIC

®

 

GAS-FIRED BOILER 

 
 

 

 

 

 

 

 
 

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 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

Summary of Contents for Thermific

Page 1: ...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 a...

Page 2: ......

Page 3: ...1 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...

Page 4: ...241 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 explosio...

Page 5: ...ermific 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 d...

Page 6: ...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 ener...

Page 7: ...es 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 cond...

Page 8: ...y 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 o...

Page 9: ...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...

Page 10: ...4 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 stacki...

Page 11: ...10 square inches It is to be located at the highest practi cal point communicating with outdoors If air is taken directly from outside the building each opening should have a net free area of 1 square...

Page 12: ...or specific installation requirements 2 The damper may be located in either side of the horizontal section of stack 3 In a multiple boiler installation one barometric damper must be installed with eac...

Page 13: ...e at maximum speed Do not operate a summer ex haust fan Close fireplace dampers 4 Place the appliance being inspected in operation Follow the lighting instructions Adjust the ther mostat so that the a...

Page 14: ...CGA B 149 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 on 1 cubic foot of natural gas...

Page 15: ...leed vents and vent the diaphragm gas valves to outdoor air field piping Gas Vents by Installer Note Provide a drip leg as shown in the vent line All vent lines should be pitched up at all times to pr...

Page 16: ...rongly recommended Even new systems may contain sufficient foreign material to eventually reduce the performance of the heat ex changer Adequate circulation of good clean water is essential to maximum...

Page 17: ...t is properly positioned to ignite the main burner 3 10 PRE START CHECK LIST Before attempting to start the boiler make sure the following items have been completed 1 Flue gas from the boiler is prope...

Page 18: ...the switch can be checked by first turning the boiler off and then turning the system pump off stopping water flow in the system After turning off the pump turn the boiler back on It should not oper...

Page 19: ...ure reference Programming Worksheet Stage 1 SetPt 1 Ta On at Tb Diff 1 Tdl Off at Ta Stage 2 SetPt 2 Tb On at Tc Diff 2 Td2 Off at Tb Select Set Enter Lo Hi Lo Operating Temperature Controller To adju...

Page 20: ...is required follow manufacturers instructions and pre set the Lo fire set ting of the actuator the same as the original actuator This must be performed by qualified service person nel To adjust gas p...

Page 21: ...of rated input Fuel adjustments for proper fuel input are made first at the gas pressure regulator with the valve actuator in the Hi fire position Lo fire fuel adjustments are made second with the val...

Page 22: ...definite stop screw until it touches the defi nite stop and lock it with the nut Note Do not utilize the Hi fire definite stop screw to adjust Hi fire air on Lo Hi Lo models Lo fire adjustments are ma...

Page 23: ...1 13 CSA 4 9 latest edition See Factory Firetest label 4 2 LIGHTING AND SHUT DOWN PROCEDURES Do not use this boiler if any part has been under water Immediately call a qualified service technician to...

Page 24: ...LER OPERATING CONDITIONS Natural Gas 1030 Btu cu ft LP Gas 2500 Btu cu ft Model Number Input Rating Btu hr Gas Rate CFH Manifold Pressure in W C Output Capacity Btu hr Gas Rate CFH Manifold Pressure i...

Page 25: ...ment in the combus tion is necessary the flue gas composition should be checked with a carbon dioxide CO2 or oxygen O2 analyzer to set conditions for about 50 excess air 5 1 3 Monthly During Operation...

Page 26: ...mbustion analysis 5 2 CLEANING THE BURNER 1 Close pilot and main gas cocks 2 Turn off the electric current to the boiler 3 Remove the top cover of the boiler 4 Disconnect the electrode wire 5 Disconne...

Page 27: ...f this boiler are specifically de signed to indicate the sequence of operations and the cause of common problems Careful observation of indicators should provide a guide to most operational conditions...

Page 28: ...ater temperature is reduced by the load on the system the operating control switch will close again The operating sequence will recycle to step 5 provided that the limits on water flow gas pressure an...

Page 29: ...a safety lockout occurs Flame Failure In the event of a flame failure during a firing period the main fuel valves are de energized and the pro grammer immediately returns to Step 7 or goes into a loc...

Page 30: ...ey by calling 570 421 7500 or 877 728 5351 Ask for the Heat Transfer Department The fax number is 570 476 7247 Refer to the parts list shown on the assembly drawing provided with this manual Technical...

Page 31: ...this Section 6 1 1 On Off On Off Wiring Diagram page 28 On Off Logic Diagram 29 6 1 1a On Off IRI On Off IRI Wiring Diagram 30 On Off IRI Logic Diagram 31 6 1 2 Lo Hi Lo Lo Hi Lo Wiring Diagram 32 Lo...

Page 32: ...Thermific Gas Fired Boiler Parts Technical Support Page 28 6 1 1 On Off On Off Wiring Diagram...

Page 33: ...Thermific Gas Fired Boiler Parts Technical Support Page 29 On Off Logic Diagram...

Page 34: ...Thermific Gas Fired Boiler Parts Technical Support Page 30 6 1 1a On Off IRI On Off IRI Wiring Diagram...

Page 35: ...Thermific Gas Fired Boiler Parts Technical Support Page 31 On Off IRI Logic Diagram...

Page 36: ...Thermific Gas Fired Boiler Parts Technical Support Page 32 6 1 2 Lo Hi Lo Lo Hi Lo Wiring Diagram...

Page 37: ...Thermific Gas Fired Boiler Parts Technical Support Page 33 Lo Hi Lo Logic Diagram...

Page 38: ...Thermific Gas Fired Boiler Parts Technical Support Page 34 6 1 2a Lo Hi Lo IRI Lo Hi Lo IRI Wiring Diagram...

Page 39: ...Thermific Gas Fired Boiler Parts Technical Support Page 35 Lo Hi Lo IRI Logic Diagram...

Page 40: ...Thermific Gas Fired Boiler Parts Technical Support Page 36 6 1 3 Water Cut Off On Off Low Water Cut Off Diagram...

Page 41: ...Thermific Gas Fired Boiler Parts Technical Support Page 37 Lo Hi Lo Low Water Cut Off Diagram...

Page 42: ...hanger 10 Blower Damper inside cabinet 11 Pressure Relief Valve 100 PSI 12 Water Flow Switch 13 Blower Motor 14 Blower Housing No Part 15 Blower Wheel 16 Press Temp Gauge w 100 PSI relief valve 17 Dam...

Page 43: ...Junction 7 Terminal Block Power 8 Flame Safeguard Programmer 8a Amplifier Flame Rod Amplifier UV Scanner 8b Timing Card 10 sec 8c Timing Card 30 sec 9 Programmer Sub Base 10 Switch On Off No Part 11...

Page 44: ...12 No Part 1 Main Gas Valve Diaphragm 2 Low Gas Pressure Switch 3 Main Gas Regulator 4 Main Gas Shut off Cock 5 Pilot Solenoid Valve 6 Pilot Regulator 7 Pilot Shut off Cock 8 High Gas Pressure Switch...

Page 45: ...12 11 9 10 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 C...

Page 46: ...es available to Buyer set forth herein are exclusive remedies and all other remedies statutory or otherwise including but not limited to the right of redhibition are waived by the buyer Buyer acknowle...

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