Patterson-Kelley Thermific, Installation & Owner'S Manual

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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