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Modu-Fire

Gas-Fired Boiler

Parts/Technical Support

No.

Part

Thermostat (Manual Re-
set)

Thermostat (Oper. Temp)

Air Flow Switch

Motor Start Relay

Terminal Block, Neutral

Terminal Block, Power

No.

Part

Flame Safeguard Pro-
grammer

7a.

Amplifier (UV Scanner)

7b.

Timing Card, 30 sec.

8. Programmer,

Sub-Base

Switch, On/Off, Lighted

10.

Ignition Transformer (not
visible)

No.

Part

10a. Ignition Cable (not visi-

ble)

11.

Indicator Light, Red

12.

Indicator Light, Green

Relays and
Sockets

Remote Control Panel

1 4

Circuit Breaker

7, 7a, 7b, 8

Forced Recycle Time

Delay Relay

Содержание MOD-04

Страница 1: ...st 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 MOD 04 ...

Страница 2: ...r 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 8 5 Water Quality 13 3 9 Burner and Ignition System 13 3 9 1 Inspection 13 3 10 Pre Start Check List 13 3 11 Safety Checks 14 3 11 1 Test of Ignition Safety System 14 3 11 2 Test of Low Water Cut off 14 3 11 3 Test of Limit Controls 14 3 11...

Страница 3: ...sult in fire or injury Read instructions safety manual before installing operating or servicing boiler c WARNING 1998 HCS Inc 800 748 0241 WARNING It is essential to read understand and follow the recommendations of this manual before installing operating or servicing this equipment Failure to do so could result in fire or explosion and serious in jury death and or property damage The same feature...

Страница 4: ...st be consulted 2 0 SAFETY 2 1 GENERAL The MODU FIRE gas fired boiler must be Installed in accordance with designs prepared by qualified facility engineers including struc tural mechanical electrical and other applica ble disciplines Operated and serviced in accordance with a comprehensive safety program determined and established by the customer Do not attempt to operate or service until such a p...

Страница 5: ...48 0241 Reorder No 5025 V1WHPK Follow lockout tagout procedure when servicing this boiler Electrical hazard Shock hazard Properly lockout tagout the elec trical 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 res...

Страница 6: ...s inlet pressure does not exceed 14 inches w c to the regulator Overfire hazard Possible fire and explosion Possible malfunction of regulators and or mo torized gas valves Maintain all gas train com ponents in good condition Do not alter wiring connections Annual inspection by factory trained personnel for proper set up and opera tion is recommended Overfire and underfire hazards Possible fire exp...

Страница 7: ... 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 c 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 wa ...

Страница 8: ... 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 abs...

Страница 9: ...4 30 24 Non combustible Sur faces 30 24 30 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 eac...

Страница 10: ...de or outside the building In Canada ventilation air openings shall be at least 10 of the cross sectional area required for combustion air but not less than 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 inch for each 4 000 Btu per hour of total ...

Страница 11: ...drain trap or pump in accordance with local codes Refer to diagram under Vent Elbows 3 6 2 Barometric Damper This boiler is certified for operation without a baro metric damper P K does not recommend the use of one 3 6 3 Automatic Vent Damper WARNING This equipment as manufactured MUST NOT be used with an automatic vent damper 3 6 4 Flue Connection The connection from the boiler to the vent should...

Страница 12: ...on 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 6 After it has been determined that each appliance remaining connected to the common venting sys tem properly vents when t...

Страница 13: ...for more information WARNING All threaded connections must be made using a pipe compound that is resistant to the action of liquefied petroleum gases Do not use Teflon tape on gas line threads Pipe Capacity for Natural Gas Equivalent Pipe Length Maximum Capacity in Cubic Feet of Natural Gas per Hour Pressure Drop of 0 5 inch Water Column Equivalent Length of Pipe in feet Nominal Iron Pipe Size Inc...

Страница 14: ...ected by an insect screen The air gas ratio control valve is equipped with a reference chamber vent filter which does not re quire any additional venting This connection is labeled COMBUSTION ATMOSPHERE If local conditions require venting to outdoors the vent line connection must be piped by the installer in accordance with the National Fuel Gas Code NFPA 54 ANSI Z223 1 which states In the case of...

Страница 15: ...lled such that no piping stresses are transmitted to the boiler The boiler should not be used as a pipe anchor 3 8 3 Boiler Water Piping by Installer Strainer To avoid possible contamination of the boiler with dirt rust or sediment from the system a strainer near the boiler inlet is strongly recommended Even new systems may contain sufficient foreign material to eventually reduce the performance o...

Страница 16: ... and finish filling the system 3 8 5 Water Quality The boiler is designed to operate in a closed loop system As such the system should be tight and not require make up water A high percentage of un treated make up water can cause premature failure due to buildup of scale Such failure is not covered by warranty Scale can also reduce efficiency For example a scale thickness of 1 16 will result in a ...

Страница 17: ...d be cycled on After all the safety limits on gas pressure water flow and temperature are satisfied the blower will run and pre purge the boiler 3 When air flow is established the ignition trans former and pilot will operate Both functions will be indicated by separate indicator lights on the flame safeguard 4 If a satisfactory pilot is established the spark will terminate and the pilot will remai...

Страница 18: ...er operation of the boiler This switch is set by the factory at 4 0 w c and must not be changed This switch must be checked by factory trained per sonnel 3 12 INITIAL ADJUSTMENTS 3 12 1A Configuring the Local Controller Applies to models furnished with programmable temperature control Operating Modes Internal Setpoint Night Setback Alternate Setpoint Outdoor Air Reset Analog Input Setpoint See Sec...

Страница 19: ...oor Air Reset The control must be configured for outdoor air reset See the configuration menu The setpoint of the boiler is controlled by an out door temperature sensor As the outdoor tempera ture falls the setpoint of the boiler is increased The boiler modulates to maintain this setpoint The boiler functions as indicated in internal setpoint however SP1 is determined by the outdoor air tem peratu...

Страница 20: ...ls can be activated from here Operation of the Control The temperature control has three levels of cascad ing menus They are USER level PARAMETER level and the CONFIGURATION level The following table indicates the menu options available from each level The options available depend on the operating mode of the boiler User Level To access the User level from the basic display press PGM Change the se...

Страница 21: ...Manual operation can only be activated if the burner relay is on If the control sets the burner relay to off during manual operation then the control is changed to automatic operation Parameter Level To access the parameter level press and hold the PGM button for longer than two 2 seconds The parameters available in this level are used for proper functioning of the boiler with the system Within th...

Страница 22: ...Modu Fire Gas Fired Boiler Installation 19 Table 1 Table of Parameters ...

Страница 23: ...l bypass switch of the BMS must be installed by the control contractor WARNING Do not bypass any safety limits with this switch 3 12 2 Air Flow Adjustments The air flow is pre set at the factory prior to ship ment The air and gas may have to be adjusted for local conditions All air flow adjustments must be performed by factory trained personnel The air and gas are adjusted at two firing rates High...

Страница 24: ... lower screw of the air gas ratio control vale Using a combustion analyzer adjust the oxygen reading between 6 5 and 7 5 Set the boiler at Low fire as described in the boiler opera tion section of the manual For initial adjustment the cabinet pressure should be the same as shown on the Factory Firetest label The Low fire gas pres sure is adjusted with the upper screw of the air gas ratio control v...

Страница 25: ... un der water 4 2 1 Lighting Procedures 1 Utilities Turn on electric supply to boiler Open gas supply valves Make sure system is filled with water and turn on circulation pump 2 Reset Switches Press reset button on gas pres sure switches attached to main gas valve at back of boiler if gas supply was turned off Press control reset button after safety lockout 3 Set desired limit and operating temper...

Страница 26: ...y Shut Off Main and pilot gas cocks should be closed immedi ately if an emergency situation occurs see Section 4 2 1 for the location of the gas cocks If overheating occurs or the gas supply fails to shut off do not turn off or disconnect the electrical sup ply to the pump Instead shut off the gas supply at a location external to the boiler 4 3 TYPICAL BOILER OPERATING CONDITIONS Natural Gas 1030 ...

Страница 27: ...e pilot and main flame A normal High fire flame is blue If the flame is yellow then corrective action must be taken In Low fire the burner will glow a yellowish orange Correct air adjustment is essential to the efficient operation of this boiler If an adjustment in the combustion is necessary the flue gas composition should be checked with a carbon dioxide CO2 or oxygen O2 analyzer to set conditio...

Страница 28: ...n or deterioration If any piping needs replacing do so immedi ately 5 Inspect heating system for other problems This work should be performed by factory trained personnel 6 Perform combustion analysis 7 The relief valve should be tested as per the valve manufacturer s recommendations at least annually or as indicated by local codes 8 Leak test gas valves 5 2 CLEANING THE BURNER Burner Assembly 1 F...

Страница 29: ... the manifold assembly containing the temperature pressure indicator relief valve and the water flow switch on the D series units dis connect at the grooved pipe coupling Victau lic 8 Remove the nuts and bolts from the flanges of the inlet and outlet nozzles at the rear of the outer casing 9 Remove the exchanger and clean the fins Note The inner and outer cabinets are separate parts and reassembly...

Страница 30: ...per position limit switch applies power to terminal 6 on the damper motor This ener gizes relay 2 and stops the air damper motor The motor contactor is energized through relay 2 The air flow switch initially shows low air flow with the LOW AIR indicator This indi cator will remain on until sufficient air flow is sensed If the damper motor is not open enough for purge relay 2 is not energized the c...

Страница 31: ...e set limit the switch is closed Manual reset is required fol lowing conditions exceeding high limit tempera ture 6 When heat is required as indicated by the outlet water temperature power is applied to Terminal 6 of the programmer which initiates the burner ignition and operation sequence 7 The flame safeguard control first energizes Terminal 5 which energizes control relay R1 energizes the motor...

Страница 32: ...g all automatic valves and halting all boiler operations When power is restored the sequence of operation will resume at Step 5 provided that all the limits are satisfied Loss of Water Flow When the Water Flow indicator is illuminated there is insufficient water flow to close the switch and burner operation is interrupted When water flow is re established the sequence returns to Step 2 provided th...

Страница 33: ...pro grammer except Terminal A which is connected to the Flame Failure indicator A manual reset of the programmer located inside the control panel is required Flame Failure In the event of a main flame failure during a firing period the main fuel valves are de energized and the programmer immediately goes into lockout mode If flame failure occurs and the indicator is illuminated the programmer must...

Страница 34: ... serial number of your boiler available 6 1 SCHEMATIC DIAGRAMS Typical schematic drawings are shown on the following pages Drawings specific to your par ticular equipment can be supplied by your local P K representative Table of Contents for this Section Standard Unit Local Control Logic Diagram Standard Unit Remote Control Logic Diagram Standard Unit Local Remote Control Logic Diagram Standard Un...

Страница 35: ...Modu Fire Gas Fired Boiler Parts Technical Support 32 2 START INTERLOCK FLAME SAFEY ALARM 1 START INTERLOCK CUSTOMER CONNECTIONS Standard Unit Local Control Logic Diagram ...

Страница 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 ...

Страница 37: ...Modu Fire Gas Fired Boiler Parts Technical Support 34 CUSTOMER CONNECTIONS 2 START INTERLOCK FLAME SAFEY ALARM 1 START INTERLOCK ANALOG INPUT Standard Unit Local Remote Control Logic Diagram ...

Страница 38: ...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 ALARM ANALOG INPUT Standard Unit Local Remote Control w Options Logic Diagram ...

Страница 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 ...

Страница 40: ...Modu Fire Gas Fired Boiler Parts Technical Support 37 ANALOG INPUT CUSTOMER CONNECTIONS 1 2 0 1 6 0 FLAME SAFETY ALARM 1 START INTERLOCK 2 START INTERLOCK IRI Unit Remote Control Logic Diagram ...

Страница 41: ...Modu Fire Gas Fired Boiler Parts Technical Support 38 ANALOG INPUT CUSTOMER CONNECTIONS 1 2 0 1 6 0 FLAME SAFETY ALARM 1 START INTERLOCK 2 START INTERLOCK IRI Unit Local Remote Control Logic Diagram ...

Страница 42: ...NALOG INPUT ANALOG INPUT SETPOINT mA V c OUTDOOR AIR TEMPERATURE 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 Logic Diagram ...

Страница 43: ...Modu Fire Gas Fired Boiler Parts Technical Support 40 Standard Unit Panel Layout ...

Страница 44: ...Modu Fire Gas Fired Boiler Parts Technical Support 41 IRI Unit Panel Layout ...

Страница 45: ...bi net 7 Pilot Tube Inside Cabinet 8 Burner Inside Cabinet 9 Heat Exchanger 10 Blower Damper 11 Pressure Relief Valve 100 PSI No Part 12 Water Flow Switch 13 Blower Motor Inside Cabinet 14 Blower Wheel Inside Cabinet 15 Press Temp Gauge Installation Owner s Manual All Models MOD CP Control Panel Section 6 2 2 EC Exterior Cabinet Section 6 2 4 IC Interior Cabinet Section 6 2 4 PG Pilot Gas Train Se...

Страница 46: ...l 6 Terminal Block Power No Part 7 Flame Safeguard Pro grammer 7a Amplifier UV Scanner 7b Timing Card 30 sec 8 Programmer Sub Base 9 Switch On Off Lighted 10 Ignition Transformer not visible No Part 10a Ignition Cable not visi ble 11 Indicator Light Red 12 Indicator Light Green 2 6 Circuit Breaker Relays and Sockets 1 4 7 7a 7b 8 9 11 3 12 5 Forced Recycle Time Delay Relay Local Control Panel ...

Страница 47: ...l Block Power No Part 7 Flame Safeguard Pro grammer 7a Amplifier UV Scanner 7b Timing Card 30 sec 8 Programmer Sub Base 9 Switch On Off Lighted 10 Ignition Transformer not visible No Part 10a Ignition Cable not visi ble 11 Indicator Light Red 12 Indicator Light Green Relays and Sockets Remote Control Panel 6 1 4 2 Circuit Breaker 7 7a 7b 8 9 11 3 12 5 Forced Recycle Time Delay Relay ...

Страница 48: ...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 ...

Страница 49: ...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 ...

Страница 50: ...I 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 ...

Страница 51: ...as 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 8 9 10 ...

Страница 52: ...rior Cabinet Top 4 Sight Glass 5 Sight Glass Bezel 6 Combustion Chamber Assy 7 Combustion Chamber Door 8 Combustion Chamber Top 9 Control Panel Label 10 Control Panel Cover 11 Control Panel Sub Panel 12 Control Panel Base Assy 4 5 12 3 1 9 10 2 2 1 3 4 5 11 9 10 12 11 8 6 7 Internal Cabinet 1000 External Cabinet 1500 2000 External Cabinet ...

Страница 53: ...rt E The suitability of any Product for any particular applica tion F Any failure resulting from misuse modification not au thorized by Seller in writing improper installation or lack of or improper maintenance G Equipment furnished by the owner either mounted or un mounted or when contracted for by the owner to be in stalled or handled H Leakage or other malfunction caused by 1 Defective installa...

Страница 54: ...c c Ratio Setting Pilot Flame Signal Volts 5 Approximate stack lengths Main Flame Signal Volts Ft Horizontal Ft Vertical Flue Pipe Diameter 6 Draft measured where stack exits boiler w c Start Up Field Test DATE w c Low High Mid Low 7 Incoming Electrical Power Volts a c Cabinet Air w c w c w c Inlet Gas w c w c w c 8 Total cycles Manifold Gas w c w c w c 9 Total hours Oxygen O2 10 Fault Cycle Carbo...

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