Patterson-Kelley TBIG-03 User's Manual
Contents
1. ININ39 340 NO OLIINH3HI 7 dW3L AVIS ATIVRION OZOLOS68LNY TI3MA3NOH M TE m WVYOVIC 181 318340 OL SI TOMINOD TINH ti 7WN43JX3 JI 834 MONJA 3AONGH Lu 330 NO TONLNOD LINN 1VNY31X3 IANA SNITIVISNI 330438 033 ows d3y 1385 XILVA 01 3009 9 22 53 03 5 0 V9 91 SINN 1H N 041 WNINS3L N03 NO NSNS fo DINE 03 1x3 92 SOLINSI BO103NNOD NO HShd 5 0 3009 WNIWY3L 13538 IW NVN G5 HOIIMS SS3Hd SV9 SVO WANN HOLIMS Qn _ INJWARO3 80 08 HOLIMS OWOIN 06 MLN 3dAL Q30v1d3H 38 ISNW LI O Q3Ovid3M 38 1500 3ONvIlddv HUM IRN ON 08 03114405 SV WNIOINO JHL JO ANY 31 mnes 93 A Y NEN 83 93 93 u2. 1 120 60 1 OFF 12 AMPS v MES rS 1 FUSED BY OTHERS m W EQUIPMENT GROUND A ON BLOWER 4 EE LE ed 4 2 STAGE TEMP CONTROL BULB HONEYWELL T775A1019 FT T2 120 Ex EOM Uf OFF POWER 2 1 E1 17 cn AUTO x NG LP FUEL ON LP WATER FLOW 18 4 LOCAL REMOTE SWITCH co ES 2 1 4 31 1 deum GAS PRESS 2 2 VALVE 3 WATER CLOSED CONTACTS amp LOW FIRE FLOW LP DRESS DRESS NG LP E14 0 EB ALVE MANUAL VALVE MANUAL VALVE CLOSED SWITCH SWITCH contacts UNO RESET 6 en B T 4 z oF z 1 AIR FLOW HEAT 20 aa aS 7 8 2 2 8 oo wit IGNITION ma E TRANSFORMER um 25 LOW ENTER 14 167 2J 5 2 EE 5 IGNITE gt uw
3. H HOLIMS SYSHLO 09 1 021 123 02510 03514 ac 61 Lz 3 xS 709008400 5 MOTA 9 01 IH O1 OlJIAN3HL 9 zen 13539 TANYA 02012568 48 TI3MA3NOH M wovis IH 1N3A WVHOVIQ ONIMIM lal ot N3dO WYON 334 1 31 8340 01 SI 10MINOO WwW 13 13 31 YIAN MOTIJA 83 43 v3 tc JAVA 330 NO 70 1 02 LNT TWNYSLX3 8 wee Sv9 01 SNITIVISNI 380338 f 330170 wy 9 ez R 41 013 22 iiv ORATE 3000 80102 T4 TEGSCWAMN N 5 5 vO ZZ S NI G3HSvd 91 SINN 1H9N HOLIMS SS3Nd SVO 91 JAVA 3NWA T
4. high gas pressure switch motorized gas valve manual TET shutoff n o vent valve regulator 1 only Items with symbol must be motorized gas valve vented to outside Refer to the low gas propane drawings packed with your pressure switch boiler for additional information Figure 4 1 Piping Schematic for the Twin Fuel Gas Train 4 0 INSTALLATION Gas Train Connection Sizes The following procedures are different from those for the single fuel model and are described in this Sec Natural Gas Propane tion 700 1000 1200 11 4 1 e Gas Piping Series Gas Bleeds and Vents 1500 1700 2000 2 11 4 SUB Series re Start Check List e Pre Start Safety Checks and Adjustments Test of Ignition Safety System Test of Low Water Cutoff Test of High Limit Control 4 1 GENERAL Installation of the twin fuel Gemini boiler is similar to that of the single fuel model Refer to Thermific Gas Fired Boiler Installation and Owner s Manual Test of Gas Pressure Switch TBIG pages 2 through 10 Gemini Twin Fuel Gas Fired Boiler Gas Pressure Adjustment Test of Motorized Gas Valves 4 2 GAS PIPING Before making the gas hook up make sure the boiler is being supplied only with the fuels shown on the boiler nameplate The boiler 1s designed to operate on vaporized natural gas and pr
5. Gs 6 4 2 1 Gas Bleeds and Vents 7 4 3 Pre Start Check 7 4 4 Pre Start Safety Checks and Adjustments 7 4 4 1 Test of Ignition Safety System 8 4 4 2 Test of Low Water Cutoff 9 4 4 3 Test of High Limit Control 9 4 4 4 Test of Gas Pressure Switch 4 4 5 Gas Pressure Adjustment 4 4 6 Leak Testing of Valves 5 0 OPERATION 5 e sicc 5 1 General eer eges Ren inn 5211 StS th aed E tus 5 1 2 Starting 5 2 Lighting and Shut Down Procedures 5 2 1 Lighting Procedures 5 2 2 Normal Shut Down Procedures 5 2 3 Emergency Shut Down 5 3 Switchover to Propane Operation 7 0 7 1 General sse 7 2 Sequence of 8 0 PARTS AND TECHNICAL SUPPORT 8 1 Wiring 8 1 1 Wiring Diagram Lo Hi Lo 8 1 2 Control Logic Diagram Lo Hi Lo 8 1 3 Wiring Diagram On Off 8 1 4 Control Logic Diagram On Off It is essentia
6. pilot gas gas valve supply natural gas connection 2 propane regulator and shutoff natural gas regulator natural gas gas valve auxiliary panel service power shutoff switch inside propane low propane m e j gas valve switc u natural gas low pressure tap pressure switch water secondary connection shutoff natural gas gas valve high gas pressure Switch natural gas regulator main gas valve pilot gas supply propane natural gas connection 1 connection 1 1 4 and shutoff and shutoff Figure 5 1 Twin Fuel Gas Train Top photo shows 1500 1700 1900 series bottom shows 700 900 1200 series 12 5 0 OPERATION 5 1 GENERAL The basic operation and control functions of the Gem ini twin fuel gas boiler are similar to the single fuel models 5 1 1 Tests Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on this boiler when the boiler underwent tests speci fied in ANSI Z21 13 latest edition or CAN 1 3 1 in Canada See Factory Firetest label 5 1 2 Starting System Do not use this boiler if any part has been under water Immediately call a qualified service technician to in spect the boiler and to replace any part of the control system and any gas control which has been under wa ter 13 Operation 5 2 LiGHTING AND SHUT DOWN PROCEDURES 5 2 1 Lighting Procedures high limit operating fuel pr
7. GEMINI NATURAL GAS AND PROPANE FIRED BOILER Companion Document to the Installation and Owner s Manual TBIG for the Thermific Gas Fired Boiler 3112 A G A Design Certified Complies with ANSI Z21 13 Low Press Boiler aT ASME Code Section IV Certified by Patterson Kelley HN Complies with CAN 1 3 1 Ind amp Comm Boilers Patterson Kelley Co harsco company P O Box 458 East Stroudsburg PA 18301 Phone 570 421 7500 Fax 570 476 7247 www patkelco com 1999 Patterson Kelley a Harsco Company GGIG 99 Gemini Twin Fuel Gas Fired Boiler TABLE OF CONTENTS 1 0 1 2 0 DESCRIPTION i 2 2 1 Principle of Operation 2 30 SAFETY 2 3 1 2 3 2 Training ect cf xs 2 9 9 Safety 3 3 4 Safety Labels 3 3 5 Safety Precautions eene 3 3 5 1 Electrical Hazards 3 3 5 2 Burn Fire and Explosion Hazards 3 3 5 3 Crush Hazards 4 3 5 4 Chemical 4 4 0 INSTALLATION 5 4 1 5 4 2 GAS PIPING
8. manual shutoff 1 0 ep low gas EM Sd n pressure switc propane 26 connection 4 shutoff regulator motorized gas valve low gas propane pressure switch 7 0 MAINTENANCE 7 1 GENERAL A WARNING Warning High voltage Shock hazard Properly lock out tagout the electrical service and all other energy sources before working on or near the machine For testing control circuits only the service power shutoff switch located inside the auxiliary panel may be used to de energize the system in lieu of normal lockout tagout procedures Use extreme caution when using this alternative 15 secondary leak test shutoff manual valves high gas pressure switch motorized gas valve n o vent valve I R 1 only Items with symbol must be vented to outside Refer to the drawings packed with your boiler for additional information Figure 7 1 Piping Schematic for the Twin Fuel Gas Train service power shutoff switch Figure 7 2 Service Power Shutoff Switch located inside the auxiliary panel at the back of the boiler Maintenance of the twin fuel gas boiler is similar to that of the standard model Refer to pages 11 through 14 of the Installation and Owner s Manual TBIG Gemini Twin Fuel Gas Fired Boiler In the case of the twin fuel boiler the phrase main gas cock or main gas val
9. FLAME ROD 2 gt 5 2 AS PILOT PILOT UE o VALVE icy 167 NG GAS B eres VALVE ON oFF 2 3 2 E E19 NO OPEN 5 Lr VENT vave e 0 COMMON LO HI GAS m __ _ ri 21 Yi Y2 x lt Jee YELLOW PES a JUMPER OPER TEMP T 11 E 177541019 Jee H J RED HIGH FIRE E9 JUMPER 4 4 FLAME FAILURE 2 CUSTOMER REMOTE FUEL SELECTION cee EIS REMOVE RED JUMPER BEFORE INSTALLING 24 vor 582 IF ANY OF THE ORIGINAL WIRE AS SUPPLIED EXTERNAL LIMIT CONTROL Vie n WITH THE APPLIANCE MUST BE REPLACED REMOVE YELLOW JUMPER IF EXTERNAL E1 IT MUST BE REPLACED WITH TYPE MTW 90 C LIMIT CONTROL IS TO OPERATE HI FIRE to IRE OR EQUIVALENT REQUIRED FOR IRI COMPLIANT UNITS ONLY LP FUEL OPERATION o 40 e 09 A311 NOSM3LIVd pa 6090086001 HOLAS AD 13538 vnNvW AWA INA 390 Gemini Twin Fuel Gas Fired Boiler 8 1 3 Wiring Diagram On Off
10. model Information which applies to both models is found in the main manual Gemini Twin Fuel Gas Fired Boiler 2 0 DESCRIPTION 2 1 PRINCIPLE OF OPERATION Natural gas and propane are permanently piped to separate connections on the boiler Each branch of the gas train is fitted with a regulator and a motorized gas valve The regulators are adjusted to properly fire the boiler from their respective sources Boiler and con trol functions are the same for both fuels In the event of interruption or restriction of the natural gas supply changeover to propane is made manually 3 0 SAFETY 3 1 GENERAL The Gemini gas fired boiler must be e Installed by qualified personnel in accordance with designs prepared by qualified facility engi neers including structural mechanical electrical and other applicable disciplines e Operated and serviced in accordance with a com prehensive safety program determined and estab lished by the customer and complying with all safety provisions of this manual Do not attempt to operate or service the boiler until such a pro gram has been established e Operated and serviced by qualified properly trained personnel in accordance with all applica ble laws and regulations by a selector switch on the boiler or by a signal from a remote switch or controller When the natural gas supply is reestablished change over is made by restoring the selector switch to its normal position
11. or by sending the appropriate signal from the remote controller 3 2 TRAINING 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 serious injury death and or property damage Proper training is the best protection against accidents Operating and service personnel must be thoroughly familiar with the basic construction of the Gemini boiler the use and locations of the controls the opera tion of the boiler adjustment of its various mecha nisms and all applicable safety precautions If any of the provisions of this manual are not fully and com pletely understood contact the Patterson Kelley Sales Department at 570 421 7500 for assistance 3 3 SAFETY FEATURES It is the responsibility of the customer to maintain the safety features of this machine such as guards safety labels safety controls interlocks lockout devices etc in place and operable 3 4 SAFETY LABELS NOE Miske gare thes anion i5 fight before closing cabinet cover ster servicing boiler When opening teak Ims valves always iga and manual Fi lik Electrical harari The safety labels shown above are affixed to your boiler Although the labels are of high quality they may become dislodged or unreadable over time Con tact Patterson Kell
12. than the minimum indicated on the rating plate 6 inches W C for natural gas 6 inches W C for propane The remaining tap 1s lo cated downstream from the secondary manual shutoff valve at the elbow where the gas line enters the back of the cabinet and is for measuring the manifold gas pressure 1 8 I P S If a replacement Lo Hi Lo actuator is required follow manufacturer s instructions and pre set the Lo fire setting of the actuator the same as the original actua tor This must be performed by qualified service per sonnel To adjust gas pressure first connect an appropriate pressure sensing device at the manifold tap then re move seal cap from regulator Turn adjusting screw clock wise to increase pressure counter clockwise to decrease pressure The manifold gas pressure on the 10 Rating Plate affixed to the back of the cabinet is provided only as a guide to the proper setting The manifold gas pressure indicated on the Factory Fire test label affixed to the back of the cabinet should be used to achieve the proper firing rate of the individual boiler as installed Replace seal cap after adjustment 4 4 6 Leak Testing of Valves Annually test for by pass leaks on all motorized gas valves If gas flows when the motorized gas valve is closed it is defective motorized gas secondary valve natural motorized gas gas valve secondary shutoff to burner downstream leak test v
13. the boiler 14 5 3 SWITCHOVER TO PROPANE OPERATION Switchover from natural gas to propane is made manually as follows 1 Tur the fuel selector switch located on the main control panel from natural gas to propane The boiler will go through a complete shutdown and restart procedure when the fuel source is changed If the changeover is controlled by a remote signal the switch on the auxiliary control panel should be set at Automatic for both natural gas and propane opera tion operation of the remote switch will change the fuel source During natural gas service interruptions or restrictions sufficient natural gas is usually available to operate the pilot In the event of complete failure of the natu ral gas supply contact Patterson Kelley at 570 421 7500 for assistance General Warning Warning In the event of low pressure in either the natural gas or propane supply the higher pressure gas could backfeed into the lower pressure line This could result in unsafe operation of other devices connected to the higher pressure supply Always shut off the gas cock to a line which exhibits low pressure Maintenance pilot regulator and motorized gas valve natural gas regulator pilot d solenoid valve mechanical link to control air Lo Hi Lo only burner shutoff natural gas connection pressure tap
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16. VNIWH3L FEMA SV9 WYNN hanvd 1x3 ee S90193NN02 NO HSNd 2 aba i BAA X8 98 SV9 01 HO193NNOO NO HSfid TWNINY3L MIYOS 2 L 22 O 300410373 Jw z ON NONPOS 3002 vNIWH3L XOLNI IL 2 3 i3 HZ INTWAInO3 80 13538 06 MIN Q30v1d3N 38 ISDW LI _ mc NU HOIMS SS3Nd 689 83291434 38 1SnW 3ONVIlddv JHL HLIM 51 CJ JNVdONd 57 5 9 NddNS SV 38 JHL 30 4 lt HOLIMS OMOIN olo HOIMMS AINO SLINA 9 On 69 ANVIIGNOD IJI 04 Q33In03N YSNYOISNVYL 69 NO2 ON 00 v 93 93 Av130 Bald IH 2 81 61 3 vii O vl 2773 F 08 7 X Z7 YOLON i vl 01 39018 9 vc i x 5 ae B 84 T L Q zi O VoL 2 11 LOH umoa 9 HOLIMS lL MOTI IV zi NH 9 02 WOO vei WYLNIN 11 0 OWA 021 ON 2 NETS WOO ou woo l 00012 lt 68 NH vi TISMA3NOH 1 4 LA 18 Parts and Technical Support 8 1 2 Control Logic Diagram Lo Hi Lo
17. alve upstream leak test valve motorized gas valve propane Figure 4 8 Leak Testing of Valves Each branch of the gas train must be tested separately as follows 1 Open the natural gas connection manual shutoff Close the propane connection manual shutoff Refer to Figure 4 1 2 Close the secondary shutoff downstream of all motorized valves 3 Attach a short piece of hose to the downstream leak test valve Refer to Figure 4 8 above In sert the free end of the hose in a cup of water 4 Open the downstream leak test valve and check for bubbles in the hose If there are no bubbles the secondary motorized gas valve is OK If there are bubbles replace the valve 5 Attach the hose to the upstream leak test valve 11 Installation 6 Open the upstream leak test valve and check for bubbles in the hose If there are no bubbles the natural gas motorized gas valve is OK If there are bubbles replace the valve To test the propane branch of the gas train open the propane connection manual shutoff Close the natural gas connection manual shutoff Then repeat steps 5 6 above Gemini Twin Fuel Gas Fired Boiler mechanical link auxiliary panel to air control service power shutoff main gas valve pressure tap i water DAN connection low pressure seconda shutoff 2 0077 switches 3 visible from side propane connection 1 1 4 Mem and shutoff
18. ey at 570 421 7500 for replace ment labels Safety 3 5 SAFETY PRECAUTIONS Provide a suitable location for the boiler away from normal personnel traffic with adequate working space adequate clearances proper ventilation and lighting with a structure sufficiently strong and rigid to support the weight of the boiler all piping and accessories 3 5 1 Electrical Hazards High voltage Shock hazard Properly lock out tagout the electrical service and all other energy sources before working on or near the machine e Install a lockable disconnect switch 3 5 2 Burn Fire and Explosion Hazards AA General Warning Hot Surface Make sare thes anion i5 before cinamg cabinet cover ster servicing boilar When apening leak valens always folc inmbructions in and satry manual Burn fire and explosion hazards Installation must be in strict conformance to all applicable codes and standards including NFPA 54 and ANSI Z223 1 or in Canada CAN B 149 Install all required vent Gemini Twin Fuel Gas Fired Boiler lines for gas devices See Section 4 below Hazard from incorrect fuels Possible fire explo sion overheating and damage Do not use any fuels except vaporized natural gas and propane Under no circumstances is liquid fuel of any kind to be introduced in the boiler Hazard from incorrect fuel connections Possible fire explosion overheating and damage Do n
19. it The limit series is complete unless an external control is placed ahead of the water flow limit replacing the red jumper wire When heat is required as indicated by outlet water temperature power is applied to Terminal 6 of the programmer which initiates the burner operating sequence and to an indicator marked Heat The programmer first energizes Terminal 4 which supplies power to the contactor for the blower mo 16 10 tor and the air flow switch which initially shows low air flow with the LowAir indicator This indicator will remain on until sufficient air flow is sensed A time delay of 10 seconds standard or 30 sec onds depending on insurance or local code re quirements occurs after the air proving switch closes and the programmer signals a continuation of the start sequence During this time period the combustion chamber is pre purged to eliminate any residual combustible gas or combustion prod ucts 10 second trial for ignition period is initiated with both Terminals 10 and 8 being energized Terminal 10 of the programmer powers the igni tion transformer and the Ignite indicator The transformer output creates a spark at the igniter Terminal 8 powers the pilot gas valve and the in dicator for Pilot When a pilot flame is detected by the flame rod a signal is sent to Terminal F in the programmer Terminal 10 is de energized shutting off the spark ignition and the pilot remains on for
20. l gas train components in good condition Do not alter wiring connections Annual inspection by factory trained personnel for proper set up and operation is recommended e Overfire and underfire hazards Possible fire ex plosion overheating and component failure Do not attempt to adjust firing rate of the boiler The firing rate must be adjusted only by factory trained personnel 3 5 3 Crush Hazards General Warning e Lifting hazards Use properly rated lifting equip ment to lift and position the boiler The load is unbalanced Test balance before lifting 3 ft above the floor Do not allow personnel beneath the lifted load Refer to approximate weights in the table below Weight in Pounds 6 6 7 Boiler Size 1 50 50 65 700 000 Btu 1 000 000 Btu 1 200 000 Btu 1 500 000 Btu 1 700 000 Btu 2 000 000 Btu 1 100 1 100 1 100 3 5 4 Chemical Hazards Ah e Environmental hazard The motorized gas valves may contain hydraulic oil Use safe procedures for the disposal of all lubricants Installation pilot regulator and motorized gas valve solenoid valve mechanical link natural gas to control air Y J Lo Hi Lo only shutoff ou burner 1 natural gs 77 connection pressure tap manual shutoff wos ge secondary leak test shutoff manual pressure switch valves propane connection regulator pilot
21. l to read understand and follow the recommenda tions of this manual before installing operating or servicing this Failure to do so could result in serious injury equipment death and or property damage The information and instructions herein pertain only to equip ment supplied by Patterson Kelley Company Patterson Kelley is not responsible for equipment supplied by others nor for any adverse effects such equipment might have on equipment sup plied by Patterson Kelley Introduction Warning This boiler requires VAPORIZED propane or natural gas Under NO CIRCUMSTANCES may liquid fuel of any kind be introduced in the boiler propane connection and shutoff natural gas connection and shutoff Figure 1 1 Twin Fuel Gas Train Shows 1500 1700 1900 Series refer to Figure 5 1 for 700 900 1200 Series 1 0 INTRODUCTION The twin fuel option for the Patterson Kelley Gem ini gas fired boiler allows the boiler to be fired by propane in the event that the supply of natural gas is temporarily interrupted or restricted The necessary fittings valves piping and controls for twin fuel op eration are factory installed This document is a companion to the Installation and Owner s Manual TBIG for the standard Thermific boiler Both documents must be used together This companion document describes those safety installa tion adjustment and maintenance procedures which differ from the single fuel
22. laced the proper distance from any combustible walls in accordance with the Clear ances section of the Installation and Owner s Manual page 3 7 Relief valves have been piped to floor drains 4 4 PRE START SAFETY CHECKS AND ADJUSTMENTS Before placing the boiler in operation perform all the following safety checks and adjustments This work must be performed by qualified service personnel Warning High voltage Shock hazard Properly lock out tagout the electrical service and all other energy sources before working on or near the machine For testing control circuits only the service power shutoff switch located inside the auxiliary panel at the rear of the boiler may be used to de energize the sys tem in lieu of normal lockout tagout procedures Use extreme caution when using this alternative Gemini Twin Fuel Gas Fired Boiler service power shutoff switch Figure 4 4 Service Power Shutoff Switch located inside the auxiliary panel at the back of the boiler General Warning Warning After checking controls by manual readjust ment make sure they are always returned to their proper settings NEVER attempt to operate a boiler that has failed to pass all the safety checks outlined below 4 4 1 Test of Ignition Safety System high limit operating fuel propane high limit temperature selector in use reset adjustments switch indicator flame control on off lo hi lo co
23. n LE 003 34v14 Q 3E 77 07 07 222 54 Oji p CZI TLL 92 ES IE 0E 10719 Op ADIY 01341 INI UD LOH 5 On 33M0 Oime HOLIAS 30151535 5 013 319 wavy 3 0 WaLN3n 81 oO 0393 23S 06 7 00125682 MNH 13533 TUMOR 3univa3dW3L 3en1v83dW31 86 198340 HOH 41 1 gt HOLIMS 98009 173MA3NOH 38007 113 3 0 58 ED 182 330 0 Ir CON gt 282 2 qune SN3H1D AE 05 1 01 193 09511 MISNI iE 20 Parts and Technical Support FUSED BY OTHERS 120 60 1 IU 12 AMPS OFF L1 8 1 4 Control Logic Diagram On Off 9 9 0 6 a 8 8 x as 28 14 8 NW Mot Yel a DAT
24. ntroller reset switch switch Figure 4 5 Lo Hi Lo Control Panel faceplate opened high limit temperature adjustment operating temperature adjustment propane in use indicator and fuel selector switch on side r high limit flame control on off reset reset switch Switch Figure 4 5a On Off Control Panel faceplate opened The boiler is provided with an ignition safety system 1 Open the faceplate on the control panel Discon nect wire 17 Lo Hi Lo or 26 On Off at the terminal block on the control panel Disconnect ing this wire disables the main gas valve ensuring that gas cannot flow during the test 2 Tum on the circulating water pump With the natural gas shutoff and secondary shutoff open and the pilot gas cock open turn the operating temperature control until the boiler cycles 3 Observe the operation of the boiler After all the safety limits on gas pressure water flow and tem perature are satisfied the blower will run and pre purge the boiler When air flow 1s established the ignition transformer and pilot will operate Both functions will be indicated by separate green lights on the control panel If a satisfactory pilot is established the green Ignite light will extin guish and the pilot will remain on alone for 10 seconds After 10 seconds the green Main Gas light will go on The main gas valve will not open with the wire disconnected and gas cannot flow t
25. nts vent to outside air NM M 2 I 1 1 n o vent 1613 valve 1 5 installations Figure 4 3 Schematic Diagram of Bleeds and Vents Gas vents to outdoor air must be provided for the pressure regulators and gas pressure switches If ap proved by authorities having jurisdiction vents may be manifolded in accordance with accepted engineer ing practices to minimize backpressure The pilot regulator is equipped with a vent limiting device and does not require external venting If equipped for Industrial Risk Insurers the normally open vent valve must be vented independ ently from other vented devices as shown above Installation 4 3 PRE START CHECK LIST Before firing the boiler make sure the following items have been completed 1 Flue gas from the boiler is properly vented 2 Gas connections have been made and the gas lines purged of air 3 Water connections are complete and the boiler and system have been filled and purged of air 4 The boiler is connected to a 120 volt power source with a lockable disconnect customer supplied having adequate overload protection 5 Combustion air openings are not obstructed in any way and have adequate capacity 6 The boiler is p
26. o the burner The Pilot will remain on along with the Main Gas for another 10 seconds and then go out Since the main flame cannot be burning at this point there will be no flame signal and the flame safeguard programmer will assume a Flame Failure and will either re cycle through the complete pre purge and ignition cycle or if in surance or local codes require go to a mode Lockout will require manual reset of the flame safeguard After completing this test turn off the boiler and reconnect the wire to the main gas valve Replace the control panel faceplate 4 4 2 Test of Low Water Cutoff The boiler is furnished with a flow switch type low water cutoff in the outlet nozzle l 2 Make sure the boiler is off Turn the system pump off stopping water flow in the system Do not shut the pump off while the boiler is operating Turn the boiler back on It should not operate and a red indicator for Low Water or Water Flow should be illuminated Perform appropriate tests on any external probe type low water cutoff 4 4 3 Test of High Limit Control The boiler is furnished with a high limit cut off l With the main burner operating turn down the temperature setting on the high limit thermostat until the main burner shuts off The high limit switch must be reset manually after testing This check should also be made for the Operating Temperature control The green Heat indica tor
27. opane high limit temperature selector in use reset adjustments switch indicator on off switch flame control controller reset switch lo hi lo Figure 5 2 Lo Hi Lo Control Panel high limit temperature propane in use adjustment indicator and operating temperature fuel selector switch adjustment on side on off switch flame control reset switch high limit reset Figure 5 2a On Off Control Panel Gemini Twin Fuel Gas Fired Boiler 1 Close main natural gas and propane and pilot shutoffs 2 Turn the On Off switch to OFF position 3 Wait 5 minutes 4 Open main natural gas and propane and pilot shutoffs 5 Turn the On Off switch to ON position 6 Push reset button on flame safeguard programmer control 7 Pushreset on low gas pressure switch and high pressure gas switch if applicable 8 Check to be sure that pilot has been established The controller will now complete the automatic firing sequence 5 2 2 Normal Shut Down Procedures 1 Close all manual gas shutoffs 2 Turn off electric power 5 2 3 Emergency Shut Down Natural gas propane and pilot gas shutoff valves on the boiler must be closed immediately if an emergency situation occurs If overheating occurs or the gas supply fails to shut off at the boiler to reduce the possibility of an electrical arc do not turn off or disconnect any electrical sup ply Instead shut off the gas supplies remote from
28. opane only Do not use any type of liquid fuel Do not attempt to fuel the boiler with MAPP gas sewage gas coal gas or other fuels Gas train connection sizes are shown in the Gas Train Connection table on the previous page for the different models available The boiler shall be installed such that the gas ignition system components are protected from water drip ping spraying rain etc during appliance operation and service circulator replacement control replace ment etc The two gas pressure regulators supplied with the boiler are set during a factory fire test to provide the proper pressure to the main burner 6 inches W C in let pressure to the regulators for both natural gas and propane The gas train components are designed to handle a maximum inlet pressure of 14 inches W C 1 2 psig If the available gas pressure exceeds 14 inches W C on either the natural gas or propane supply a suitable intermediate gas pressure regulator of the lock up type must be provided to reduce the pressure to less than 14 inches W C boilers are designed to oper ate at rated input with a minimum inlet pressure of 6 inches W C with natural gas 6 inches W C with LP gas natural gas supply remote gas shutoff union not supplied P 12 shutoff drip leg on boiler propane KH shutoff supply on boiler remote gas shutoff union 4 not supplied P Cx v drip leg Figu
29. ot attempt to connect the propane supply to the natu ral gas connection or vice versa Fire and explosion hazards Close both the natural gas and propane shutoffs before servicing boiler Burn hazard Possible hot surfaces Do not touch gas vent during firing operation Use only factory recommended B vent components Fire and explosion hazards Use caution when servicing burner Propane is heavier than air and may linger the combustion chamber vent lines or elsewhere Gas leak hazard Make sure all connections to main burner are tight when reassembling the burner These connections cannot be tested after burner 15 assembled Gas leak hazard Test motorized gas valves annu ally for leakage as described in Section 4 4 6 Gas leak hazard threaded gas connections must be made using a pipe compound that is resis tant to propane Do not use Teflon tape on threaded gas piping Gas leak hazard Check entire gas train for leaks after installation If there is a smell of gas shut down the boiler and obtain immediate assistance from trained service personnel and or your local fire department Overfire hazard Possible fire and explosion from excess gas pressure Make sure that gas inlet pres sure does not exceed 14 inches W C to the regulator on either the natural gas or propane sup ply line Overfire hazard Possible fire and explosion Possible malfunction of regulators and or motorized gas valves Maintain al
30. re 4 2 Gas Supply Piping Refer to table above for connection sizes Install a sediment trap drip leg and a union connec tion ahead of the primary manual shutoff valves on the boiler as shown in the figure above AII gas piping must be installed in accordance with National Fuel Gas Code ANSI Z223 1 latest edition and any other local codes which may apply in Canada gas piping must be installed in accordance with CAN B 149 General Warning Warning All threaded connections must be made us ing a pipe compound that is resistant to the action of liquefied petroleum gases Do not use Teflon tape on gas line threads The boiler and all gas piping connections must be pressure tested and must be checked for leaks before being placed into service Test with compressed air or gas if possible The boiler must be disconnected at both boiler manual shutoff valves located at the end of the supplied gas train from the gas and propane supply systems during any pressure testing of the system at pressures in ex cess of 1 2 psig 14 inches W C During any pressure testing of the gas supply piping system at pressures equal to or less than 1 2 psig 14 inches W C the boiler should be isolated from the gas supply piping system by closing both manual shutoff valves Some leak test solutions including soap and water may cause corrosion These solutions should be rinsed off with water after testing 4 2 1 Gas Bleeds and Ve
31. rom Patterson Kelley by calling 570 421 7500 Ask for the Boiler Department The fax number is 570 476 7247 Refer to the parts list shown on the assembly drawing provided with this manual Technical information is also available at the above number 17 Maintenance 12 When the water temperature is reduced by the load on the system the operating control switch will close again The operating sequence will re cycle to step 5 provided that the limits on water flow gas pressure and high temperature are all met Before calling please have the model number and se rial number of your boiler available 8 1 WIRING DIAGRAMS Wiring and control schematic drawings are shown on the following pages d Boiler Ire Twin Fuel Gas Fi ini Gem Lo Hi Diagram Lo iring 8 1 1 W 029 1124 5
32. ten seconds during the flame establishing period After the flame establishing period Terminal 9 is energized which opens the motorized main gas valve and the motorized gas valve to the fuel sup ply in use and lights the Main Gas indicator The boiler fires After ten seconds Terminal 8 is de energized and the pilot valve and indicator light are extinguished An auxiliary panel prevents the motorized gas valves for natural gas and propane to be open at the same time Lo Hi Lo When Terminal 9 1s energized the Lo Hi Lo valve will be maintained in the low fire po sition for low fire start for ten seconds If the operating temperature control calls for high fire the programmer will initiate high fire Terminal 21 at the same time the pilot valve and indicator is de energized A power failure during operation closes all motor ized gas valves and shuts down the boiler When power is restored the controller recycles to Step 1 all steps and safety checks are repeated The mo torized gas valves cannot reopen in the absence of ignition 11 When the desired water temperature is reached the operating control switch opens and the pro grammer is de energized at Terminal 6 and the in dicator for Heat 1s turned off This action also de energizes Terminal 9 thus closing both main gas valves and turning off the indicator for Main Gas 8 0 PARTS AND TECHNICAL SUPPORT Spare parts and replacement parts can be ordered f
33. ve as used in the Installa tion and Owner s Manual applies to the manual shut offs for both the natural gas and propane supplies 7 2 SEQUENCE OF OPERATION Status red and green indicators located on the front of the control panel of 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 and problems Refer also to the wiring diagrams in Section 8 The sequence of operation for the twin fuel model differs slightly from the standard model l When the On Off main power switch is turned a green indicator marked Power or the am ber switch is illuminated Power is applied through a series of normally closed limit switches including water flow gas pressure and high tem perature and through the operating temperature control to the flame safeguard programmer The water flow limit switch is closed when there 1s adequate water flow through the boiler When adequate gas pressure is available the low gas pressure limit switch is closed Manual reset is required following conditions resulting in low gas pressure If the temperature sensed by the high limit tem perature control is below the set limit the nor mally closed position of the switch sends power to the operating temperature control Manual reset is required following conditions exceeding high temperature lim
34. will go out See the Installation and Owner s Manual page 8 for Lo Hi Lo units Readjust thermostats to desired operating tem perature and set high limit temperature typically 20 F above operating temperature Installation 4 4 4 Test of Gas Pressure Switch ___ Reset Figure 4 6 Gas Pressure Switch The boiler is furnished with a low gas pressure switch 1 Slowly close the manual shutoff valve on the natural gas supply while the burner is operating The low gas pressure switch should shut down the main burner before combustion problems are en countered When the gas pressure switch opens the Low Gas or Gas Press indicator will illu minate 2 Reopen the manual shutoff valve The Low Gas or Gas Press indicator should remain on until the low gas pressure switch is reset Gemini Twin Fuel Gas Fired Boiler 4 4 5 Gas Pressure Adjustment Decrease Increase Figure 4 7 Regulator The gas pressure is set initially during a factory fire test A final adjustment must be made after the boiler has been installed as follows See rating plate for the minimum and maximum gas pressure of the boiler Each boiler is furnished with three plugged taps in the gas train for test gauge connections Two taps are lo cated at the natural gas and propane manual shutoff valves and are for measuring the gas supply pressure 1 4 LP S The supply pressure during main burner operation must be greater
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