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Patterson-Kelley MOD-04 User's Manual

1. A e eee e Bu n o e T 2 a EY amp Ja amp asa R E Ki E E 8 2 n ae a 5 od z S N o E a S o Y S DA y s E S a 3 E E S E S z 9 5 y MES Om vm az uo Nos e oo 3 Eu a nz z S E Vuen ex E O AL34VS IWYT4 ex E 2 YOOTHAINI z j LUVIS7 s Z S XJOTKZINI gt 7 S LUVLST c SNOILO3NNO9 39VL10A MOT 23NNOO 3OVLIOA H IH 36 Ca Modu Fire Gas Fired Boiler IRI Unit Remote Control Logic Diagram Parts Technical Support D a f aL Q a O EN 2 NI N Cl NI NI Ni NI NI NI NI N E TRUE 31 O N s E SEN E Sa pu z a e rz a B x 3 S 3 amp ES a o i a ES PES 29 E A A i z N amp Al N u NI e 0 3 g S m ea E S5 o o es 66 NI i ll
2. Sima j 90MM S un cz SI 3 uo S 5 zE s a BER S S nz NV S Si m Se nyy E S 3 A34YS ZWVI4 l S S o 2 ex S S S O yoorwaini S S u LUWLS TA lt u S S jas X201031NI S S zat IUWIST o S S D S SNOLLO3NNOO 39vL10A MOT SNOLO3NNOO JOVLIOA HOIH 33 Modu Fire Gas Fired Boiler Parts Technical Support Standard Unit Local amp Remote Control Logic Diagram e e e gt n ala m fl of ral sz x a lt ou ul gt ad N N AN N a A N ON E N N N A N Ja 3 ty Gio be FAA u Bast gest aes L o0 m o xa Fa 23C e x m 5 J a E m lt z o a a 2 o den D K VALVE MAIN INTE RATIO VALVE ARCA CONTRI 14A OPTIONAL gd rel Dei ES EE gs E B A MET B g Js SN Jaen 757 aa 3 g a ER S E m a s IS BI amp o Z So 5 nau DOWNY wn ama
3. UY SCANNER PO Ii Ns Ceramic Spider Ignition Electrode Before re installing the burner check the cleanliness of the heat exchanger and the condi tion of the combustion chamber If corrosion or leaks are noticed green or otherwise please call the factory for assistance Install the burner and mixer core Reconnect the pilot tube main gas union 4 burner hold down nuts electrode wire ground wire mixer core tube UV Scanner Be sure the Pilot tube is not touching any other component 5 3 REMOVING THE EXCHANGER 1 zt en ei oes oes Remove the burner as above Remove the front doors by pulling forward and upward Remove the top panel of the inner cabinet Close the isolation valves to the system Drain the boiler Disconnect the supply and return lines Remove 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 26 Maintenance 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 is easier if the inner cabinet and exchanger are removed together as one unit WARNING The heat exchanger is h
4. Nominal Equivalent Pipe Length Maximum Capacity in Cubic Feet of Natural Gas per Hour Iron Internal Pressure Drop of 0 5 inch Water Column Equivalent Length of Pipe Diameter Pipe in feet Size Inches 90 Ell Tee Inches Feet Feet 20 40 60 80 100 150 200 1 1 4 1 380 3 45 6 9 950 1 1 2 1 610 4 02 8 04 1 460 990 810 2 2 067 5 17 10 3 2 750 1 900 1 520 1 300 1 150 950 800 2 1 2 2 469 6 16 12 3 4 350 3 000 2 400 2 050 1 850 1 500 1 280 3 3 068 7 67 15 3 7 700 5 300 4 300 3 700 3 250 2 650 2 280 4 4 026 10 1 20 2 15 800 10 900 8 800 7 500 6 700 5 500 4 600 10 Modu Fire Gas Fired Boiler 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 at the end of the supplied gas train from the gas supply piping system during any pressure testing of the system at pressures in excess of 1 2 psig 14 inch w c During any pressure testing of the gas supply piping system at pressures equal to or less than 1 2 psig 14 inch w c the boiler should be isolated from the gas supply piping system by closing the manual shut off Some leak test solutions including soap and water may cause corros
5. The National Fuel Gas Code Handbook goes on to say that Insects insect nests ice or freezing rain can block outdoor vents The pilot regulator is equipped with a vent limiting device and does not require external venting Gas Vents by Installer Note Provide a drip leg in all vent bleed lines All vent lines should be pitched up at all times to prevent building a trap into the vent line Vent limiters are NOT to be installed on this boiler The air gas ratio control valve is equipped with a reference chamber vent filter which does not re quire any additional venting 3 8 BOILER WATER PIPING 3 8 1 Piping Design Water Flow in System Ideal operation of the P K MODU FIRE Boiler would consist of a 20 F temperature differential across the heat exchanger at High fire Insufficient flow may result in excessive short cycling of the boiler and eventual damage or premature failure of the equipment Minimum Return Water Temperature should be greater than 130 F to avoid problems of condensa tion on the outside of the heat exchanger or in the flue passages Proper flow rates and return water temperature may be achieved through a combination of primary and secondary flow loops Multiple zones and pumps may result in different flow rates at different times Modu Fire Gas Fired Boiler Consideration must be given to all possible condi tions and their consequences Piping With Refrigeration Machines
6. SOTWNY g E 2 em N Be uan 8E ANAL HIH 2 N wt vous GaLHOM WL Aerm NOLON L L L gt ON a4 E NC 32018 WNIWH3L OP dN SN3WIS 38 Modu Fire Gas Fired Boiler Parts Technical Support IRI Unit Local amp Remote Control w Options Logic Diagram 2R le A 2K 2 2 2 2C CH 36 FLAME FAILURE x o fe pa ES za D EL mM Y Hn a ES SEI EIS S IS z ai B E S z l 8 E 4 20A sE ie B e og r E D D N Leon u X Di o kao S S E E Ek gt ka T S D ES o 5 g eg N N x OPTIONAL m cq E TO og S E D INTERLOCK 1 A amp 4 b 1 o m 9 CJ man avTag j 90WNV dWNd SN 2 V SINIOd s x6 UNITY lt SE e 5 3 oo Vue 39NVY ME E e Co 1NIOd13S
7. 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 entering the boiler when the system is operated in the cooling mode Piping With Air Handling Units The boiler piping system of a hot water heating boiler connected to heating coils located in air han dling units where they may be exposed to refriger ated air circulation must be equipped with flow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle 3 8 2 Boiler Inlet and Outlet Connections Relief Valve Drain Union Outlet to system Isolating I Valve Isolating Valve Inlet from T I system Boiler Drain Isolating Strainer Valve Boiler Inlet and Outlet Connections Make water connections as the application warrants or at a minimum as shown but always in compli ance with the local requirements 12 Installation Note Pipe unions and isolating valves must be installed in both water connections for ease of service The bottom connection to the boiler is the INLET and must be used for the return from the system The top connection to the boiler is the OUTLET and must be connected as the supply to the system Piping must be installed such that no piping stresses are transmitted to the boiler The boiler should not be used as
8. 10 Fault Cycle 11 Fault Hours 12 Fault Code 13 What time in ignition cycle Additional Comments Please return a copy to P K ATTN Boiler Tech Support Department Patterson Kelley 100 Burson Street E Stroudsburg PA 18301 P 570 476 7261 F 570 476 7247 www pkboilers com
9. a L ba zi 3 t m 8 E iD x 8 Pes x E 7 o ot z ki g y a 3 REMOTE vi A a M E i o wl lt Ris E cl ow Y N 1 MOON VNINHIL 020109684 AS TI3MAJNOH 1 START INTERLOCK 1 N ort 48 S e d ana u EES uo now ZF oo Eu E nz 3 5 ZS wavy i O A33VS JW o EN o 5 CX x 81 o YOOTURLN 3 amp IWVLST 27 A 5 a E da 3201831NI o os LUVLS TE o z amp El NNOO 39VL10A MOT SNOILOANNOOD 39VI10 HOIH 32 Modu Fire Gas Fired Boiler Parts Technical Support Standard Unit Remote Control Logic Diagram e gt E o x x ul gt A N N N GN N NI N N BLUE Ka 3 lt E a l o s DG aja E a E p E lt i T m 28s E F E gt 2 29 1 CYCLE l TOR DOB FORCED REI vi i 0 0 HITE GA BLUE 6 FX LIGHTED SWITC RELAY
10. S Ium S 28 wevi R N avena O AL34VS IWY s E XJOTUZINI 2 LUVLS ZA o INOd13S zi F AS La ona c SOTYNY 3 ks fg SZ LUVIST LO SNOLLOINNOD 3OVLOA MO SNOLLO3NNOD J9VLIOA HOM 39 Ca Modu Fire Gas Fired Boiler Standard Unit Panel Layout Parts Technical Support HIGH LIMIT o o THERMOSTAT EN E Ba Zei due 57 a NUN UN 1 44 5720 EE E G BB 12 387 EEN A J uf el E 3 um i MOTOR L2 2H 13 KR RELAY 1 22 27 3 F15 154 14 37 E 238 230 A pe abs 6A 15 7 an sed Xue 4D 4H NUR gt 48 16 IBR 45A m 6 5 5A HONEYWELL 17 7A 78 234 238 25 SR E EH GIG RELAY lolo 7 1 25 18 194 23A pasas SS 48 48116 45 454 7 747 D 1 019 8 2 Tel ch 16 168 24 j 9 r4 20 46 7 7 BUS TIME DELAY RELAY 47 3 10 2 24 244 21 s GEES E ee HD Dye 0 JA 38 6 LJ at 4D HA zd GROUND 48 HD 40 ab ole 5 20 20 BUS 20 wo s eD d jM wa 7 4C 18 i no c 1 Soh C 16B 17 4A ld 1617 22009
11. The result is modular full modulation Modu Fire This new hybrid boiler combines the best of our earlier de signs with a new generation of burner and control technology You will achieve even higher part load efficiencies but without the complexity you might expect in this type of high performance boiler High performance made simple and dependable for years of trouble free operation This manual covers installation of the P K MODU FIRE Boiler Series 1000 1500 and 2000 The model numbers may be followed by a prefix or suf fix letter in some cases to indicate special features or different options While details may differ slightly basic operation is the same for all models Boilers are built to operate with natural gas or pro pane Check the rating plate for the correct gas type and flow rate The boiler is only a part of the complete heating system This boiler may be fully operational and yet because of poor circulation controls or other oper ating characteristics not deliver heat to the desired location Additional equipment such as temperature sensors pumps flow switches balancing valves and check valves will be required for satisfactory opera tion of any system Patterson Kelley cannot be re sponsible for the design or operation of such sys tems and a qualified engineer or contractor must be consulted 2 0 SAFETY 2 1 GENERAL Introduction Safety e Operated and serviced in accordance with a comprehensiv
12. any accumulated dust or lint 2 Clean burner of any accumulated dust or lint See Section 5 2 on Cleaning the Burner Modu Fire Gas Fired Boiler 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 recommended monthly service 1 Check burner and clean off any soot or foreign material that may have accumulated See Sec tion 5 2 on Cleaning the Burner Check for corrosion of the burner and its parts If there is evidence of deterioration or corrosion replace immediately 2 Inspect combustion chamber through access door on front side of boiler To remove doors remove fasteners pull door forward slightly then pull upward Note any signs of deteriora tion Take corrective action as necessary 3 Inspect and clean heat exchanger Clean exte rior of finned tubes and flush inside of heat ex changer as required separate from system flush 4 Examine the venting system at least once a year a Checkall joints and pipe connections for tightness b Check pipe for corrosion 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 Perform co
13. 3 8 1 Piping Design 11 1 3 8 2 Boiler Inlet and Outlet Connections 12 1 3 8 3 Boiler Water Piping by Installer 12 1 3 8 4 Flushing and Filling 13 1 3 8 5 Water Quality 0 aaa aka 13 2 3 9 Burner and Ignition System 13 2 3 9 1 INSPECTION aaa 13 2 3 10 Pre Start Check Uet kana 13 2 3 11 Safety Checks aaa aaa 14 3 3 11 1 Test of Ignition Safety System 14 3 3 11 2 Test of Low Water Cut off 14 4 3 11 3 Test of Limit Controls 14 4 3 11 4 Test of Low Gas Pressure Switch 15 5 3 11 5 Test of High Gas Pressure Switch 15 5 3 12 Initial Adjustments 15 5 3 12 1A Configuring the Local Controller 15 5 3 12 1B Optional Remote Control 20 5 3 12 2 Air Flow Adjustments 20 5 3 12 3 Gas Pressure Adjustment 21 5 4 OPERATION iit are agda eee 22 5 41 General ni dee 22 6 4 1 1 Control Panel Front 22 6 4 2 Lighting and Shut Down Procedures 22 7 4 2 1 Lighting Procedures 22 7 4 2 2 Normal Shut Down Procedures 23 8 4 2 3 Emergency Shut Off 23 8 4 3 Typical Boiler Operating Conditions 23 8 5 0 MAINTENANCE zna ia sova eege e 24 8 5 1 Maintenance and Inspection Schedule 24 8 51 Bally ii et cime trees 24 9 5 1 2
14. 850 000 1500 1 500 000 1 456 1 275 000 2000 2 000 000 1 942 1 700 000 Modu Fire Gas Fired Boiler 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 re quires that the valve be removed from the boiler and securely placed in a vice prior to performing any maintenance 5 1 MAINTENANCE AND INSPECTION SCHEDULE WARNING Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing 5 1 1 Daily Observe operating temperature and general condi tions Make sure that the flow of combustion and ventilating air to the boiler is not obstructed De termine the cause of any illuminated red indicators unusual noises or operating conditions and make the necessary corrections WARNING Check daily to be sure that the boiler area is free and clear of any combustible materials including flammable vapors and liquids The motorized gas valves contain hydraulic oil which may be hazardous to the environment Should a leak develop use safe procedures for dis posal of this or any other lubricant 24 Maintenance 5 1 2 Weekly Observe the
15. Cover Control Panel Sub Panel Control Panel Base Assy 49 Parts Technical Support Modu Fire Gas Fired Boiler 7 0 LIMITED WARRANTY Subject to the terms and conditions herein and except as pro vided below with respect to products or parts not manufactured by Patterson Kelley Co Seller warrants to the original owner at the original installation site that products manufactured by Seller Products comply at the time of manufacture with recognized hydronics industry regulatory agency standards and requirements then in effect and will be free from defects in ma terials and workmanship for a period of five 5 years from date of shipment the Warranty Period For products or parts not manufactured by Patterson Kelley the warranty obligations shall in all respects be limited to one year REMEDY The sole remedy of this warranty is expressly limited to the repair or replacement of any part found to be defective under conditions of normal use within the Warranty Period Installation is not included Warranty The owner must notify the original installer of the Product and Seller Attention Patterson Kelley Co Box 458 East Stroudsburg PA 18301 in writing within the Warranty Period providing a detailed description of all claimed defects Transportation to the factory or other designated facility for repairs of any products or items alleged defective shall in all events be the responsibility and at the cost
16. Weekly edente aote Zeen end 24 9 5 1 3 Monthly During Operation 24 11 5 1 4 Semi Annuallly eek 24 11 5 1 5 Annually sss 25 11 5 2 Cleaning the Burner coocccccincccccociconoccnanncoos 25 Modu Fire Gas Fired Boiler 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 Modulating eek 28 5 6 Troubleshooting sesssse 29 6 0 PARTS TECHNICAL SUPPORT 31 6 1 Schematic Diagrams 31 Standard Unit Local Control Logic Diagram32 Standard Unit Remote Control Logic DIAG FAM ie cie cete nicer ie ted 33 Standard Unit Local amp Remote Control Logic Diagram oak kakaa 34 Standard Unit Local amp Remote Control w Options Logic Diagram 35 Improper use may result in fire or injury Read instructions safety manual before installing 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 features which permit this boiler to achieve high efficiency performance make it unlike most other boilers of t
17. 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 of the heat exchanger Adequate circulation of good clean wa ter is essential to maximum efficiency and long life of the boiler Relief Valve and Piping Each boiler is supplied with a pressure relief valve sized in accordance with ASME requirements The relief valve should be piped to a suitable floor drain Reducing couplings or other restrictions are not permitted in the discharge line Low Water Cut off The boiler is furnished with a flow switch type low water cut off as required by Section IV ASME Code no field piping is required If the flow switch does not sense water flow the boiler will shut down and a red indicator will be illuminated on the control panel This flow switch only proves that flow is present It does not prove adequate flow as required by this boiler Installation of an external low water cutoff or man ual reset low water switch may be required by cer tain codes or in certain installations Consult your local code for details Modu Fire Gas Fired Boiler WARNING Never install a valve that can isolate the low water cutoff from the boiler Drain Valve and Piping The boiler is not provi
18. and has not moved in shipment see Section 5 2 Clean ing the Burner for proper location Verify that the total number of pieces shown on the packing slip agrees with those actually received Important Note any damage or shortage on the freight bill and immediately notify the carrier File all claims for shortage or damage with the carrier 3 1 2 Storage Prior to Installation If the boiler is not installed immediately it must be stored in a location adequately protected from the weather preferably indoors If this is not possible then it should remain in the shipping container and be covered by a tarpaulin or other waterproof covering Note Controls and other equipment that are damaged or fail due to weather exposure are not covered by warranty 3 2 COMPLIANCE WITH CODES Installation 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 absence of such requirements in the U S to the Na tional Fuel Gas Code ANSI Z223 1 NFPA 54 latest edition In Canada the equipment shall be installed in accordance with the current Installation Code for Gas Burning Appliances and Equipment CAN CGA B 149 and applicable Provincial Regulations for the class which should be carefully followed in all cases Authorities having jurisdiction
19. between 6 596 and 7 596 Run the firing rate up and down through the com plete firing range and verify that the oxygen read ings are within the proper range BASIC COMBUSTION ADJUSTMENT PROCEDURE C Start boiler in test mode CI Adjust start pressure with orange cam 1 0 1 2 H20 cabinet air L Adjust pilot gas for good pilot See factory run out label Start boiler and measure combustion O2 between 6 0 8 0 Ramp to high fire adjust cabinet air to nameplate with red cam Combustion O2 between 7 0 7 5 L Ramp to low fire 0 3 adjust cabinet air with blue cam Check high fire and low fire again 21 Modu Fire Gas Fired Boiler Operation 4 0 OPERATION Cabinet Air Pressure 4 1 GENERAL Pilot Gas Pressure Test 4 1 1 Control Panel Front Main Gas Pressure Test Temperature Control Operating Instructions High Gas Pressure Switch Low Gas Pressure Switch Patterson Kelley Harsco FARURE Pilot Gas Cock Indicator Lights On Off Switch Main Gas The front of the control panel shows Operating In Cock structions and a series of illuminated indicator lights which show the condition of the boiler 4 2 LiGHTING AND SHUT DOWN PROCEDURES Do not use this boiler if any part has been under wa ter Immediately call factory trained personnel to inspect the boiler and to replace any part of the con trol system and any gas control which has be
20. gt 3 2 SE zz 8 mi N ox Gi ka E s E iL 5 2 E E ES o mos ol N wo s moo I amp m 2 D a Y o LN oS of Joa a Qo al Q oq 3 ia lt 8 PES e nE 3 z Ee oF m o SE N y E e z m A Je VN Md 1ndNI z r o _ 901VNY um EES uo S oo amp Ru Kl nz S 2 j wavy Oo O SNOILOINNO9 3O LIOA 37 gt ALJAVS ENE YOOTUSLN ZI lavis ap YOOTUSLN LVS T NNOO 39v DEI Parts Technical Support Modu Fire Gas Fired Boiler Logic Diagram IRI Unit Local amp Remote Control 3104038 03 ao Te Hz TAW Tae Old ci oz ama Ge d eno HOLMS div SC op ac 39 Tac VOC d Vid OLON ISS 7 v jc L IVNOILdO z E E OB TVNIAS3L BLOLTI EI Wuviv A133VS 3WV14 J201831NI LUVLS TH 3201831NI LUIS T S a S 3 9 2 5 ER gt D auld HOI se L 3509 D 9 nado Tv Ha j v9 Nsdo 9 SNOILDANNOD YAWOLSND LAdN SNILVINGOW ENESKER EENS St
21. ie A bet 4D D a EA 7 4C 18 NC c SS 16 17 4A 11 2A16A17A 28 06 H ch MESE 13 996 7 OOG sa 3 43 KO GOOD 7 Q5 op eBoy PL OOH BOG 2 g 9 E BFO o OBO DACE 00 O J ke ZEE LH E A 7 PR 2k 40 41 2L 2D 26 9621 18 28 10 PLUG PLUG 9 PIN RECEPTACLE __15_PIN MOTOR MOTOR CONTACTOR ACTUATOR RECEPTACLE 9 PIN RECEPTACLE 2 PIN PLUG TRANSFORMER CONNECTOR 2P 2P 2P 2P 2M 8 SA 26 20A 20 4 213 ED Tm Cw FLAME aM M ES LIGHTEO MODU FIRE IRI PANEL SWITCH 41 Modu Fire Gas Fired Boiler Parts Technical Support 6 2 BOILER PARTS LIST 6 2 1 Main Assembly 5 4 3 11 13 14 9 No Part No Part 1 Mixer Core Burner Inside Cabinet 12 Water Flow Switch 2 Burner Orifice Inside Cabinet 13 Blower Motor Inside Cabinet 3 Spark Igniter Electrode 14 Blower Wheel Inside Cabinet 4 UV Scanner 15 Press Temp Gauge 5 Thermowell w Clamp 6 Electrode Assembly w Mica Inside Cabi net Installation Owner s Manual All Models MOD 7 Pilot Tube Inside Cabinet CP Control Panel Section 6 2 2 8 Burner Inside Cabinet EC Exterior Cabinet Section 6 2 4 9 Heat Exchanger IC Interior Cabinet Section 6 2 4 10 Blower Damper PG Pilot Gas Train Section 6 2 3 11 Pressure Relief Valve 100 PST MG Mam Gas Train Section 6 2 3 42 Modu Fire Gas Fired Boiler Parts Technical Support 6 2 2 Control Panel Circuit Breaker Relays and 1 4 Sockets 2 7 7a 7b 8 6 9 Forced Recycle Time Delay Relay 3
22. lt NMOBI ae OO Co E nz E S oS S Hav E E S S O pj AMvSawni jo e 3201831NI l E LUVIS TE s E 8 YOOTWSLN E ES I isie yo a SM amp Y SNOILJINNOJ 39VLIOA MOT SNOILOANNOD FOVLIOA H9IH 34 Modu Fire Gas Fired Boiler Parts Technical Support Standard Unit Local amp Remote Control w Options Logic Diagram gt al ol a o rz z e x o u a eq a IRA Z LA as y z Om f E 8 amp 2 2 i t S 9 1 e 2 E q S y E 3 g 3 8 87 a po o 3 2 P 3 E o a E S F l i 5 E Ka amp i iB e J A inaNi Avia E 901VNY dWNd 2 V SLNIOd r lin mv P OO Wuvi 19NVY 1NIOd13 1NI0d13S nE Og JLYNYILTY 2 3 res 3univu3dw3L o AAAS TI e ex EM XOTINI l 1WVIST 3 1NIOd13S 2 a 1ndNi 3200831NL icd LUIS T o ER LO OZNNOO 39VI10A HOIH 35 Modu Fire Gas Fired Boiler Parts Technical Support IRI Unit Local Control Logic Diagram
23. that the other limits are satisfied Low Air If the Low Air indicator remains on for longer than 20 seconds there is insufficient airflow through the burner An extended low air indication does not mean that the low air switch is defective Modu Fire Gas Fired Boiler Check the cabinet pressure for a minimum of 0 3 w c e Check burner is clean refer to Section 5 2 Ignition Failure In the event the pilot flame 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 energized At this time a safety lockout occurs which de energizes all outputs from the 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 Maintenance 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 be manually re set WARNING If any Manual Reset limit device trips DO NOT reset without determining and correcting the cause Flame safeguard high or low gas pressure high temperature limit stack temperature 30 Modu Fire Gas Fired Boiler 6 0 PARTS TECHNICAL SUPPORT Spare parts and replacement parts can be ordered from your local represent
24. 11 ER Pial rn HE Geier geb ere EN AIR SWITCH 22 27 3 2N 1 Wiere ab 269 15 28 O GG 9 OOo BOG 244 E A AE GOL s BRO 20 OOE 60 vob 98 9897 dd PR ESA 9 PIN RECEPTACLE 2 2D 26 2021 18 28 10 PLUG PLUG ACTUATOR 15 PIN MOTOR MOTOR CONTACTOR RECEPTACLE 9 PIN RECEPTACLE TEMP CONTROL 2 PIN PLUG Ge TRANSFORMER CONNECTOR 2P 2P 2P 2P 2M 8 5A 26 12 20A 15A a 4 1 i els f Gase GO ERA PR GE LEE CS KL d is Oy RSS EL Kee rm gt LIGHTED MODU FIRE STANDARD PANEI SWITCH 40 ae Modu Fire Gas Fired Boiler Parts Technical Support IRI Unit Panel Layout g Wen LIMIT 9 9 CN THERMOSTAT 7 S ne d Een 54 a obi 5 LON 1 44 FTA u E D ULD ir G hs 6 164 J12 NL 38 u vA y 27 al E MOTOR Lep2H 13 e vi RELAY j Las 15A J iA 8 22 24 3 F15 15A AF 43314 o 2 EC se 4 48 9 9A 15 5 6B 6A 16 o N e Ga 5A HONEYWELL 17 17 17 gt 7 7A CONTROL 7 17A 178 STA 25 40 18 1 ODI RELAY DIG 43 43 NEUTRAL BUS pis 41419 2 o 4 9 ru 42 424420 HOT BUS EES SS 10 21 21 mle s eH 42 F 22 at d M ae Ls J e 44
25. 12 5 11 Local Control Panel No Pat No Part No Part 1 Thermostat Manual Re 7 Flame Safeguard Pro 10a Ignition Cable not visi set grammer ble 2 Thermostat Oper Temp 7a Amplifier UV Scanner 11 Indicator Light Red 3 Air Flow Switch 7b Timing Card 30 sec 12 Indicator Light Green 4 Motor Start Relay 8 Programmer Sub Base 3 Terminal Block Neutral 9 Switch On Off Lighted 6 Terminal Block Power 10 Ignition Transformer not visible 43 Modu Fire Gas Fired Boiler Eh tb Circuit Breaker Forced Recycle Time Delay Relay Part Thermostat Manual Re set Thermostat Oper Temp Air Flow Switch Motor Start Relay Terminal Block Neutral Terminal Block Power Relays and Sockets 1 3 12 5 Remote Control Panel Part Flame Safeguard Pro grammer Amplifier UV Scanner Timing Card 30 sec Programmer Sub Base Switch On Off Lighted Ignition Transformer not visible 44 Parts Technical Support 11 No 10a 11 12 7 7a 7b 8 Part Ignition Cable not visi ble Indicator Light Red Indicator Light Green Modu Fire Gas Fired Boiler 6 2 3 Gas Trains 6 2 3 1 Standard Gas Train 1000 N l 2 3 4 5 6 7 8 9 O Part Main Gas Shutoff Cock Main Gas Valve Actuator Main Gas Valve Air Gas Ratio Control Low Gas Pressure Switch High Gas Pressure Switch Leak Test Valve Pilot Gas Cock Vent Filter 45 Parts Technical Su
26. For example assume the following settings Installation 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 F If the temperature increases to 172 F which is Set point 1 SP1 160 High Temp Differential HyS3 12 it will shut off Once it shuts off it will not re start until the temperature drops to 155 F which is Setpoint 1 SP1 160 Low Temp Differential Hys1 5 The Low Temp Setpoint SPL prevents the operator from setting Setpoint 1 SP1 lower than Low Temp Setpoint SPL 150 The High Temp Setpoint SPH prevents the operator from setting Setpoint 1 SP1 higher than the High Temp Setpoint SPH 195 Alternate Setpoint The control must be configured for night setback See the configuration menu When the Alternate Setpoint contact is closed the boiler switches to its alternate setpoint The alternate setpoint can be determined by several different values It can be a fixed alternate setpoint SP2 It can be a fixed differential from SP1 called dsP dsP will offset the main setpoint SP1 by the value of dsP dsP can be positive or negative The Alternate Setpoint can also be determined by an external analog source such as a 4 20 mA signal Outdoor Air Reset The control must be configured for outdoor air reset See the conf
27. MOD 04 PATTERSON KELLEY THERMIFIC MODU FIRE 9 GAS FIRED BOILER Installation and Owner s Manual m C S A Design Certified Ser Complies with ANSI Z21 13 CSA 4 9 Gas Fired Low Pressure Steam and Hot Water Boilers art d ASME Code Section IV Certified by Patterson Kelley P C S A Design Certified ow Complies with ANSI Z21 13 CSA 4 9 A ET a Gas Fired Low Pressure Steam and Hot Water Boilers Installation Date Patterson Kelley Harsco 100 Burson Street P O Box 458 East Stroudsburg PA 18301 Telephone 877 728 5351 Facsimile 570 476 7247 www pkboilers com Modu Fire Gas Fired Boiler 1 0 INTRODUCTION 2 0 SAFETY 2 1 General 2 2 Training 2 3 Safety Features 2 4 Safety Labels 2 5 Safety Precautions 2 5 1 Electrical Hazards 2 5 2 Burn Fire and Explosion Hazards 2 5 8 Crush Hazards 2 5 4 Chemical Hazards 2 5 5 Pressure Hazards 2 5 6 Slip Fall Hazards 3 0 INSTALLATION 3 1 Receiving and Storage 3 1 1 Initial Inspection 3 1 2 Storage Prior to Installation 3 2 Compliance with Codes 3 3 Setup 3 3 1 Foundation 3 3 2 Placement 3 3 3 Clearances 3 4 Electrical Connections 3 5 Combustion Air 3 6 Flue Venting 3 6 1 Vent Elbows 3 6 2 Barometric Damper 3 6 3 Automatic Vent Damper 3 6 4 Flue Connection 3 6 5 Vent Termination 3 6 6 Removing an Existing Boiler 3 7 Gas Piping 3 7 1 Gas Supply Piping by Installer 3 7 2 Gas Bleeds and Vents by Installer 3 8 Boiler Water Piping Table of Contents 1
28. ard Hot fluids Install isolation valves on boiler water inlet and outlet Make sure isolation valves are closed before servicing boiler e Pressure hazard Hot fluids Annually test safety relief valve for proper operation Do not operate boiler with faulty relief valve Safety 2 5 6 Slip Fall Hazards LA WARNING Improper use may result in fire or injury Read instructions safety manual before installing operating or servicing boiler O 1998 HCS Inc 800 748 0241 e Tripping hazard Do not install piping on floor surfaces Maintain clear path around boiler e Slip and fall hazard Use drip pan to catch wa ter while draining the boiler Maintain dry floor surfaces e Slip and fall hazard Do not locate intake or exhaust terminations directly above a walkway dripping of condensation can cause icing of the walking surface Modu Fire Gas Fired Boiler 3 0 INSTALLATION 3 1 RECEIVING AND STORAGE 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 components mounted on the back which may show damage from mishandling The exterior cabinet must be reasonably air tight for the burner to operate correctly Leaks caused by dents in the sheet metal or panels out of position may cause the limit controls to show Low Air Check to be sure that the mixer core in the top burner is centered
29. ative or Patterson Kelley by calling 570 476 7261 or Toll Free 877 728 5351 The fax number is 570 476 7247 Refer to the parts list shown on the assembly drawing pro vided with this manual Technical information is also available at the above number When ordering replacement parts please have the model number and serial number of your boiler available 31 Parts Technical Support 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 amp Remote Control Logic Diagram Standard Unit Local amp Remote Control w Options Logic Diagram IRI Unit Local Control Logic Diagram IRI Unit Remote Control Logic Diagram IRI Unit Local amp Remote Control Logic Diagram IRI Unit Local amp Remote Control w Options Logic Diagram Standard Unit Panel Layout IRI Unit Panel Layout Modu Fire Gas Fired Boiler Parts Technical Support Standard Unit Local Control Logic Diagram ee e ee gt a a a m a o rc x lt 5 ul gt S N N N N N N NON N N A A N N IGNITER J BLUE rm nui GNITION E TRANSF 20 OPE
30. been completed 1 Flue gas from the boiler is properly vented Modu Fire Gas Fired Boiler 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 power source with proper polarity and dedi cated machinery ground Provide a disconnect having adequate overload protection 5 Combustion air openings are not obstructed in any way and have adequate capacity See Sec tion 3 5 6 The boiler is placed the proper distance from any combustible walls or substances in accor dance with Section 3 3 3 7 Relief valves have been properly piped to floor drains 3 11 SAFETY CHECKS The following checks of safety systems must be made before putting the boiler into normal opera tion Before firing the boiler refer to Sections 4 1 and 4 2 for information on the use of the controls lighting and shut down procedures WARNING Never attempt to operate a boiler that has failed to pass all the safety checks described below WARNING After checking controls by manual adjustment make sure they are always reset to their proper settings 3 11 1 Test of Ignition Safety System Test the ignition system safety shutoff as follows 1 Close the gas cock which is downstream from th
31. conditions of the 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 CO or oxygen O2 analyzer to set conditions Refer to Section 3 12 2 and 3 12 3 5 1 3 Monthly During Operation 1 Test flame detection by voltage reading at the control programmer 2 Test high limit control by reducing setting be low the operating temperature Burner should shut off After readjusting the thermostat press the button to reset the switch 3 Test operating temperature controls by reducing or increasing temperature setting as necessary to check burner operation 4 Check flue gas temperature at outlet If there is a temperature increase over previous readings this probably indicates sooting or water scale build up 5 Test the water cutoff by trying to restart boiler with the system pump off The boiler should not operate Water flow indicator should light 6 Test low gas pressure switch by closing main gas cock and attempting to restart boiler This work should be performed by factory trained personnel 5 1 4 Semi Annually In addition to the recommended monthly service 1 Inspect and clean blower fan and inlet screen of
32. d providing power to the modulating con trol of the boiler If main flame has not been es tablished the unit will lock out on main flame failure 14 The unit modulates between the low fire setting and the high fire setting to maintain the desired outlet water temp set point 15 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 operating limit setpoint value At this point the operating control switch opens and the combus tion control is de energized at Terminal 6 and the indicator for HEAT is turned off This ac tion also de energizes Terminal 9 thus closing the main gas valve and the air gas ratio control valve Terminal 14 is energized which applies power to the close terminal of the air damper motor The air damper closes 16 When the water 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 the limits on water flow gas pressure and high temperature are all met 5 6 TROUBLESHOOTING Loss of Power In the event of loss of power the entire boiler sys tem is de energized closing 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 29 Maintenance Loss of Water Flow When the Water Flow indicat
33. ded 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 boiler can be completely drained through the bottom header by removing the flush plug in the bottom end plate This plug may also be used to flush accumulated sediment from the bottom of the boiler 3 8 4 Flushing and Filling Flushing the System Before filling the boiler flush the system to remove the debris Clean and flush old piping thoroughly before installing the boiler as recommended by your water conditioning or chemical treatment supplier Under no circumstances should the hydronic system be flushed while the boiler is attached to the system since the debris or corrosion products could accu mulate in the boiler and plug the boiler heat ex changer If the piping system attached to this unit will be chemically cleaned the boiler must be disconnected from the system and a bypass installed so that the chemical cleaning solution does not circulate through the boiler Filling To be sure that the boiler is not air bound open the pressure relief valve located at the rear of the boiler Leave the relief valve open until a steady flow of water is observed Close the valve 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 pe
34. e at least 0 3 w c Modu Fire Gas Fired Boiler 3 12 3 Gas Pressure Adjustment See rating plate for the minimum and maximum 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 supply pressure during main burner op eration must be greater than the minimum indicated on the rating plate The second tap is located down stream from the last main gas control in the union elbow where the gas line enters the back of the cabinet and is for measuring the manifold gas pres sure 1 8 LP S Low fire Adjustment High fire Adjustment Gas Pressure Adjustment Installation To adjust the gas pressure remove the cover plate from the air gas ratio control valve Set the boiler at High fire as described in the boiler operation sec tion of the manual The High fire gas pressure is adjusted with the 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 valve Using combustion measurement equipment adjust the oxygen reading
35. e first turn from horizontal to vertical should be made with a 135 boot tee A tee cover with a conden sate drain shall be provided at the bottom of the boot Installation tee The condensate drain must be routed to a sewer 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 be as direct as possible and the upward slope of any hori zontal breaching should be at least 1 4 inch per linear foot This boiler should not be connected into any por tion of a mechanical draft system operating under positive pressure Provisions must be made for sup ports to prevent contact of the vent with combustible surfaces Note Make sure that the weight of the vent is not supported by the boiler vent collar The collar is not designed to support the weight of the vent Structural support and spacing from combustible surfaces must be in accordance with the vent manufacturer s re quirements 3 6 5 Vent Termination The minimum vent height above the flue outlet must be five 5 feet and the vent should extend at least three 3 feet above the roof snowline or at least two 2 f
36. e local conditions in general and specifically sediment or lime precipitation in the tubes and or headers or corrosive elements in the atmosphere 3 Misuse in general and specifically operation and maintenance contrary to the written instructions fur nished with the unit disconnection alteration or addi tion of components or apparatus not approved by seller operation with fuels or settings other than those set forth on the rating plate or accidental or exterior damage I Production of noise odors discoloration or rusty water J Damage to surrounding area or property caused by leakage or malfunction K Costs associated with the replacement and or repair of the unit including any freight shipping or delivery charges any removal installation or reinstallation charges any ma terial and or permits required for installation reinstallation or repair charges to return the boiler and or components Seller s liability under this warranty shall not in any case exceed the amount paid for the Product found to be defec tive THIRD PARTY WARRANTIES For goods or components not manufactured by Seller the war ranty obligations of Seller shall in all respects conform and be limited to one year from the date of shipment SEVERABILITY To the extent that any provision of this warranty would be void or prohibited under applicable law such provisions shall be limited in effect to the minimum extent necessary to render the r
37. e safety program determined and established by the customer Do not attempt to operate or service until such a program has been established e Operated and serviced by qualified factory trained personnel in accordance with all appli cable codes laws and regulations e The use of the term factory trained personnel throughout this manual indicates Patterson Kelley trained on this specific piece of equip ment 2 2 TRAINING LIA WARNING Improper use may result in fire or injury Read instructions safety manual before installing operating or servicing boiler 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 serious injury death and or prop erty damage Proper training is the best protection against acci dents Operating and service personnel must be thoroughly familiar with the basic construction of the MODU FIRE boiler the use and locations of the controls the operation of the boiler adjustment of its various mechanisms and all applicable safety precautions If any of the provisions of this manual are not fully and completely understood contact the Patterson Kelley Sales Department 2 3 SAFETY FEATURES The MODU FIRE gas fired boiler must be e Installed in accordance with designs prepared by qualified facility engineers including struc tural mechanical elect
38. e two safety shut off valves in the vertical line 14 Installation 2 With the main gas cock inlet manual gas valve open and the pilot gas cock open the burner should 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 Ifa satisfactory pilot is established the spark will terminate and the pilot will remain on alone for 10 seconds 5 After 10 seconds the Main light on the flame safeguard will go on gas will not flow since the downstream cock is closed The Pilot will remain on along with the Main Gas for an other 10 15 seconds and then go out Since the gas cock is closed at this point there will be no main flame signal and the flame safeguard pro grammer will assume a Flame Failure and go to a lockout mode Lockout will require man ual reset of the flame safeguard After completing this test turn off the boiler and reopen the downstream gas cock 3 11 2 Test of Low Water Cut off The boiler is furnished with a flow switch type low water cutoff in the outlet nozzle Test as follows Operation of the switch can be checked by first turn ing the boiler off and then turning the system pump off stopping water flow in the system Afte
39. eavy use proper lifting equipment and techniques 5 4 AFTER ALL REPAIRS OR MAINTENANCE 1 Follow Pre Start Check List Section 3 10 and all Safety Checks Section 3 11 2 Check gas pressure and adjust gas flow if neces sary See Gas Pressure Adjustment Section 3 12 3 3 Check air pressure and adjust air flow if neces sary See Air Flow Adjustment Section 3 12 2 4 Perform combustion check Modu Fire Gas Fired Boiler 5 5 SEQUENCE OF OPERATION 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 T Power is also applied through the start logic string a series of normally closed switches in cluding water flow gas pressure high stack temp high limit temperature and operating temperature to the flame safeguard programmer 8 2 The water flow limit switch is closed when there is water flow through the boiler Note The closing of this switch does not prove that flow is adequate Refer to Technical Data Sheet TD110 for proper flow requirements 3 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 4 When the temperature sensed by the high limit 10 temperature cont
40. eet above the highest part of any structure within ten 10 feet of the vent Modu Fire Gas Fired Boiler Incorrect Termination too restrictive Correct Listed Termination 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 system is likely to be too large for proper venting of the appliances remaining connected to it At the time of removal of an existing boiler while the other appliances remaining connected to the common venting system are not in operation the following steps should be followed with each appliance remain ing connected to the common venting system placed in operation 1 Seal any unused openings in the common venting system 2 Visually inspect the venting system for proper size and horizontal pitch and determine that there is no blockage or restriction leakage corrosion or other deficiency which could cause an unsafe condition 3 Insofar as is practical close all building doors and windows and all doors between the space in which the appliances remaining connected to the com mon venting system are located and other spaces of the building Turn on clothes dryers and any appliances not connected to the common venting system Turn on any exhaust fan
41. emaining provisions hereof enforceable NO OTHER WARRANTIES Seller makes no implied warranty of merchantability or fitness for a particular purpose or other warranties with respect to any products or services except as expressly set forth in this limited warranty Patterson Kel ley Established 1880 Harsco MODU FIRE BOILER START UP REPORT BOILER SERIAL MODEL DATE INSTALLATION Name City State Zip Installer Name Type of Installation Hotel School Etc 1 Factory Fire Test copy from boiler label Cabinet Air Inlet Gas Manifold Gas Oxygen O2 Carbon Dioxide CO2 Carbon Monoxide CO Net Stack Temperature Pilot Gas Pressure Pilot Flame Signal Main Flame Signal Start Up Field Test Oxygen O2 Carbon Dioxide CO2 Carbon Monoxide CO Net Stack Temperature Pilot Gas Pressure Pilot Flame Signal Main Flame Signal Cam Setting ORANGE Performed by 2 Combustion Air Temperature E 3 Water Inlet temperature F Water Outlet temperature E gpm flow through boiler 4 a Operating Temperature Setpoint E from internal OR external control b Bias Setting c Ratio Setting 5 Approximate stack lengths Ft Horizontal Ft Vertical Flue Pipe Diameter 6 Draft measured where stack exits boiler W C w c Low 7 Incoming Electrical Power Volts a c Less than 1 volt between neutral and ground 8 Total cycles 9 Total hours
42. en un der water 4 2 1 Lighting Procedures M Utilities Turn on electric supply to boiler Open gas supply valves Make sure system is filled with water and turn on circulation pump 2 ResetSwitches 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 temperature in Reset Switch side control panel On Off Switch 22 Modu Fire Gas Fired Boiler 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 electric power 4 2 3 Emergency 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 23 Operation 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 Input 1030 Btu cu Ft Model Rating Gas Output No Btu hr Rate Capacity CFH Btu Hr 1000 1 000 000 971
43. epurge pe riod The combustion chamber is Prepurged for 30 seconds A 10 second trial for ignition period is initi ated with both Terminal 8 and 10 being ener gized Terminal 10 of the combustion control powers the ignition transformer The trans former output creates a spark at the igniter Terminal 8 powers the pilot gas valve When a pilot flame is detected by the UV scan ner a signal is sent to the combustion control When this signal is detected Terminal 10 of the combustion control is de energized terminating the spark After the 10 second trial for ignition period if pilot flame has been established Terminal 9 of the Combustion Control is energized This opens the main gas valve and energizes the air gas ratio control The 10 second Main trial for ignition period begins If pilot flame has not been established the unit will lock out on pilot flame failure After the 10 second main trial for ignition pe riod if flame has been established Terminal 8 of the combustion control is de energized clos ing the pilot valve Terminal 21 is energized energizing Relay 1 If main flame has not been established the unit will lock out on main flame failure Relay 1 releases the temperature control to modulate The unit modulates between the low fire setting and the high fire setting to maintain the desired outlet water temp set point Modu Fire Gas Fired Boiler 14 15 When the load is belo
44. eration and service circulator replacement control replace ment etc The gas train components are designed to handle a maximum inlet pressure of 14 inches water column 1 2 psig If the available gas pressure exceeds 14 inch w c a suitable additional intermediate gas pres sure regulator of the lock up type must be provided to reduce the pressure to less than 14 inch w c Modu Fire Gas Fired Boiler By Installer Remote Gas 4 Shutoff not supplied E Drip Leg N Shutoff on a boiler Gas Meter not supplied Gas Piping Note Install a sediment trap drip leg and a union connection ahead of the primary manual shutoff valve Pipe Capacity for Natural Gas Installation on the boiler Gas piping should be installed in accor dance with National Fuel Gas Code ANSI 2223 1 latest edition and any other local codes which may apply in Canada see CAN 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 per 1 000 Btu per hour input 1 e 900 000 Btu per hour requires about 900 cubic feet per hour See Typical Boiler Operating Conditions Section 4 3 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
45. eriod The combustion chamber is Prepurged for 30 seconds When the Prepurge time period elapses the flame safeguard control energizes terminal 14 which drives the damper motor through the po sition switch to the start position When the damper motor is at the start position the start position limit switch is made which energizes the low fire switch input terminal 18 on the flame safeguard control A 10 second trial for ignition period is initiated with both Terminal 8 and 10 being energized Terminal 10 of the combustion control powers the ignition transformer The transformer output creates a spark at the igniter Terminal 8 powers the pilot gas valve When a pilot flame is detected by the UV scan ner a signal is sent to the combustion control When this signal is detected Terminal 10 of the combustion control is de energized terminating the spark After the 10 second Pilot Flame Establishing period if pilot flame has been established Ter Modu Fire Gas Fired Boiler 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 Flame Establishing Period if flame has been established Terminal 8 of the combustion control is de energized closing the pilot valve Terminal 15 is ener gize
46. g of the high gas pressure switch is essential for proper 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 15 Installation 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 Section 3 12 1B Analog Input Direct Drive Multiple boiler Controls Definitions SP1 Setpoint 1 This is the primary setpoint of the boiler SP2 Setpoint 2 An alternate setpoint Available through the alternate setpoint con tact closure An alternate setpoint differential from SP1 Available through the alternate setpoint con tact closure tA Air temperature Measurement of out side air temperature SP E External Setpoint Measurement of the external setpoint dSP Differential Setpoint Ee KE Low temperature dif ferential Ee osos High temperature dif ferential Internal Setpoint The boiler water outlet temperature is controlled to SP1 setpoint 1 and the boiler modulates to main tain SP1 subject to the upper and lower temperature differentials and the upper and lower setpoint limit Modu Fire Gas Fired Boiler
47. g on tho configuration of night setback dSP Sp2 Measurement of the outside temperature via external air sensor Measurement of the I external setpoint or a setpoint shift I via analog input setpoint I I I I I I KWR User Level To access the User level from the basic display press PGM Change the setpoint SP1 with M or V Change to setpoint SP2 or dSP with PGM Change the setpoint SP2 or dSP with A or Vv Return to the basic display with EXIT Manual Operation of the Boiler The boiler firing rate can be controlled manually Modu Fire Gas Fired Boiler 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 AN or y The firing rate increases as long as AN is pressed The firing rate decreases as long as Y is pressed LED s on the control indicate if the firing rate is increasing or decreasing To change back to automatic operation press EXIT for 5 seconds Manual operation can only be activated if the burner relay is on If the control sets the burner relay to off 18 Installation 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 t
48. he system Within the parameter level you can go to the next parameter by pressing PGM The parameters and their functions are listed in Ta ble 1 on the following page The actual parameters available depend on the configuration of the control Modu Fire Gas Fired Boiler Installation Table 1 Table of Parameters Setpoint range 1999 9999 digit alarm value C112 limit comparator controller type setpoint SP1 locking Alarm hysterisis 0 1 999 9 digit Switching differential at the edges for the limit comparators C112 limit comparator controller type setpoint SP1 locking Proportional band Pb 1 0 1 999 9 digit NES Affects the P response of the controller Derivative time 0 9999 sec Affects the D response of the controller Within dt 0 the controller has no D response Integral action time rt 0 9999 sec Affects the I response of the controller With rt 0 the controller has no I response Contact spacing 0 999 9 digit For floating output dead band 1 RA db 100 SCH Actuator running 10 3000 sec 18 sec Stroke time of the actuator time Switch on burner HYS1 0 199 9 digit ES c Boiler turns on when the temperature of HYS 1 is below the setpoint Switch off 1 HYS3 0 999 9 digit Section 5 2 High fire operation Response threshold 0 999 9 Section 5 6 Response threshold Q Slope for outdoor os MN gt Section 5 5 1 Heat
49. his general size so it is im portant to understand how this boiler operates Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance Table of Contents IRI Unit Local Control Logic Diagram 36 IRI Unit Remote Control Logic Diagram 37 IRI Unit Local amp Remote Control Logic Diagram eiie Geil eats 38 IRI Unit Local amp Remote Control w Options Logic Diagram sess 39 Standard Unit Panel Layout 40 IRI Unit Panel Layout 41 6 2 Boiler Parts LiSf aaa 42 6 2 1 Main Assembly sssss 42 6 2 2 Control Panel 43 6 2 3 Gas Trains 45 6 2 4 Cabinet diede 49 7 0 LIMITED WAPDDANTV kaaa 50 WARNING Installation and service must be performed by a qualified installer service agency or gas supplier What to do if you smell gas e Do not try to light any appliance e Do not touch any electrical switch e Do not use any phone in your building Imme diately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions e If you cannot reach your gas supplier call the fire department Modu Fire Gas Fired Boiler 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 time tested modular hot water boiler design
50. iguration menu 16 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 perature The setpoint SP1 is reset using a linear relationship with outdoor air temperature As the outdoor air temperature drops the setpoint SP1 is increased a proportional amount This increase is determined by the Heating Slope H See Table 1 at the end of this section For example if H is set at 1 then for every degree the outdoor air temp drops the set point SP1 will increase 1 degree This heating curve has a reference temperature of 68 This reference can be offset using the Parallel shift parameter P See Table 1 at the end of this section If P is set to O the setpoint SP1 will be 68 when the outdoor temp is 68 If P is set to 10 the setpoint SP1 will be 78 when the outdoor temp is 68 The minimum setpoint of the boiler is limited by the control In the above example the actual set point SP1 of the boiler will not go below 150 Analog Input Setpoint The control must be configured for external set point See the configuration menu The setpoint of the boiler is controlled by an exter nal signal The boiler functions as described with the internal setpoint using the value deter
51. ing curve slope air reset Offset for outdoor 90 90 gt Section 5 5 Weather dependent air reset 1 f setpoint shift This parameter is affected by the setting of the decimal place 19 Modu Fire Gas Fired Boiler 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 controlled by an external 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 Remote Local Firing Rate Remote Local and Firing Rate Switches Local control is used for setting up and testing the boiler Local control of the boiler firing rate can be obtained by placing the Remote Local switch in the local position This does not bypass 1 start inter lock 1 start interlock must be made for the boiler to fire With the boiler in local mode the up down switch can be used to control the firing rate of the boiler Pressing this switch in the up direction in creases the firing rate Placing this switch in the down position decreases the firing rate To operate the boiler independently from the BMS Building Management System or
52. ion 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 explosion overheating and component failure Do not attempt to adjust firing rate of the boiler The firing rate must be adjusted only by fac tory trained personnel Safety 2 5 3 Crush Hazards General Warning Lifting hazards Use properly rated lifting equipment to lift and position the boiler The load is unbalanced Test balance before lifting 3 ft above the floor Do not allow personnel be neath the lifted load Refer to approximate weights in the table below 1 000 000 Btu 595 1500 000Bu 990 2 000 000 Btu 1 025 Bump hazard from overhead piping Install pip ing with adequate vertical clearance 2 5 4 Chemical Hazards General Warning Environmental hazard The motorized gas valves may contain hydraulic oil Use safe pro cedures for the disposal of all lubricants Chemical hazards from cleaning products Use caution when cleaning the system The use of professional assistance is recommended Use safe procedures for the disposal of all cleaning solutions Modu Fire Gas Fired Boiler 2 5 5 Pressure Hazards LA WARNING Improper use may result in fire or injury Read instructions safety manual before installing operating or servicing boiler 1998 HCS Inc 800 748 0241 e Pressure haz
53. ion These solutions should be rinsed off with water after testing 3 7 2 Gas Bleeds and Vents by Installer If your unit is equipped with a diaphragm gas valve the bleed vents on the diaphragm gas valves have been factory piped to terminate at the burner as re quired by ANSI Z21 13 This feature provides com bustion of any gas which leaks past a ruptured dia phragm during operation Gas vents to outdoor air must be provided for the main pressure regulator The pilot regulator is equipped with a vent limiting device and does not require external venting e When installing per ASME CSD 1 discon nect factory piped bleed vents and vent the diaphragm gas valves to outdoor air field piping If a N O normally open vent valve is provided it must be vented independently of any other bleeds and vents Discharge of vent lines should be pro tected 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 11 Installation in accordance with the National Fuel Gas Code NFPA 54 ANSI Z223 1 which states In the case of vents leading outdoors means shall be employed to prevent water from entering this piping and also to prevent blockage of vents by in sects and foreign matter
54. mbustion analysis 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 25 Maintenance 5 2 CLEANING THE BURNER Ignition Electrode UV Scanner Burner Tube Pilot Burner Tube Screen Burner Assembly 1 Follow Lock out Tag out procedures for Elec tric Gas and Water connections 2 Remove the top cover of the boiler 3 Disconnect the pilot tube main gas union elec trode wire ground wire mixer core tube UV Scanner and the 4 burner hold down nuts 4 Remove the burner and mixer core from the boiler and place it on the floor 5 Use low pressure air max 20 psig to blow in side the burner first then outside of the burner in order to remove any accumulated dust or lint build up Also blow the air down the pilot tube to clean away any dust or dirt 6 Check that the electrode is not touching the wall of the pilot tube Also be sure the electrode is not cracked and that the ceramic spider is able to move up and down freely 7 Use a soft clean cloth to remove accumulated contaminants from the UV radiation tube UV scanner glass envelope Modu Fire Gas Fired Boiler L KE NI Vy Si VN x IGNITION TRANSFORMER NEW BURNER IGNITION CABLE GROUND WIRE
55. mined by the external analog signal Modu Fire Gas Fired Boiler Analog Input Direct Drive The firing rate of the boiler is controlled by 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 Refer also to Section 3 12 1B Use of the Controller Operating Limit Closed Firing Rate Decreasing Firing Rate Increasing Actual Value Display red _ Setpoint Manual Opera Display tion green Alarm Relay Energized Decrease Increase Value Value PROGRAM EXIT But Button ton 7865p02e 0200 The diagram shows the RWF40 after switching on power This condition is called the basic display The actual value and the currently active setpoint are shown here Manual operation self setting and the user parameter and configuration levels can be activated from here Operation of the Control The temperature control has three levels of cascad ing menus They are USER level M Installation 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 A Ra RR Ka RR RR an LER man aaa LER ERE ERE ERR ERR KRAK Kaaa daa daa naa ona Basic display r I User level I Display depends on code 111 H Dependin
56. of the owner EXCLUSIONS Seller shall have no liability for and this warranty does not cover A Incidental special or consequential damages such as loss of the use of products facilities or production inconven ience loss of time or labor expense involved in repairing or replacing the alleged defective Product B The performance of any Product under conditions varying materially from those under which such Product is usually tested under industry standards as of the time of shipment C Any damage to the Product due to abrasion erosion corro sion deterioration abnormal temperatures or the influence of foreign matter or energy D The design or operation of owner s plant or equipment or of any facility or system of which any Product may be made a part 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 50 Limited Warranty 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 installations in general and specifically any installation which is made a in violation of applicable state or local plumbing housing or building codes b contrary to the written instructions furnished with this unit 2 Advers
57. or 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 that the other limits are satisfied Gas Pressure When the Gas Press indicator is illuminated there has been either insufficient gas pressure or the gas pressure to the manifold is too high for safe and proper operation of the boiler The power to the programmer will be interrupted If a gas supply shut off valve is closed for any rea son a low gas condition will result When gas pressure is restored the Gas Press indi cator will remain on and the boiler will remain locked out until the gas pressure switch is manually reset In the event of a high gas manifold pressure condi tion the Gas Press indicator will illuminate indi cating a potential air gas ratio control failure This must be corrected by factory trained personnel be fore restarting the boiler Once the switch is reset the sequence returns to Step 3 provided that the other limits are satisfied High Water Temperature When the boiler water has exceeded both the operat ing and high limit temperature power to the pro grammer is interrupted When the water tempera ture falls below the high limit temperature the boiler will remain locked out until the switch is manually reset Once the switch is reset the se quence returns to Step 4 to await heat demand pro vided
58. ould not be operated during construction while the possibility of dry wall dust demolition dust etc exists Provisions for combustion and ventilation air must be in accordance with Section 5 3 Air for Combustion and Ventilation of the National Fuel Gas Code ANSI 2223 1 latest edition or applicable provisions of the local building codes In Canada combustion air open ings shall comply with CSA 4 9 The formula is 1 sq in per 1 000 Btu hr of gas input not less than 100 sq in The location shall be neither more than 18 nor less than 6 above the floor level The boiler room shall be provided with two openings to ensure adequate combustion air and proper ventila tion One opening should be 6 to 12 inches above the floor and the other 6 to 12 inches below the ceiling preferably on opposite walls The size of each open ing is determined by whether air is taken from inside 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 Installation 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 boiler input For instance 300 square inches 2 1 12 square feet are required for 1 200 000 Btu per hour input When air is taken from the o
59. pport Modu Fire Gas Fired Boiler 6 2 3 2 Standard Gas Train 1500 amp 2000 Parts Technical Support O N 1 2 3 4 5 6 7 8 9 Part Main Gas Shutoff Cock Main Gas Valve Actuator Main Gas Valve Air Gas Ratio Control Low Gas Pressure Switch High Gas Pressure Switch Leak Test Valve Pilot Gas Cock Vent Filter 46 Modu Fire Gas Fired Boiler Parts Technical Support 6 2 3 3 IRI Gas Train 1000 No Part Main Gas Shutoff Cock Main Gas Valve Actuator Main Gas Valve Air Gas Ratio Control Low Gas Pressure Switch High Gas Pressure Switch Leak Test Valve Normally Open Vent Valve Pilot Gas Cock 0 Vent Filter m 09 cd ON Us te 47 Modu Fire Gas Fired Boiler 6 2 3 4 IRI Gas Train 1500 amp 2000 Parts Technical Support No cr gy cp I cm Part Main Gas Shutoff Cock Main Gas Valve Actuator Main Gas Valve Air Gas Ratio Control Low Gas Pressure Switch High Gas Pressure Switch Leak Test Valve Normally Open Vent Valve Pilot Gas Cock Vent Filter 48 Modu Fire Gas Fired Boiler 6 2 4 Cabinet Internal Cabinet CP RPADWMWAYN az o 1000 External Cabinet 1500 2000 External Cabinet Part Exterior Cabinet Assy Exterior Cabinet Door Exterior Cabinet Top Sight Glass Sight Glass Bezel Combustion Chamber Assy Combustion Chamber Door Combustion Chamber Top Control Panel Label Control Panel
60. prove that flow is adequate Refer to Technical Data Sheet TD110 for proper flow requirements When gas pressure is available the low gas pressure limit switch is closed Manual reset is required following conditions resulting in low gas pressure When the temperature sensed by the high limit temperature control is below the set limit the switch is closed Manual reset is required fol 28 10 11 12 Maintenance lowing conditions exceeding high limit tempera ture 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 The flame safeguard control first energizes Terminal 5 which energizes control relay R1 energizes the motor contactor for the blower motor and supplies power to the air flow switch which initially shows low air flow with the Low Air indicator This indicator will remain on until air flow is sensed Terminal 12 is also energized which drives the air damper to the open position When the damper motor is at the full open position the high fire limit switch is made which energizes the high fire switch in put terminal 19 on the flame safeguard control Once sufficient airflow is indicated by the air flow switch Terminal 7 of the flame safeguard control is energized If the high fire switch and proof of closure switch are in the correct state this starts the Prepurge p
61. r turn ing off the pump turn the boiler back on It should not operate and a red indicator for Low Water or Water Flow should be illuminated Do not shut the pump off while the boiler is operating Perform appropriate tests on any external probe type low water cutoff 3 11 3 Test of Limit Controls Fire the boiler and test the high limit control as fol lows With the main burner operating turn down the tem perature setting on the high limit thermostat until Modu Fire Gas Fired Boiler 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 temperature and set high limit temperature typically 20 F above operating tem perature 3 11 4 Test of Low Gas Pressure Switch Manual Reset I Mineyw il Gas Pressure Switch The boiler is furnished with a low gas pressure switch The operation of this switch must be checked by slowly closing the main gas cock while the burner is operating The switch should shut down the main burner When the gas pressure switch opens the Gas Press indicator will light Upon reopening the main gas cock the Gas Press indicator should remain on until the low gas pres sure switch is manually reset 3 11 5 Test of High Gas Pressure Switch The correct settin
62. rcentage of un 13 Installation 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 12 596 loss of efficiency The water quality should be within the guidelines established by the American Boiler Manufacturers Association as follows e Total solids 2 500 ppm e Total alkalinity 500 ppm e Total hardness 150 ppm The amount of oils fats grease and other organic matter should be limited to 10 ppm Consult your water conditioning or chemical treat ment supplier for analysis and recommendations If antifreeze is to be used in the system the cus tomer should perform a hazard analysis to determine the use and disposal of the antifreeze 3 9 BURNER AND IGNITION SYSTEM 3 9 1 Inspection Inspect the burners to be sure nothing was damaged or knocked loose during shipment Make sure that the mixer core in the top of the burner is centered in the burner head see burner photo in section on Cleaning the Burner Section 5 2 Inspect the pi lot line main gas train and ignition electrode to be sure they were not damaged during shipment or in stallation Check to see that the pilot is securely attached and that it 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
63. rical and other applica ble disciplines 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 ae Modu Fire Gas Fired Boiler 2 4 SAFETY LABELS Make sure this union is tight before closing cabinet cover after servicing boiler 01998 HCS Inc 800 748 0241 Reorder No 8032 02NHAK When opening leak test valves always follow instructions in operation and safety manual Q 1998 HCS Inc 800 748 0241 Reorder No 8032 01NHPK LA WARNING Improper use may result in fire or injury Read instructions safety manual before installing operating or servicing boiler 1998 HCS Inc 800 749 0241 Reorder No 6020 V2WHPK e AWARNING Electrical hazard Follow lockout tagout procedure when servicing this boiler 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 Contact Patterson Kelley for replacement labels 2 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 2 5 1 Electrical Hazards A WARNING Elec
64. rol is below the set limit the switch is closed Manual reset is required fol lowing conditions exceeding high limit tempera ture 5 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 11 6 The programmer first energizes Terminal 4 which supplies power to a normally open con tact of relay 2 the air damper position limit switch and the air flow switch If the damper motor is on the low fire side of the damper posi tion limit switch relay 3 is energized through normally closed contact of relay 2 This supplies 12 power to the open terminal of the air damper through the normally open contact of relay 3 The air damper opens to its start position and 13 the damper position limit switch applies power to terminal 6 on the damper motor This ener 27 Maintenance 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 combus tion air blower will not start and the combustion sequence does not go any farther Once sufficient airflow is indicated by the air flow switch Terminal 7 of the combustion con trol is energized This starts the Pr
65. s such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer ex haust fan Close fireplace dampers Installation 4 Place the appliance being inspected in operation 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 tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous conditions of use Any improper operation of the common venting sys tem should be corrected so the installation conforms with the National Fuel Gas Code ANSI Z223 1 When resizing any portion of the common venting sys tem the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part II in the National Fuel Gas Code ANSI Z223 1 3 7 GAS PIPING Before making the gas hook up make sure the boiler is being supplied with the type of fuel shown on the boiler nameplate The boiler shall be installed such that the gas ignition system components are protected from water drip ping spraying rain etc during appliance op
66. s it is defined in ANSI Z21 13 CSA 4 9 latest edition The vent material must be listed Category II Vent pipe 316L or AL 29 4C Stainless Under no circumstances shall a Category I material e g B vent be used Modu Fire Gas Fired Boiler WARNING This boiler should not be installed with an automatic damper on the flue Damper failure could 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 local distributor for information on proper selec tion The venting system and the horizontal portions of the venting system shall be supported to prevent sagging Consult your local vent supplier for correct vent sizing and structural support requirements Vent diameter is dictated by the length and height of horizontal and ver tical portions of the vent installation and the materials of construction It is not necessarily the same size as the boiler connection Correct sizing should be based on High fire input at a nominal 04 w c draft pres sure at the boiler outlet with a gross stack temp of 325 F and CO ratings at 7 5 3 6 1 Vent Elbows Pitch toward m boiler 1 4 per w foot minimum i A N 6 min Boot Tee 135 Tee a Trap Loop d mn Condensate Line i d To sewer trap or condensate drain Th
67. sequencer an external bypass switch of the BMS must be installed by the control contractor WARNING Do not bypass any safety limits with this switch 20 Installation 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 fire and Low fire The boiler modulates between these two rates to maintain a steady outlet tempera ture Fuel adjustments for proper fuel air ratio are made first at High fire then at Low fire Blue Air Flow Adjustments The air flow rates are adjusted by setting the end switches in the damper actuator The red end switch sets the High fire position The blue end switch sets the Low fire position To set the position of the switch rotate the colored wheel corresponding to either High fire or Low fire until it indicates the de sired setting Once the desired setting is set move the damper to a mid position and then back to either Low or High fire as desired The red air flow cam should be set so that the cabi net pressure at High fire is at or below that indicated on the rating plate for High fire The blue cam should be set so that the cabinet pressure at Low fire is at or above that indicated on the rating plate for Low fire The cabinet air pressure at Low fire must b
68. servicing boiler Modu Fire Gas Fired Boiler 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 Hot fluids Use caution when servicing or draining boiler Fire and explosion hazards Use caution when servicing burner Propane LPG is heavier than air and may linger in 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 af ter the burner is assembled Gas leak hazard All threaded gas connections must be made using a pipe compound that is re sistant to liquefied petroleum Do not use Tef lon 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 as sistance from factory trained personnel and or your local fire department Overfire hazard Possible fire and explosion from excess gas pressure Make sure that gas 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 condit
69. should be consulted before installations are made Where required by local codes the installation must conform to American Society of Mechanical Engi neers Safety Code for Controls and Safety Devices for Automatically Fired Boilers ASME CSD 1 In the Commonwealth of Massachusetts a this unit must be installed by a licensed pipe fitter plumber b field installed gas cocks must be T handle type and c piping of condensate shall conform with the State Plumbing Code 3 3 SETUP The P K MODU FIRE Boiler with standard compo nents and many options complies with American Na tional Standard CSA Standard ANSI Z21 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 psig maximum operating pressure and or 250 F maximum operating 3 3 1 Foundation Provide a firm level foundation preferably of con crete Note The boiler may be installed on a combustible floor however the boiler must never be installed on carpeting 3 3 2 Placement The boiler must be level to function properly To as sist in leveling the boiler the four 4 leg bolts 1 2 NC holding the boiler to the shipping skid must be reinstalled in the threaded legs on the bottom The adjustable legs are also necessary to provide adequate floor clearance and prevent distortion on the cabinet twisting e
70. tallation with zero clearance to combustible surfaces but 24 inch service clearances are recommended 3 4 ELECTRICAL CONNECTIONS All field wiring connections for power and control are in the rear service panel on the back of the boiler Low voltage and high voltage terminal strips are indi cated on the wiring diagram The boiler power circuit Modu Fire Gas Fired Boiler 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 ensure that the proper voltage and amperage are connected to the boiler An external electrical disconnect not supplied with the boiler with adequate overload protection is re quired The boiler must be grounded in accordance with local codes or in the absence of such require ments in the U S with National Electrical Codes ANSI NFPA No 70 latest edition and in Canada wire according to the current Canadian Electrical Code Note A dedicated earth ground green wire is re quired to avoid nuisance shutdowns Do not ground through the conduit It is also important that proper polarity be maintained 3 5 COMBUSTION AIR Combustion air must be free from dust lint etc The presence of such materials in the air supplied to the burner could cause nuisance Low Air shutdowns or premature burner failure The boiler sh
71. tc in addition to leveling Modu Fire Gas Fired Boiler 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 problems servicing the boiler The boiler must be installed in a space large in com parison to the boiler as described in Section 6 3 of the National Fuel Gas Code ANSI Z223 1 latest edition No pipes ducts etc in this area Front of Boiler Installation Minimum Clearances from Adjacent Walls Ceiling and Obstructions Type of Surface Dimensions inches A B Ct D Combustible Surfaces 30 24 30 24 Non combustible Sur 30 24 30 24 faces T 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 each boiler when there is insufficient access at the rear to allow for service and adjustment In Canada The boilers are approved for ins
72. trical hazard Follow lockout tagout procedure when servicing this boiler Safety e Shock hazard Properly lockout tagout the elec trical service and all other energy sources before working on or near the machine e Shock hazard Boiler is not rated for wash down service 2 5 2 Burn Fire and Explosion Hazards General Warning Hot Surface LA WARNING Improper use may result in fire or injury Read instructions safety manual before installing operating or servicing boiler 01998 HCS Inc 800 748 0241 Reorder No 6020 V2WHPK Make sure this union is tight before closing cabinet cover after servicing boiler O 1998 HCS Inc 800 748 0241 Reorder No 6032 02NHAK When opening leak test valves always follow instructions in Operation and safety manual 1998 HCS Inc 800 748 0241 Reorder No 6032 01NHPK e Burn fire and explosion hazards Installation must be in strict conformance to all applicable codes and standards including NFPA 54 ANSI Z223 1 and CAN CGA B 149 Install all re quired ventlines for gas devices Refer to Sec tion 3 7 2 e Hazard from incorrect fuels Possible fire ex plosion overheating and damage Do not use any fuels except the design fuel for the unit e Overfire hazards High pressure in gas or pro pane supply could result in overfiring of other devices supplied from the same source e Fire and explosion hazards Close the main gas shutoff before
73. utdoors through a vertical duct 1 square inch per 4 000 Btu per hour is required If a horizontal duct is used 1 square inch per 2 000 Btu per hour is required i e 600 square inches for 1 200 000 Btu per hour input If air is taken from another interior space each open ing should have a net free area of 1 square inch for each 1 000 Btu per hour of boiler input 1 200 square inches for a 1 200 000 Btu per hour WARNING Under no circumstances shall the boiler room ever be under a negative pressure Particular care should be taken when exhaust fans compressors air handling units or other equipment may rob air from the boiler The combustion air supply must be completely free of chemical fumes which may be corrosive when burned in the boiler Common chemicals which must be avoided are fluorocarbons and other halogenated com pounds most commonly present as refrigerants or sol vents such as freon trichlorethylene perchlorethyl ene chlorine etc These chemicals when burned form acids which quickly attack the boiler tubes tube sheets flue collectors and the boiler stack The result is improper combustion and premature boiler failure 3 6 FLUE VENTING This boiler requires a special vent system Vent instal lations shall be in accordance with Part 7 Venting of Equipment of the National Fuel Gas Code ANSI Z223 1 CSA B149 code or applicable provisions of the local building codes This boiler is Category II a
74. w 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 indicator for HEAT is turned off This action also de energizes Terminal 9 thus closing the main gas valve and the air gas ratio control valve Relay 1 and 2 are de energized which applies power to the close terminal of the air damper motor The air damper closes When the water 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 the limits on water flow gas pressure and high temperature are all met 5 5 2 IRI Modulating L 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 the flame safeguard control to the damper close terminal Power is also ap plied through the proof of closure switch on the air gas ratio control and to the start logic string a series of normally closed switches in cluding water flow gas pressure high stack temp high limit temperature and operating temperature to the flame safeguard programmer The water flow limit switch 1s closed when there is water flow through the boiler Note The closing of this switch does not

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