FD-06C PATTERSON-KELLEY MODU-FIRE® FORCED DRAFT GAS-FIRED BOILER Installation and Owner's Manual C.S.A. Design-Certified Complies with ANSI Z21.13/CSA 4.9 Gas-Fired Low Pressure Steam and Hot Water Boilers ASME Code, Section IV Certified by Patterson-Kelley C.S.A. Design-Certified Complies with ANSI Z21.13/CSA 4.9 Gas-Fired Low Pressure Steam and Hot Water Boilers Installation Date: _______________________ 100 Burson Street, P.O.
FORCED DRAFT Gas-Fired Boiler Table of Contents 1.0 INTRODUCTION ........................................2 3.6.6 Vent Terminations...............................12 2.0 SAFETY......................................................2 3.6.7 Venting for Multiple Boilers .................13 2.1 General ....................................................... 2 3.6.8 Removing an Existing Boiler ...............13 2.2 Training ....................................................... 2 3.7 Gas Piping...........
FORCED DRAFT Gas-Fired Boiler Table of Contents 5.1.3 Monthly ............................................... 24 6.1.3 Main Control Panel Point to Point ........33 5.1.4 Annually .............................................. 25 6.1.4 Junction Box Point to Point and Customer Connections ...........................34 5.2 Cleaning the Burner.................................. 25 6.1.5 Customer Connections Details ............35 5.3 Removing the Exchanger ......................... 26 6.1.6 Gas Train ..
MODU-FIRE® FORCED DRAFT Gas-Fired Boiler Safety mechanical, electrical, and other applicable disciplines. 1.0 INTRODUCTION The MODU-FIRE® FORCED DRAFT Gas-Fired Boiler is a revolutionary advance. Patterson-Kelley now combines full-modulation burner control and forced draft advances with our time-tested modular hot water boiler design. The result is a fullmodulation boiler utilizing reduced vent sizing for installation and cost efficiencies.
MODU-FIRE® FORCED DRAFT Gas-Fired Boiler Safety 2.5.1 Electrical Hazards 2.4 SAFETY LABELS The following words are used in this manual to denote the degree of seriousness of the individual hazards. ! WARNING Electrical hazard. Follow lockout/tagout procedure when servicing this boiler. C 1998 HCS, Inc. 800-748-0241 DANGER – Used to indicate an imminently hazardous situation which, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme conditions.
MODU-FIRE® FORCED DRAFT Gas-Fired Boiler • Overfire hazards! High pressure in gas or propane supply could result in overfiring of other devices supplied from the same source. • Fire and explosion hazards! Close the main gas shutoff before servicing 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 appliance. • Burn hazard! Possible hot surfaces. Do not touch the stack during firing operations.
MODU-FIRE® FORCED DRAFT Gas-Fired Boiler 2.5.6 General Hazards 2.5.4 Chemical Hazards General Warning • General Warning 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. • Tripping hazard! Do not install piping on floor surfaces. Maintain clear path around boiler. • Slip and fall hazard! Use drip pan to catch water while draining the boiler.
MODU-FIRE® FORCED DRAFT Gas-Fired Boiler Installation tablished by the authorities having jurisdiction or, in the absence of such requirements, in the U.S. to the National Fuel Gas Code, ANSI Z223.1/NFPA 54, latest edition, and the specific instructions in this manual. In Canada, the equipment shall be installed in accordance with the current Installation Code for Gas Burning Appliances and Equipment, CSAB.
MODU-FIRE® FORCED DRAFT Gas-Fired Boiler Installation 3.3.3 Installation Clearances If the boiler is to be installed near combustible surfaces, six (6”) inches minimum clearance to the combustible surface must be maintained. Op eratin g Ins tructio ns fo r this P-K Mod u-Fir e Gas -Fired Boiler W ATE R FLO W S ta rting B o iler 1. U tilities: T urn on th e electric supply t o the boi ler. O pen the gas supp yl valv es . Make s ure thes ystem i s fill ed wi th water a nd turn on thecir culating pump. 2.
MODU-FIRE® FORCED DRAFT Gas-Fired Boiler Notice: A dedicated earth ground (green wire) is required to avoid nuisance shutdowns. Do not ground through the conduit. It is also important that proper polarity be maintained. 9 10 11 12 13 14 15 16 17 18 Outdoor Air Override – Use for override of outdoor air schedule. Closing this circuit overrides the outdoor air reset schedule to a fixed setpoint.
MODU-FIRE® FORCED DRAFT Gas-Fired Boiler Installation the cross sectional area required for combustion air, but not less than 10 square inches. It is to be located at the highest practical point communicating with outdoors. Low Voltage (LV) Strip Header Sensor – Connected when a header sensor is used. The temperature control should be in Mode 2 or 5. The sensor is available from the local P-K Representative.
MODU-FIRE® FORCED DRAFT Gas-Fired Boiler wall or through the roof routing for the supply of combustion air through a duct. It is important to locate the intake duct in such a way that it does not become blocked due to snow, ice, and other natural or man-made obstructions. Installation 3.6 VENTING (STACK) This boiler requires a special vent system. This boiler is not certified for use with Type "B" vent. This boiler is a Category IV appliance as defined in ANSI Z21.13/CSA 4.9, latest edition.
MODU-FIRE® FORCED DRAFT Gas-Fired Boiler 3.6.1 Venting Components Installation 3.6.2 Barometric Damper The connection from the boiler to the vent should be made using an adapter that is designed to fit the OD of the boiler outlet. The vent manufacturer’s adapter must be sealed to the boiler outlet with sealant listed for use with the vent material. The first turn from horizontal to vertical should be made with a tee. A tee cover with a condensate drain shall be provided at the bottom of the tee.
MODU-FIRE® FORCED DRAFT Gas-Fired Boiler Installation The minimum vent height should extend at least 3 feet above the roof, or at least 2 feet above the highest part of any structure within 10 feet of the vent. meters, regulators, or relief equipment. See the diagrams on this page to further illustrate clearance requirements. WARNING! d < 10'. Do not locate intake or exhaust terminations directly above a walkway; dripping of condensation can cause icing of the walking surface.
MODU-FIRE® FORCED DRAFT Gas-Fired Boiler Installation 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 common 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 fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan.
MODU-FIRE® FORCED DRAFT Gas-Fired Boiler 3.7 GAS PIPING Installation 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 and all gas piping connections should be pressure-tested and must be checked for leaks before being placed into service. Test with compressed air or inert gas if possible. The boiler must be installed such that the gas system components are protected from water (dripping, spraying, rain, etc.
MODU-FIRE® FORCED DRAFT Gas-Fired Boiler Installation Pipe Capacity for Natural Gas Notice: See Pipe Capacity for Natural Gas chart 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, i.e., 500,000 Btu per hour requires about 500 cubic feet per hour. (See "Typical Boiler Operating Conditions," Section 4.3, for more information.
MODU-FIRE® FORCED DRAFT Gas-Fired Boiler Installation exchanger. Adequate circulation of good clean water is essential to maximum efficiency and long life of the boiler. 3.8.2 Boiler Water Connections Relief Valve and Piping Relief Valve Drain Each boiler is supplied with a pressure-relief valve sized in accordance with ASME requirements. The relief valve must be piped to a suitable drain prior to placing the boiler into service and in a manner that prevents water spray from contacting any person.
MODU-FIRE® FORCED DRAFT Gas-Fired Boiler Installation Under no circumstances should the hydronic system be flushed while the boiler is attached to the system since the debris or corrosion products could accumulate in the boiler and plug the boiler heat exchanger. If water/glycol is to be used in the system, the customer should perform a hazard analysis to determine proper use and disposal.
MODU-FIRE® FORCED DRAFT Gas-Fired Boiler Installation After completing this test, turn off the boiler and reconnect the wires to the main gas valve. 3.11 SAFETY CHECKS The following checks of safety systems must be made before putting the boiler into normal operation. 3.11.2 Test of Low Water Cut-off The boiler is furnished with a flow-switch-type low water cut-off in the outlet nozzle. Test as follows: Before firing the boiler refer to Sections 4.1 and 4.
MODU-FIRE® FORCED DRAFT Gas-Fired Boiler 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 pressure switch is manually reset.
MODU-FIRE® FORCED DRAFT Gas-Fired Boiler Mode 4 – outdoor reset and reset override operation using parallel piping. The boiler is operated as in Mode 1. However the target temperature is based on outdoor reset. The outdoor reset temperature can be remotely overridden. Mode 5 – outdoor reset and reset override operation using primary/secondary piping. The boiler is operated as in Mode 2. However, the target temperature is based on outdoor reset.
MODU-FIRE® FORCED DRAFT Gas-Fired Boiler Installation To adjust the gas valve on hi fire, turn the top screw “V” clockwise to reduce the % O2 or turn it counterclockwise to raise the % O2 . Once high fire is adjusted, place the boiler in low fire using the toggle switch and adjust the % O2 if necessary, by turning the bottom screw “N” clockwise to reduce the % O2 and counterclockwise to increase the % O2. 3.12.2 Air Flow Adjustment There are no required start-up or field adjustments for air flow control.
MODU-FIRE® FORCED DRAFT Gas-Fired Boiler 4.0 OPERATION Operation Interior Control Panel (See 6.1.2 for details) 4.1 GENERAL Indicator Lights Instructions Pop-Latch (2) Air Inlet Temperature Control On/Off Switch The front of the control panel shows Operating Instructions and a series of illuminated indicator lights and the temperature control. The boiler operating controls are accessed by turning the pop-latches ¼ turn, and opening the front cover.
MODU-FIRE® FORCED DRAFT Gas-Fired Boiler 4.2.1 Initial Lighting Procedures Operation 4.3 TYPICAL BOILER OPERATING CONDITIONS 1. Utilities: Turn on electrical supply to the boiler. Open the gas supply valves. Make sure the system is filled with water and turn on the circulation pump. 2. Reset Switches: Press the reset button on both the high gas and low gas pressure switches if the gas supply had previously been turned off. Press the control reset button after a safety lockout. 3.
MODU-FIRE® FORCED DRAFT Gas-Fired Boiler Maintenance 5.1.2 Weekly 5.0 MAINTENANCE Observe the conditions of the main flame. A normal high fire flame shows an orange screen with a blue halo. In Low fire the burner should display a reddish orange glow. WARNING! Installation and service must be performed by a qualified and knowledgeable individual, such as a PK representative, qualified installer, service agency, or gas supplier.
MODU-FIRE® FORCED DRAFT Gas-Fired Boiler Maintenance 5.1.4 Annually In addition to the recommended monthly service: 5.2 CLEANING THE BURNER 1. Check burner and wash off (do not scrub or use wire brush) any soot or foreign material that may have accumulated. See Section 5.2 on "Cleaning the Burner." Check the burner and its parts. If there is evidence of deterioration or corrosion, replace immediately. Burner Assembly Air-Gas Mixing Head Blower 2. Inspect combustion chamber.
MODU-FIRE® FORCED DRAFT Gas-Fired Boiler Maintenance rectly. If adjustment is required, refer to section 3.12.3. 10. Check that gap between the electrode and the ground rod. It should be 1/8 inch (+1/16, -0). For Propane, the gap should be exactly 1/8”. The electrode height is not adjustable. If adjustment is necessary, only the ground rod should be adjusted. Check for cracking of the electrode. Do NOT overtighten the electrode. 5.
MODU-FIRE® FORCED DRAFT Gas-Fired Boiler Maintenance flow switch does not close, the red “low air” light remains illuminated and the combustion sequence does not go any farther. 5.5 SEQUENCE OF OPERATION 1. When the 230V/1Ph/60Hz fused disconnect is energized, there is power to the combustion blower speed control. When the On/Off (boiler power) switch is turned on, the power LED illuminates and power is provided to the flame safeguard control and the transformer for the temperature control.
MODU-FIRE® FORCED DRAFT Gas-Fired Boiler Maintenance 5.6 TROUBLESHOOTING WARNING If any “Manual Reset” limit device trips, DO NOT reset without determining and correcting the cause. (Manual Reset Limits include: Flame safeguard, high or low gas pressure, high temperature limit, stack temperature.) If a gas-supply shutoff valve is closed for any reason, a low gas condition will result.
MODU-FIRE® FORCED DRAFT Gas-Fired Boiler Maintenance Low Air Flame Failure CAUTION The air switch has been factory set and should not be adjusted in the field. In the event of a main flame failure during a firing period, the main gas control valve is de-energized and the programmer immediately goes into "lockout" mode. If flame failure occurs and the indicator is illuminated, the programmer must be manually reset.
MODU-FIRE® FORCED DRAFT Gas-Fired Boiler Parts/Technical Support 6.0 PARTS/TECHNICAL SUPPORT Spare parts and replacement parts can be ordered from your local representative or Patterson-Kelley by calling (877) 728-5351. The fax number is (570) 476-7247. Refer to the parts list shown on the assembly drawing provided with this manual. Factory direct replacement parts must be used to ensure that the boiler operates correctly. 6.
6.1.
MODU-FIRE® FORCED DRAFT Gas-Fired Boiler Parts/Technical Support 6.1.
MODU-FIRE® FORCED DRAFT Gas-Fired Boiler 6.1.3 Main Control Panel Point to Point Harsco Patterson-Kelley East Stroudsburg, PA 18301 570-476-7261 www.pkboilers.
MODU-FIRE® FORCED DRAFT Gas-Fired Boiler Parts/Technical Support 6.1.
MODU-FIRE® FORCED DRAFT Gas-Fired Boiler Parts/Technical Support 9 10 11 12 13 14 15 16 17 18 SEE INSTALLATION & OWNER'S MANUAL FOR RATINGS AND DESCRIPTIONS 1 OUTDOOR AIR SENSOR 3 4 5 6 7 8 ANALOG OUTPUT 0 - 10 V 2 HEADER SENSOR ANALOG INPUT DIRECT DRIVE 4 - 20 mA 35 19 START INTERLOCK 120VAC 8 #2 7 AUXILIARY LOW WATER CUTOFF 120VAC 6 FLAME FAILURE ALARM 120VAC PILOT DUTY ONLY 5 ALL LIMIT POINTS ALARM DRY CONTACT 4 PUMP ENABLE WITH DELAY OFF DRY CONTACT #1 3 OUTDOOR SETPOIN
MODU-FIRE® FORCED DRAFT Gas-Fired Boiler Parts/Technical Support 6.1.
MODU-FIRE® FORCED DRAFT Gas-Fired Boiler Parts/Technical Support 6.1.
MODU-FIRE® FORCED DRAFT Gas-Fired Boiler Parts/Technical Support 6.1.
MODU-FIRE® FORCED DRAFT Gas-Fired Boiler Parts/Technical Support 6.1.
MODU-FIRE® FORCED DRAFT Gas-Fired Boiler Limited Warranty 1. 7.0 LIMITED WARRANTY Subject to the terms and conditions herein and except as provided below with respect to products or parts not manufactured by Patterson - Kelley Co.
MODU-FIRE® FORCED DRAFT Gas-Fired Boiler 8.0 FIELD STARTUP REPORT ® MODU-FIRE FORCED DRAFT BOILER START-UP REPORT Boiler Serial # Model #: Date: Installation Name: Address: State: City: Contact: Zip: Phone: Type of Installation: Installer Name: 2. Sealed Combustion 1. Factory Fire-Test: (copy from boiler label) High Low YES / NO 2a. Combustion Air Temperature °F Inlet Gas "w.c. "w.c. 2b. Approximate Elevation (ft) Oxygen (O2) % % 3.
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