Patterson Kelley MOD 04 User Manual

MOD-04

PATTERSON-KELLEY

THERMIFIC^®

MODU-FIRE® 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. Box 458,

East Stroudsburg, PA 18301

Telephone: (877) 728-5351, Facsimile: (570) 476-7247

www.pkboilers.com

Modu-Fire^®Gas-Fired Boiler

Table of Contents

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 .................................... 28

5.6 Troubleshooting........................................ 29

6.0 PARTS/TECHNICAL SUPPORT..............31

6.1 Schematic Diagrams.................................. 31

Standard Unit - Local Control - Logic Diagram32

IRI Unit - Local Control - Logic Diagram.......36

IRI Unit - Remote Control - Logic Diagram...37

IRI Unit - Local & Remote Control - Logic

Diagram..................................................38

IRI Unit - Local & Remote Control w Options -

Logic Diagram ........................................39

Standard Unit – Panel Layout.......................40

IRI Unit – Panel Layout.................................41

6.2 Boiler Parts List .........................................42

6.2.1 Main Assembly....................................42

6.2.2 Control Panel ......................................43

6.2.3 Gas Trains...........................................45

6.2.4 Cabinet................................................49

7.0 LIMITED WARRANTY.............................50

Standard Unit - Remote Control - Logic

Diagram.................................................. 33

Standard Unit - Local & Remote Control -

Logic Diagram........................................ 34

Standard Unit - Local & Remote Control w

Options - Logic Diagram ........................ 35

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

Reorder No. 6020-V2WHPK

WARNING!

Installation and service must be performed by a

qualified installer, service agency, or gas supplier.

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.

What to do if you smell gas:

•

Do not try to light any appliance.

Do not touch any electrical switch.

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.

If you cannot reach your gas supplier call the

fire department.

The same features which permit this boiler to

achieve high-efficiency performance make it unlike

most other boilers of this 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.

•

Modu-Fire^®Gas-Fired Boiler

Introduction/Safety

•

Operated and serviced in accordance with a

comprehensive safety program determined and

established by the customer. Do not attempt to

operate or service until such a program has been

established.

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. 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.

•

Operated and serviced by qualified, factory-

trained personnel in accordance with all appli-

cable codes, laws, and regulations.

The use of the term “factory-trained personnel”

throughout this manual indicates Patterson-

Kelley trained on this specific piece of equip-

ment.

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.

2.2 TRAINING

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

Reorder No. 6020-V2WHPK

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.

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.

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.

2.0 SAFETY

2.3 SAFETY FEATURES

2.1 GENERAL

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.

The MODU-FIRE^®gas-fired boiler must be:

•

Installed in accordance with designs prepared

by qualified facility engineers including: struc-

tural, mechanical, electrical, and other applica-

ble disciplines.

Modu-Fire^®Gas-Fired Boiler

Safety

2.4 SAFETY LABELS

•

Shock hazard! Properly lockout/tagout the elec-

trical service and all other energy sources before

working on or near the machine.

NOTE

Make sure this union is

tight before closing cabinet

cover after servicing boiler.

Shock hazard! Boiler is not rated for wash-

down service.

1998 HCS, Inc. 800-748-0241

Reorder No. 8032-02NHAK

NOTE

When opening leak test valves,

always follow instructions in

operation and safety manual.

2.5.2 Burn, Fire, and Explosion Hazards

1998 HCS, Inc. 800-748-0241

Reorder No. 8032-01NHPK

WARNING

Improper use may

result in fire or injury.

Read instructions/safety

manual before installing,

operating or servicing boiler.

Reorder No. 6020-V2WHPK

General Warning

Hot Surface

WARNING

Electrical hazard.

Follow lockout/tagout

procedure when

servicing this boiler.

WARNING

Improper use may

result in fire or injury.

Read instructions/safety

manual before installing,

operating or servicing boiler.

Reorder No. 5025-V1WHPK

1998 HCS, Inc. 800-748-0241

Reorder No. 6020-V2WHPK

NOTE

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.

Make sure this union is

tight before closing cabinet

cover after servicing boiler.

1998 HCS, Inc. 800-748-0241

Reorder No. 8032-02NHAK

NOTE

When opening leak test valves,

always follow instructions in

operation and safety manual.

1998 HCS, Inc. 800-748-0241

Reorder No. 8032-01NHPK

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.

•

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.

•

Hazard from incorrect fuels! Possible fire, ex-

plosion, overheating, and damage. Do not use

any fuels except the design fuel for the unit.

2.5.1 Electrical Hazards

Overfire hazards! High pressure in gas or pro-

pane supply could result in overfiring of other

devices supplied from the same source.

WARNING

Electrical hazard.

Follow lockout/tagout

procedure when

servicing this boiler.

C 1998 HCS, Inc. 800-748-0241

Reorder No. 5025-V1WHPK

Fire and explosion hazards! Close the main gas

shutoff before servicing boiler.

Modu-Fire^®Gas-Fired Boiler

Safety

2.5.3 Crush Hazards

•

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.

General Warning

•

Lifting hazards! Use properly rated lifting

•

Burn hazard! Hot fluids. Use caution when

servicing or draining boiler.

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:

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.

Boiler Size

1,000,000 Btu

1,500,000 Btu

2,000,000 Btu

Weight in Pounds

•

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.

595

990

1,025

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.

•

Bump hazard from overhead piping. Install pip-

ing with adequate vertical clearance.

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.

2.5.4 Chemical Hazards

•

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.

General Warning

•

Environmental hazard! The motorized gas

valves may contain hydraulic oil. Use safe pro-

cedures for the disposal of all lubricants.

Overfire hazard! Possible fire and explosion.

Possible malfunction of regulators and/or mo-

torized gas valves. Maintain all gas train com-

ponents in good condition. Do not alter wiring

connections. Annual inspection by factory-

trained personnel for proper set-up and opera-

tion is recommended.

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.

•

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.

Modu-Fire^®Gas-Fired Boiler

2.5.5 Pressure Hazards

Safety

2.5.6 Slip, Fall Hazards

WARNING

Improper use may

result in fire or injury.

Read instructions/safety

manual before installing,

operating or servicing boiler.

Read instructions/safety

manual before installing,

operating or servicing boiler.

1998 HCS, Inc. 800-748-0241

•

Pressure hazard! Hot fluids. Install isolation

valves on boiler water inlet and outlet. Make

sure isolation valves are closed before servicing

boiler.

•

Tripping hazard! Do not install piping on floor

surfaces. Maintain clear path around boiler.

Slip and fall hazard! Use drip pan to catch wa-

ter while draining the boiler. Maintain dry floor

surfaces.

Pressure hazard! Hot fluids. Annually test

safety relief valve for proper operation. Do not

operate boiler with faulty relief valve.

•

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

Installation

temperature. Other codes or approvals which apply

will be labeled on the boiler.

3.0 INSTALLATION

3.1 RECEIVING AND STORAGE

3.1.1 Initial Inspection

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 should be consulted

before installations are made.

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 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.

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.

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.

3.3 SETUP

3.1.2 Storage Prior to Installation

3.3.1 Foundation

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.

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.

Note: Controls and other equipment that are damaged

or fail due to weather exposure are not covered by

warranty.

3.3.2 Placement

3.2 COMPLIANCE WITH CODES

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, etc.) in addition to leveling.

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 250º F maximum operating

Modu-Fire^®Gas-Fired Boiler

Installation

Adjustable Legs for Leveling and Floor Clearance

Minimum Clearances from Adjacent Walls, Ceiling, and

Obstructions

3.3.3 Clearances

Type of Surface

Dimensions (inches)

If the boiler is to be installed near combustible sur-

faces, the minimum clearances shown in the table be-

low must be maintained.

C†

Combustible Surfaces

Non-combustible Sur-

faces

30 24* 30 24**

Failure to provide for the service access clearances,

even with non-combustible surfaces, may cause future

problems servicing the boiler.

† "C" dimension includes clearance to remove the

burner. Do not put pipes, ducts, etc. in this area above

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.

* 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.

No pipes,

ducts, etc.

in this area.

In Canada: The boilers are approved for installation

with zero clearance to combustible surfaces, but 24

inch service clearances are recommended.

Front of

Boiler

Back of

Boiler

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

Installation

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.

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 outdoors 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.

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.

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.)

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.

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.

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 should not be

operated during construction while the possibility of

drywall dust, demolition dust, etc. exists.

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.

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

Z223.1, 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."

3.6 FLUE VENTING

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.

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 as 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

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.

WARNING!

This boiler should not be installed with an automatic

damper on the flue. Damper failure could create an

explosion hazard.

3.6.2 Barometric Damper

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.

This boiler is certified for operation without a baro-

metric damper. P-K does not recommend the use of

one.

The venting system and the horizontal portions of the

venting system shall be supported to prevent sagging.

3.6.3 Automatic Vent Damper

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 325º

F and CO₂ratings at 7.5%.

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.

3.6.1 Vent Elbows

Pitch toward

boiler 1/4" per

foot minimum.

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.

6' min.

3.6.5 Vent Termination

Boot Tee /135º

Tee

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) feet above the highest part of any structure within

ten (10) feet of the vent.

Trap Loop

3" min.

Condensate Line

To sewer trap or

condensate drain.

The 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

Modu-Fire^®Gas-Fired Boiler

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.

Incorrect

Termination

(too restrictive)

Correct Listed

Termination

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.

Vent Termination

The vent must be provided with a weather cap of ap-

proved design and adequate capacity.

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.

3.6.6 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:

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 operation

and service (circulator replacement, control replace-

ment, etc.)

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.

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.

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 fans, 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.

Modu-Fire^®Gas-Fired Boiler

Installation

on the boiler. Gas piping should be installed in accor-

dance with National Fuel Gas Code, ANSI Z223.1,

latest edition, and any other local codes which may

apply; in Canada see CAN/CGA-B 149.

By Installer

Remote Gas

Shutoff (not

supplied)

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, i.e., 900,000 Btu per hour requires about 900

cubic feet per hour. (See Typical Boiler Operating

Conditions, Section 4.3, for more information.)

Union

Drip Leg

WARNING!

Shutoff (on

boiler)

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.

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

Nominal

Equivalent Pipe Length

Maximum Capacity in Cubic Feet of Natural Gas per Hour

Iron

Pipe

Internal

Diameter

(Inches)

Pressure Drop of 0.5 inch Water Column/Equivalent Length of

Pipe (in feet)

Size

(Inches)

1-1/4

1-1/2

90º Ell

(Feet)

3.45

Tee

(Feet)

6.9

100

150

200

1.380

1.610

2.067

2.469

3.068

4.026

950

4.02

8.04

10.3

12.3

15.3

20.2

1,460

2,750

4,350

7,700

990

810

5.17

1,900

3,000

5,300

1,520

2,400

4,300

1,300

2,050

3,700

7,500

1,150

1,850

3,250

6,700

950

800

2-1/2

6.16

1,500

2,650

5,500

1,280

2,280

4,600

7.67

10.1

15,800 10,900 8,800

Modu-Fire^®Gas-Fired Boiler

Installation

3.7.1 Gas Supply Piping by Installer

in accordance with the National Fuel Gas Code

(NFPA 54), ANSI Z223.1, which states:

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.

“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.”

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.).

The National Fuel Gas Code Handbook goes on to

say that “Insects, insect nests, ice, or freezing rain

can block outdoor vents....”

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.

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.

Some leak test solutions, including soap and water,

may cause corrosion. These solutions should be

rinsed-off with water after testing.

“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.

3.7.2 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!

3.8 BOILER WATER PIPING

3.8.1 Piping Design

Water Flow in System

•

When installing per ASME CSD-1, discon-

nect factory piped bleed vents and vent the

diaphragm gas valves to outdoor air (field

piping.)

Ideal operation of the P-K MODU-FIRE^®Boiler

would consist of a 20º 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.

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.

Minimum Return Water Temperature should be

greater than 130º F to avoid problems of condensa-

tion on the outside of the heat exchanger or in the

flue passages.

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.

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.

If local conditions require venting to outdoors, the

vent line connection must be piped by the installer

Modu-Fire^®Gas-Fired Boiler

Installation

Consideration must be given to all possible condi-

tions and their consequences.

Note: Pipe unions and isolating valves must be

installed in both water connections for ease of

service.

Piping With Refrigeration Machines

The bottom connection to the boiler is the INLET

and must be used for the return from the system.

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.

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 a pipe anchor.

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.

3.8.3 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.

3.8.2 Boiler Inlet and Outlet Connections

Relief Valve

Drain

Union

Outlet (to

system)

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.

Isolating

Valve

Isolating

Valve

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.

Inlet (from

system)

Boiler

Drain

Isolating

Valve

Strainer

Boiler Inlet and Outlet Connections

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.

Make water connections as the application warrants,

or at a minimum, as shown, but always in compli-

ance with the local requirements.

Modu-Fire^®Gas-Fired Boiler

Installation

treated make-up water can cause premature failure

due to buildup of scale. Such failure is not covered

by warranty.

WARNING!

Never install a valve that can isolate the low water

cutoff from the boiler.

Scale can also reduce efficiency. For example, a

scale thickness of 1/16" will result in a 12.5% loss

of efficiency.

Drain Valve and Piping

The boiler is not provided 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.

The water quality should be within the guidelines

established by the American Boiler Manufacturers

Association, as follows:

•

Total solids:

Total alkalinity:

Total hardness:

2,500 ppm

500 ppm

150 ppm

This plug may also be used to flush accumulated

sediment from the bottom of the boiler.

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.

3.8.4 Flushing and Filling

Flushing the System

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.

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.

3.9 BURNER AND IGNITION SYSTEM

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.

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.

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.

3.10 PRE-START CHECK LIST

Before attempting to start the boiler, make sure the

following items have been completed.

3.8.5 Water Quality

The boiler is designed to operate in a closed-loop

system. As such, the system should be tight and not

require make-up water. A high percentage of un-

1. Flue gas from the boiler is properly vented.

Modu-Fire^®Gas-Fired Boiler

Installation

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.

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. Water connections are complete, and the boiler

and system have been filled and purged of air.

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. 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.

4. If a satisfactory pilot is established, the spark

will terminate and the pilot will remain on,

alone, for 10 seconds.

5. Combustion air openings are not obstructed in

any way and have adequate capacity. (See Sec-

tion 3.5)

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.

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.

After completing this test, turn off the boiler and

reopen the downstream gas cock.

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.

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:

WARNING!

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. After 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.

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.

Perform appropriate tests on any external probe-type

low water cutoff.

3.11.1 Test of Ignition Safety System

3.11.3 Test of Limit Controls

Test the ignition system safety shutoff as follows:

Fire the boiler and test the high limit control as fol-

lows:

1. Close the gas cock which is downstream from

the two safety shut off valves (in the vertical

line).

With the main burner operating, turn down the tem-

perature setting on the "high-limit" thermostat until

Modu-Fire^®Gas-Fired Boiler

Installation

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 20º F above operating tem-

perature.

3.12 INITIAL ADJUSTMENTS

3.12.1A – Configuring the Local Controller

(Applies to models furnished with programmable

temperature control.)

Operating Modes:

ꢀ

Internal Setpoint

3.11.4 Test of Low Gas Pressure Switch

Night Setback (Alternate Setpoint)

Outdoor Air Reset

Analog Input Setpoint (See Section 3.12.1B.)

Analog Input Direct Drive (Multiple boiler

Controls)

Manual Reset

Definitions:

SP1- Setpoint 1: ...................This is the primary

setpoint of the boiler.

SP2- Setpoint 2 :...................An alternate setpoint.

Available through the

Gas Pressure Switch

alternate setpoint con-

tact closure.

dSP- Differential Setpoint : ..An alternate setpoint

differential from SP1.

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.

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.

HyS1:....................................Low temperature dif-

ferential.

3.11.5 Test of High Gas Pressure Switch

The correct setting 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.

HyS3:....................................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.

This switch must be checked by factory-trained per-

sonnel.

Modu-Fire^®Gas-Fired Boiler

Installation

For example, assume the following settings:

Item

Display

Value

Setpoint 1

SP1

HyS1

HyS3

SPL

160

-5

Low Temp Differential

High Temp Differential

Low Temp Setpoint

High Temp Setpoint

150

195

SPH

The boiler will modulate to try to maintain 160 ^oF.

If the temperature increases to 172 ^oF 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 ^oF 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.

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.

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.

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 0 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°.

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.

Analog Input Setpoint

The control must be configured for external set-

point. (See the configuration menu.)

Outdoor Air Reset

The control must be configured for outdoor air reset.

(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 determined by

the external analog signal.

Modu-Fire^®Gas-Fired Boiler

Installation

Analog Input Direct Drive

ꢀ

PARAMETER level, and the

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.

CONFIGURATION level.

The following table indicates the menu options

available from each level. The options available

depend on the operating mode of the boiler.

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)

Manual Opera-

tion

Setpoint

Display

(green)

Alarm Relay

Energized

Decrease

Value

Increase

Value

PROGRAM

Button

EXIT But-

ton

User Level:

ꢀ

To access the User level from the basic display

press PGM.

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.

ꢀ

Change the setpoint SP1 with ꢁor ꢂ.

Change to setpoint SP2 or dSP with PGM.

Change the setpoint SP2 or dSP with ꢁor ꢂ.

Return to the basic display with EXIT.

Operation of the Control

Manual Operation of the Boiler

The temperature control has three levels of cascad-

ing menus. They are:

The boiler firing rate can be controlled manually.

ꢀ

USER level,

Modu-Fire^®Gas-Fired Boiler

Installation

ꢀ

To change to manual operation press EXIT for

5 seconds.

during manual operation, then the control is changed

to automatic operation.

ꢀ

The LED above the hand symbol lights up.

Parameter Level

Change the firing rate of the boiler with ꢁor

ꢂ.

To access the parameter level press and hold the

PGM button for longer than two (2) seconds. The

parameters available in this level are used for proper

functioning of the boiler with the system.

ꢀ

The firing rate increases as long as ꢁis pressed.

The firing rate decreases as long as ꢂis

pressed.

Within the parameter level you can go to the next

parameter by pressing PGM.

LED's on the control indicate if the firing rate is

increasing or decreasing.

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.

ꢀ

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

Modu-Fire^®Gas-Fired Boiler

Installation

Table 1 - Table of Parameters

Modu-Fire^®Gas-Fired Boiler

Installation

Configuration Level

3.12.2 Air Flow Adjustments

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.

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.

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.

Fuel adjustments for proper fuel/air ratio are made

first at High fire, then at Low fire.

An operating limit control ensures that the boiler

temperature does not exceed the set value.

Red

Blue

Remote/

Local

Firing Rate

Air Flow Adjustments

Remote/Local and Firing Rate Switches

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.

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.

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.

To operate the boiler independently from the BMS

(Building Management System) or sequencer, an

external bypass switch of the BMS must be installed

by the control contractor.

The cabinet air pressure at Low fire must be at least

0.3” w.c.

WARNING!

Do not bypass any safety limits with this switch.

Modu-Fire^®Gas-Fired Boiler

Installation

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” I.P.S.)

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 between 6.5%

and 7.5%.

Low-fire Adjustment

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.

High fire Adjustment

Gas Pressure Adjustment

BASIC COMBUSTION ADJUSTMENT PROCEDURE

Start boiler in test mode

Adjust start pressure with orange cam 1.0” – 1.2” H2O cabinet air

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.

Ramp to low fire 0.3” adjust cabinet air with blue cam

Check high fire and low fire again

Modu-Fire^®Gas-Fired Boiler

Operation

4.0 OPERATION

Cabinet Air

Pressure

Test

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

Pilot Gas

Cock

Indicator Lights

On-Off Switch

Main Gas

Cock

The front of the control panel shows Operating In-

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 been un-

der water.

4.2.1 Lighting Procedures

1. Utilities: Turn on electric supply to boiler.

Open gas supply valves. Make sure system is

filled with water and turn on circulation pump.

2. Reset Switches: Press reset button on gas pres-

sure switches (attached to main gas valve at

back of boiler) if gas supply was turned off.

Press control reset button after safety lockout.

3. Set desired limit and operating temperature (in-

side control panel).

Reset Switch

On-Off Switch

Modu-Fire^®Gas-Fired Boiler

Operation

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.

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

4.2.2 Normal Shut Down Procedures

1. Close all manual gas valves.

2. Turn off electric power.

Input

(1030 Btu/cu. Ft.)

Model Rating

Gas

Rate

(CFH)

Output

Capacity

(Btu/Hr.)

No.

(Btu/hr)

4.2.3 Emergency Shut Off

1000 1,000,000

1500 1,500,000

2000 2,000,000

971

850,000

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.

1,456 1,275,000

1,942 1,700,000

If overheating occurs or the gas supply fails to shut

off, do not turn off or disconnect the electrical sup-

Modu-Fire^®Gas-Fired Boiler

Maintenance

5.1.2 Weekly

5.0 MAINTENANCE

Observe the 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.

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.

Correct air adjustment is essential to the efficient

operation of this boiler. If an adjustment in the

combustion is necessary, the flue gas composition

should be checked with a carbon dioxide (CO₂) or

oxygen (O₂) analyzer to set conditions. Refer to

Section 3.12.2 and 3.12.3.

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.

5.1.3 Monthly (During Operation)

5.1 MAINTENANCE AND INSPECTION SCHEDULE

1. Test flame detection by voltage reading at the

control programmer.

WARNING!

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.

Label all wires prior to disconnection when servicing

controls. Wiring errors can cause improper and

dangerous operation.

3. Test operating temperature controls by reducing

or increasing temperature setting as necessary to

check burner operation.

Verify proper operation after servicing.

5.1.1 Daily

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.

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.

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.

WARNING!

Check daily to be sure that the boiler area is free

and clear of any combustible materials, including

flammable vapors and liquids.

This work should be performed by factory-trained

personnel.

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.

5.1.4 Semi-Annually

In addition to the recommended monthly service:

1. Inspect and clean blower fan and inlet screen of

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

Maintenance

3. Inspect burner for any signs of deterioration or

corrosion. Replace immediately if deterioration

or corrosion is evident.

5.2 CLEANING THE BURNER

Ignition

Electrode

The blower motor is permanently lubricated and

does not require periodic lubrication.

Mixer

Core

This work should be performed by factory-trained

personnel.

Scanner

5.1.5 Annually

In addition to the recommended monthly service:

Burner

Tube

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.

Pilot

Tube

Burner

Screen

Burner Assembly

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.

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.

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. Remove the burner and mixer core from the

boiler and place it on the floor.

4. Examine the venting system at least once a year.

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

a. Check all joints and pipe connections for

tightness.

b. Check pipe for corrosion or deterioration. If

any piping needs replacing, do so immedi-

ately.

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.

5. Inspect heating system for other problems. This

work should be performed by factory-trained

personnel.

7. Use a soft, clean cloth to remove accumulated

contaminants from the UV radiation tube (UV

scanner) glass envelope.

6. Perform combustion analysis.

7. The relief valve should be tested as per the

valve manufacturer’s recommendations at least

annually or as indicated by local codes.

8. Leak test gas valves.

Modu-Fire^®Gas-Fired Boiler

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.

Pilot

Tube

WARNING!

Ceramic Spider

The heat exchanger is heavy; use proper lifting

equipment and techniques.

Ignition

Electrode

5.4 AFTER ALL REPAIRS OR MAINTENANCE

8. 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)

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.)

9. 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.

3. Check air pressure and adjust air flow if neces-

sary. (See "Air Flow Adjustment", Section

3.12.2.)

4. Perform combustion check.

5.3 REMOVING THE EXCHANGER

1. Remove the burner as above.

2. Remove the front doors by pulling forward and

upward.

3. Remove the top panel of the inner cabinet.

4. Close the isolation valves to the system.

5. Drain the boiler.

6. Disconnect the supply and return lines.

7. 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]).

Modu-Fire^®Gas-Fired Boiler

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.

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.

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.

7. Once sufficient airflow is indicated by the air

flow switch, Terminal 7 of the combustion con-

trol is energized. This starts the Prepurge pe-

riod. The combustion chamber is Prepurged for

30 seconds.

8. 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.

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.

9. 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.

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

temperature control is below the set limit, the

switch is closed. Manual reset is required fol-

lowing conditions exceeding high limit tempera-

ture.

10. 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.

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. 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.

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

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

the damper position limit switch applies power

to terminal 6 on the damper motor. This ener-

12. Relay 1 releases the temperature control to

modulate.

13. 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

Maintenance

14. 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

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.

lowing conditions exceeding high limit tempera-

ture.

6. When heat is required as indicated by the outlet

water temperature, power is applied to Terminal

6 of the programmer, which initiates the burner

ignition and operation sequence.

7. The flame safeguard control first energizes

Terminal 5 which energizes control relay R1,

energizes the motor 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.

15. 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.

8. 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 period. The combustion

chamber is Prepurged for 30 seconds.

5.5.2 IRI 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 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.

9. 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.

10. 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.

2. The water flow limit switch is closed when

there is water flow through the boiler.

3. Note: The closing of this switch does not prove

that flow is adequate. Refer to Technical Data

Sheet # TD110 for proper flow requirements.

4. When gas pressure is available, the low gas

pressure limit switch is closed. Manual reset is

required following conditions resulting in low

gas pressure.

11. 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.

5. When the temperature sensed by the high limit

temperature control is below the set limit, the

switch is closed. Manual reset is required fol-

12. After the 10 second “Pilot Flame Establishing”

period, if pilot flame has been established, Ter-

Modu-Fire^®Gas-Fired Boiler

Maintenance

Loss of Water Flow

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.

When the "Water Flow" indicator is illuminated,

there is insufficient water flow to close the switch,

and burner operation is interrupted. When water

flow is re-established, the sequence returns to Step

2, provided that the other limits are satisfied.

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-

gized, 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.

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.

14. The unit modulates between the low fire setting

and the high fire setting to maintain the desired

outlet water temp set point.

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.

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.

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.

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.

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 that the other limits are satisfied.

5.6 TROUBLESHOOTING

Loss of Power

Low Air

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.

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

Maintenance

Flame Failure

•

Check the cabinet pressure for a minimum of

0.3" w.c.

Check burner is clean (refer to Section 5.2).

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.

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.

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.)

Modu-Fire^®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 (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.

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.

Technical information is also available at the above

number.

Table of Contents for this Section:

When ordering replacement parts please have the

model number and serial number of your boiler

available.

Standard Unit - Local Control - Logic Diagram

Standard Unit - Remote Control - Logic Diagram

Standard Unit - Local & Remote Control- Logic

Diagram

Standard Unit - Local & Remote Control w/ Options

- Logic Diagram

IRI Unit - Local Control - Logic Diagram

IRI Unit - Remote Control - Logic Diagram

IRI Unit - Local & Remote Control - Logic Diagram

IRI Unit - Local & 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

M R A A L

E Y E S A L M F F

K C O L R E T I N

A R S T 2 #

K C O L R E T I N

A R S T 1 #

Modu-Fire^®Gas-Fired Boiler

Parts/Technical Support

Standard Unit - Remote Control - Logic Diagram

G O

P U I N

A N A L

A L A R M

E S A F F E L Y A M

K C

I N T E R L O

2 # S T A R T

I N T E R L O

1 # S T A R T

Modu-Fire^®Gas-Fired Boiler

Parts/Technical Support

Standard Unit - Local & Remote Control - Logic Diagram

T U P I N

A L O A N

M R A L A

F E Y

F L A M E S A

O L C R E T I N

# 2 S T A R T

O L C R E T I N

# 1 S T A R T

Modu-Fire^®Gas-Fired Boiler

Parts/Technical Support

Standard Unit - Local & Remote Control w Options - Logic Diagram

T U I N P

L A E D

G O A L A N

M P P U

M R A

T S N I A L P O

L L A L I M I T

A R E A N L G R A

T N I S E T P O

T N I P O S E T

T E A N R A L T E

A R A L

F E E S A A M F L

U T R E E R A M E P T

O D O R A O U T

R I

T N I

O L C R K I N T E

T R A T S # 2

S E T P O

T U I N P

G O A N A L

O L C R K I N T E

T R A T S # 1

Modu-Fire^®Gas-Fired Boiler

Parts/Technical Support

IRI Unit - Local Control - Logic Diagram

A R A L

F E T E S A M F L

K C O

I N T E R L

A R S T 2 #

K C O

I N T E R L

A R S T 1 #

Modu-Fire^®Gas-Fired Boiler

Parts/Technical Support

IRI Unit - Remote Control - Logic Diagram

I N P U T

G O L A A N

M R A A L

E S A L M F F

Y T E

O C R K E L I N T

A R S T 2 #

O C R K E L I N T

A R S T 1 #

Modu-Fire^®Gas-Fired Boiler

Parts/Technical Support

IRI Unit - Local & Remote Control - Logic Diagram

P U I N

G O L A A N

A L A R M

F E A T Y E S A L M F

O L C R T E I N

A T R S T # 2

O L C R T E I N

A T R S T # 1

Modu-Fire^®Gas-Fired Boiler

Parts/Technical Support

IRI Unit - Local & Remote Control w Options - Logic Diagram

P U I N

D E L A Y

P U M

G O L A A N

A S L T A N R I M P O

M I A L L L I

M R A L

R A N G E A

T N O I T P S E

I N O T P S E T

A L T E R N A T

A L A R M

S E A M F E T F L A

E R U A T E R M E P T

R I

O D O R A O U T

K C O L R T E I N

S T A # R 2 T

O P I N T S E T

T U P I N

O L G A A N

K C O L R T E I N

S T A # R 1 T

Modu-Fire^®Gas-Fired Boiler

Standard Unit – Panel Layout

Parts/Technical Support

Modu-Fire^®Gas-Fired Boiler

IRI Unit – Panel Layout

Parts/Technical Support

Modu-Fire^®Gas-Fired Boiler

Parts/Technical Support

6.2 BOILER PARTS LIST

6.2.1 Main Assembly

13, 14.

No.

Part

No.

Part

1. Mixer Core, Burner (Inside Cabinet)

2. Burner Orifice (Inside Cabinet)

3. Spark Igniter Electrode

4. UV Scanner

12. Water Flow Switch

13. Blower, Motor (Inside Cabinet)

14. Blower, Wheel (Inside Cabinet)

15. Press./Temp. Gauge

5. Thermowell w/Clamp

6. Electrode Assembly w/Mica (Inside Cabi-

net)

7. Pilot Tube (Inside Cabinet)

8. Burner (Inside Cabinet)

9. Heat Exchanger

Installation/Owner’s Manual All Models-MOD

CP Control Panel (Section 6.2.2)

EC Exterior Cabinet (Section 6.2.4)

IC Interior Cabinet (Section 6.2.4)

PG Pilot Gas Train (Section 6.2.3)

MG Main Gas Train (Section 6.2.3)

10. Blower Damper

11. Pressure Relief Valve (100 PSI)

Modu-Fire^®Gas-Fired Boiler

Parts/Technical Support

6.2.2 Control Panel

Circuit Breaker

Relays and

Sockets

7, 7a, 7b, 8

Forced Recycle Time

Delay Relay

Local Control Panel

No.

Part

No.

Part

Flame Safeguard Pro-

grammer

No.

Part

10a. Ignition Cable (not visi-

ble)

Thermostat (Manual Re-

set)

Thermostat (Oper. Temp)

Air Flow Switch

Motor Start Relay

Terminal Block, Neutral

Terminal Block, Power

7a. Amplifier (UV Scanner)

7b. Timing Card, 30 sec.

11. Indicator Light, Red

12. Indicator Light, Green

Programmer, Sub-Base

Switch, On/Off, Lighted

10. Ignition Transformer (not

visible)

Modu-Fire^®Gas-Fired Boiler

Parts/Technical Support

Relays and

Sockets

Circuit Breaker

7, 7a, 7b, 8

Forced Recycle Time

Delay Relay

Remote Control Panel

No.

Part

No.

Part

Flame Safeguard Pro-

grammer

No.

Part

Thermostat (Manual Re-

set)

10a. Ignition Cable (not visi-

ble)

Thermostat (Oper. Temp)

Air Flow Switch

Motor Start Relay

Terminal Block, Neutral

Terminal Block, Power

7a. Amplifier (UV Scanner)

7b. Timing Card, 30 sec.

11. Indicator Light, Red

12. Indicator Light, Green

Programmer, Sub-Base

Switch, On/Off, Lighted

10. Ignition Transformer (not

visible)

Modu-Fire^®Gas-Fired Boiler

Parts/Technical Support

6.2.3 Gas Trains

6.2.3.1 Standard 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

Pilot Gas Cock

Vent Filter

Modu-Fire^®Gas-Fired Boiler

Parts/Technical Support

6.2.3.2 Standard Gas Train - 1500 & 2000

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

Pilot Gas Cock

Vent Filter

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

10. Vent Filter

Modu-Fire^®Gas-Fired Boiler

Parts/Technical Support

6.2.3.4 IRI Gas Train - 1500 & 2000

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

10. Vent Filter

Modu-Fire^®Gas-Fired Boiler

Parts/Technical Support

6.2.4 Cabinet

4,5

Internal Cabinet

1500/2000 - External Cabinet

1000 - External Cabinet

No.

Part

1. Exterior Cabinet, Assy.

2. Exterior Cabinet, Door

3. Exterior Cabinet, Top

4. Sight Glass

5. Sight Glass Bezel

6. Combustion Chamber, Assy.

7. Combustion Chamber, Door

8. Combustion Chamber, Top

9. Control Panel, Label

10. Control Panel, Cover

11. Control Panel, Sub Panel

12. Control Panel, Base Assy.

Modu-Fire^®Gas-Fired Boiler

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.

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.

H. Leakage or other malfunction caused by:

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. Adverse 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.

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 of the owner.

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.

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.

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.

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.

SEVERABILITY

C. Any damage to the Product due to abrasion, erosion, corro-

sion, deterioration, abnormal temperatures or the influence

of foreign matter or energy.

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

remaining provisions hereof enforceable.

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.

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.

F. Any failure resulting from misuse, modification not au-

thorized by Seller in writing, improper installation or lack

of or improper maintenance.

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)

High

Low

Cabinet Air

"w.c.

2. Combustion Air Temperature

3. Water Inlet temperature:

Water Outlet temperature:

° F

Inlet Gas

° F

Manifold Gas

° F

gpm flow through boiler

° F

Oxygen (O2)

Carbon Dioxide (CO2)

Carbon Monoxide (CO)

Net Stack Temperature

Pilot Gas Pressure

Pilot Flame Signal

Main Flame Signal

4. a. Operating Temperature Setpoint:

(from internal OR external control)

ppm

° F

ppm

° F

b. Bias Setting

c. Ratio Setting

"w.c.

Volts

5. Approximate stack lengths:

Ft. Horizontal

Ft. Vertical

Flue Pipe Diameter

6. Draft (measured where stack exits boiler)

"w.c.

Start-Up Field Test:

DATE:

" w.c. (Low)

Volts a.c.

High

Mid

Low

7. Incoming Electrical Power

Cabinet Air

"w.c.

Less than 1 volt between neutral and ground

Inlet Gas

8. Total cycles:

Manifold Gas

9. Total hours

Oxygen (O2)

10. Fault Cycle

Carbon Dioxide (CO2)

Carbon Monoxide (CO)

Net Stack Temperature

Pilot Gas Pressure

Pilot Flame Signal

Main Flame Signal

11. Fault Hours

ppm

° F

ppm

12. Fault Code

13. What time in ignition cycle?

Additional Comments:

"w.c.

Volts

Cam Setting

RED

ORANGE

BLUE

Performed by:

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

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