Patterson-Kelley P-K STORM ST-1250, Installation & Owner'S Manual

Page 1: ...atterson Kelley The descriptions and specifications contained in this manual were in effect at the time this manual was approved for publication While Patterson Kelley will continue to support earlier...

Page 2: ...lation and lighting with a structure sufficiently strong and rigid to support the weight of the boiler all piping and accessories NOTICE Each safety device must be maintained and checked per the recom...

Page 3: ...fety precautions If any of the provisions of this manual are not fully and completely understood contact Patterson Kelley Technical Service at 570 476 7261 or toll free at 877 728 5351 Hazard Warnings...

Page 4: ...Explosion Hazards Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other gas fired appliance Burn hazard Possible hot surfaces Do not touch gas vent du...

Page 5: ...7 GAS PIPING CONSIDERATIONS 12 2 8 WATER QUALITY STANDARD 12 3 INSTALLATION 12 3 1 OVERVIEW 12 3 2 APPLIANCE CONNECTIONS 12 Appliance Connections 13 3 3 ELECTRICAL CONNECTIONS 14 Power Requirements 14...

Page 6: ...ure Switch Tests 43 3 11 FUEL AIR ADJUSTMENTS 44 Gas Pressure Adjustment 44 Manual Control Mode for High and Low Fire Adjustment 45 Adjusting High Fire 46 Adjusting Low Fire 46 Checking Flame Signal 4...

Page 7: ...nal Block 67 6 2 WIRING DIAGRAMS 68 ST 1250 ST 1500 ST 1750 ST 2000 Natural Gas 68 6 3 BOILER PARTS IDENTIFICATION ST 1250 ST 1500 ST 1750 ST 2000 70 Main Boiler Assembly 70 Control Panel 71 Heat Exch...

Page 8: ...any system Patterson Kelley cannot be responsible for the design or operation of such systems and a qualified engineer or contractor must be consulted If the information in this manual is not followed...

Page 9: ...om RCFs and avoid contact with Skin or Eyes The National Institute for Occupational Safety and Health NIOSH recommends the use of a respirator meeting current standards to avoid inhalation of dust Als...

Page 10: ...understand the content please contact Patterson Kelley Technical Service at 570 476 7261 or toll free at 877 728 5351 1 2 Common Abbreviations Abbreviation Description AMP Ampere or Amperage ANSI Ame...

Page 11: ...itive control of it at all times Do not attempt to move the boiler on surfaces that are not level Failure to heed this warning could result in personal injury or death NOTICE The boiler may be install...

Page 12: ...Edition Maximum Allowable Working Pressure 160 PSIG Maximum Allowable Design Temperature 210 F Hi Limit Setpoint 200 F Maximum Setpoint 185 F Installation of the boiler must conform to all the requir...

Page 13: ...es the installation must conform to American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers ASME CSD 1 In the Commonwealth of Massachusetts...

Page 14: ...ce Use a bubble level and make sure housekeeping pad is level before installation of appliance There are four 3 4 holes in the base which may be used for 5 8 anchor bolts Two of these are located insi...

Page 15: ...to combustible surfaces of 18 or as specified in the vent manufacturer s listed installation instructions The boiler must be installed in a space large in comparison to the boiler as described in the...

Page 16: ...ials can result in serious injury or death due to fire or asphyxiation Before connecting a boiler to a venting system it must be determined whether the boiler is to be installed in a conventional or d...

Page 17: ...al is certified for Category II or IV operation NOTE For Category II installations ensure the flue venting system is designed to maintain a slightly negative exhaust pressure between 0 01 W C and 0 05...

Page 18: ...from different manufacturers within the same system As per ANSI Z21 13b CSA 4 9b The use of cellular core PVC CPVC and Radel as venting materials is prohibited The use of external insulation on plast...

Page 19: ...ent Sealed Combustion Systems Clearances The vent terminal shall be located at least 12 in from any air opening into a building The bottom of the vent terminal shall be at least 12 in above grade Both...

Page 20: ...opening 6 in 15 cm for appliances 10 000 Btuh 3 kW 12 in 30 cm for appliances 10 000 Btuh 3 kW and 100 000 Btuh 30 kW 36 in 91 cm for appliances 100 000 Btuh 30 kW F Clearance to a mechanical air sup...

Page 21: ...t and function properly For more information refer to Harsco Industrial Patterson Kelley s Water Quality Standards for Hydronic Boilers in Multi Metal Systems in Appendix C Water Quality Standards Qua...

Page 22: ...son Kelley 2019 All Rights Reserved 2691000099 P K Storm Installation and Owners Manual docx Page 13 Appliance Connections All connections must be in compliance with national state and local code requ...

Page 23: ...ctions The electrical service to the boiler must be installed and grounded in accordance with local codes or in the absence of such requirements in the U S with National Electrical Codes ANSI NFPA No...

Page 24: ...OT L2 Connect the 2nd hot lead of the 208 240VAC single phase 60Hz electrical service to the TB2 2 terminal Be sure to check the nameplate on the boiler before connecting the electrical supply NOTICE...

Page 25: ...zed air damper This circuit is energized with 120VAC so the contacts on the end limit switch must be rated for minimum 120VAC The appliance ships with a factory installed jumper across the Air Damper...

Page 26: ...t generally closure of the Enable Disable circuit provides a call for heat to the boiler Opening this circuit prevents the boiler from running 4 20mA Analog Input TB1 3 and TB1 4 can be used to provid...

Page 27: ...ormal operation This circuit is energized by the boiler with a 5VDC potential so the contacts on the day night timer must be rated for minimum 5VDC 4 20mA Analog Output TB1 15 and TB1 16 provide a 4 2...

Page 28: ...cate directly with the outdoors or through a vertical or horizontal duct that communicates to the outdoors Minimum free area of the opening is 1 square inch for each 3 000 Btu Hr 700 mm2 kW of install...

Page 29: ...C When combustion air is supplied by natural airflow into a space containing the type of appliance described in Paragraph B the cross sectional area of the opening shall not be less than the sum of t...

Page 30: ...cts etc The combustion air supply 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 Th...

Page 31: ...d most installation codes require the use of motorized combustion air dampers with end limit switches installed in the combustion air intake ductwork upstream of each appliance This damper isolates th...

Page 32: ...appliance itself All end limit switches must be rated for 120VAC External power supplies are required for Relay A Relay B Relay C and Relay D Because power is provided from an external source the powe...

Page 33: ...esponsible for the effects such adverse conditions may have on the operation of the appliances Vertical vents are allowed to be terminated with a variety of ends including plain straight pipe elbow or...

Page 34: ...le for vent design parameters P K STORM Boiler Model Draft Stack Temperature CO2 Natural Gas ST 1250 ST 1500 ST 1750 ST 2000 Category II 0 01 to 0 05 W C 220 F gross 8 5 ST 1250 ST 1500 ST 1750 ST 200...

Page 35: ...the exhaust back pressure within the appliance and upstream of this damper The 0 04 W C in the common flue will also help make sure the exhaust gases from an online appliance does not backflow through...

Page 36: ...ained by the combustion air fan Allowable configurations of vent and air intake terminations are illustrated below The combined pressure drop of the air supply duct and exhaust vent must not exceed 0...

Page 37: ...htly negative exhaust pressure between 0 01 W C and 0 05 W C NOTE For Category IV installations ensure the flue venting system is designed to maintain a slightly positive exhaust pressure which MUST B...

Page 38: ...ive exhaust pressure between 0 01 W C and 0 05 W C NOTE For Category IV installations ensure the flue venting system is designed to maintain a slightly positive exhaust pressure which MUST BE in the f...

Page 39: ...9 Released October 2 2019 Patterson Kelley 2019 All Rights Reserved 2691000099 P K Storm Installation and Owners Manual docx Page 30 When terminating on the same vertical axis the air intake must use...

Page 40: ...h a non positive vent static pressure and with a vent temperature that may cause excessive condensate production in the vent There are several requirements for reliable operation of the boilers under...

Page 41: ...hat any and all integral gasketing is properly assembled and creates a gas and water tight seal Systems that require silicone caulking for gasketing should only be installed with silicone caulk that i...

Page 42: ...tructure within ten 10 feet of the vent The exhaust vent may ONLY terminate through a wind and vent cap and must be supported independently from the boiler Boiler clearance for combustibles non combus...

Page 43: ...ke certain the end of the drain line is not submerged or otherwise blocked 3 All condensate plumbing must be protected from freezing Do not locate the condensate piping such that an ice dam of frozen...

Page 44: ...emoved 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 whil...

Page 45: ...r operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe 6 After it has been determined that each appliance remaining connected to the common venting system properly vent...

Page 46: ...p type must be provided to reduce the pressure to less than 14 W C Refer to the table below or the appliance s label for the minimum inlet gas pressure ST 1250 ST 1500 ST 1750 ST 2000 Natural Gas 3 5...

Page 47: ...16 12 3 4350 3000 2400 2050 1850 1500 3 3 068 7 67 15 3 7700 5300 4300 3700 3250 2650 2280 4 4 026 10 1 20 2 15800 10900 8800 7500 6700 5500 4600 Pressure Testing the Gas Piping The appliance and all...

Page 48: ...aulic to NPT are available from Patterson Kelley The bottom rear connection to the boiler is the INLET and must be used for the return from the system The top rear connection to the boiler is the OUTL...

Page 49: ...isplay is depressed Installation of external limit controls may be required by certain codes or in certain installations Review applicable local codes for details Drain Valve and Piping The P K Storm...

Page 50: ...water treatment can be found on our website www pattersonkelley com type in search water quality For information please refer to Patterson Kelley Multi Metal Systems Water Quality Standards as it appe...

Page 51: ...y generating a heat request The method for this will depend on your boiler configuration 2 During the pre purge cycle before ignition smoothly close the downstream manual isolation valve inside the bo...

Page 52: ...urnished with a manual reset high temperature limit which features a probe installed near the boiler s outlet in order to measure the outgoing supply water temperature This probe is connected to the m...

Page 53: ...stion blower to supply the correct gas air mixture for optimum firing performance and efficiency The combustion blower speed is controlled automatically by the boiler controller The blower speed deter...

Page 54: ...the boiler to operate at low fire high fire or anywhere in between To prevent the appliance from cycling off prematurely during adjustment ensure that any load devices air handlers control valves radi...

Page 55: ...observe proper operating parameters for the system Set boiler to the Manual Control Firing Rate mode as described above and decrease the firing rate to 1 Once the boiler has reached low fire operation...

Page 56: ...e complete control setup please refer to the NURO Boiler Controller Advanced User s Guide Part Number is 1004905979 which is helpful for more complex installations For more complex boiler or water hea...

Page 57: ...ture Inlet Return Temperature Exhaust Temperature Firing Rate etc Pressing the Info button in the lower left corner will load the Information screen For the setup wizard press the Settings button in t...

Page 58: ...at the bottom of the screen The NURO control also allows the user to back track at any time by pressing PREVIOUS in the bottom left corner of the screen The Setup Wizard allows the user to assign fun...

Page 59: ...and swinging open to the left Factory Tests Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on this boiler when the boiler underwent factory...

Page 60: ...nd take necessary corrective action before proceeding 3 Set the desired high temperature limit and operating temperature The NURO controller will now begin the automatic firing sequence Normal Shut Do...

Page 61: ...f any combustible materials including flammable vapors and liquids NOTICE Proper maintenance schedule and record keeping is critical for optimum performance and to maintain the Patterson Kelley warran...

Page 62: ...n adjustment to the combustion is necessary call a qualified and knowledgeable installer or service agency that has been trained on the Patterson Kelley appliance Monthly 1 Press the Info button on th...

Page 63: ...ce NOTE Patterson Kelley recommends cleaning the heat exchanger at least once annually Some of the items listed under this section are easily accessible during that procedure Patterson Kelley recommen...

Page 64: ...ck to the factory preferred settings The burner may be cleaned with compressed air if any accumulated dust or lint is found This must be done with the burner outside of the combustion chamber 4 Inspec...

Page 65: ...valve on the heat exchanger That hose or piping should be run to a floor drain Open the drain valve to drain water from the boiler piping It is then recommended to remove the flow switch from the out...

Page 66: ...orrosion or deterioration If any piping needs replacing do so immediately c Inspect and clean any screens in the vent terminal 8 Qualified service personnel should thoroughly inspect the heating syste...

Page 67: ...head on the back that secure the casting to the blower plate The transition casting will remain in place resting on the studs on the burner door c Using the handle provided on the casting remove the...

Page 68: ...ss for cleaning the exchanger 10 With the coils to the heat exchanger now accessible clean the coils with a non steel brush preferably nylon Vacuum out any large debris that is knocked loose ANY CLEAN...

Page 69: ...ght torque each stud in staggered sequence to 50 Nm 37ft lbs 20 Reinstall the blower to burner transition casting a Be sure to have replaced both the top gasket and the burner door gasket b Align the...

Page 70: ...ains a Combustion Area lined with REFRACTORY CERAMIC FIBERS RCFs similar to many other devices produced in this industry RCFs have been identified by the International Agency for Research on Cancer IA...

Page 71: ...e gas valves open elapsed time 7 seconds 6 After a successful ignition the fan is driven to low fire and the CH LOW FIRE HOLD TIME timer is started Once the LOW FIRE HOLD TIME timer expires the boiler...

Page 72: ...opens when there is or has been insufficient gas pressure available for proper operation of the boiler If an external gas supply shut off valve is closed for any reason a low gas condition will result...

Page 73: ...hrough the flame observation port during the trial for ignition When 106 Flame Lost in Main Flame Establish Period 107 Flame Lost Early in Run or 108 Flame Lost in Run is displayed the boiler lost the...

Page 74: ...e by calling or visit the Patterson Kelley website www pattersonkelley com When ordering replacement parts please have the model number and serial number of your boiler available Typical schematic dra...

Page 75: ...A Analog Output Tracks Boiler Firing Rate 100 Firing Rate 20mA 1 Firing Rate 4mA 15 4 20mA ANALOG OUTPUT 14 NIGHT SETBACK Contact Closure Enables Night Setback Operation Open Circuit Disables Night Se...

Page 76: ...nt 20 RELAY B 19 RELAY C User Configurable Normally Open Dry Contact C 120VAC Max Voltage 1 2Amp Max Current 18 RELAY C 17 RELAY D User Configurable Normally Open Dry Contact D 120VAC Max Voltage 1 2A...

Page 77: ...ervice 1 877 728 5351 Revised October 2 2019 Released October 2 2019 Patterson Kelley 2019 All Rights Reserved 2691000099 P K Storm Installation and Owners Manual docx Page 68 6 2 Wiring Diagrams ST 1...

Page 78: ...mTM Gas Fired Boiler Technical Service 1 877 728 5351 Revised October 2 2019 Released October 2 2019 Patterson Kelley 2019 All Rights Reserved 2691000099 P K Storm Installation and Owners Manual docx...

Page 79: ...77 728 5351 Revised October 2 2019 Released October 2 2019 Patterson Kelley 2019 All Rights Reserved 2691000099 P K Storm Installation and Owners Manual docx Page 70 6 3 Boiler Parts Identification ST...

Page 80: ...Fired Boiler Technical Service 1 877 728 5351 Revised October 2 2019 Released October 2 2019 Patterson Kelley 2019 All Rights Reserved 2691000099 P K Storm Installation and Owners Manual docx Page 71...

Page 81: ...d Boiler Technical Service 1 877 728 5351 Revised October 2 2019 Released October 2 2019 Patterson Kelley 2019 All Rights Reserved 2691000099 P K Storm Installation and Owners Manual docx Page 72 Heat...

Page 82: ...ired Boiler Technical Service 1 877 728 5351 Revised October 2 2019 Released October 2 2019 Patterson Kelley 2019 All Rights Reserved 2691000099 P K Storm Installation and Owners Manual docx Page 73 N...

Page 83: ...oiler Technical Service 1 877 728 5351 Revised October 2 2019 Released October 2 2019 Patterson Kelley 2019 All Rights Reserved 2691000099 P K Storm Installation and Owners Manual docx Page 74 Burner...

Page 84: ...chnical Service 1 877 728 5351 Revised October 2 2019 Released October 2 2019 Patterson Kelley 2019 All Rights Reserved 2691000099 P K Storm Installation and Owners Manual docx Page 75 Burner Blower A...

Page 85: ...for repairs of any products or party alleged defective shall in all events be at Buyer s sole risk and cost This warranty applies only if the original installer and Seller Attention Harsco Industrial...

Page 86: ...n whole or in part from any modification or alteration Buyer makes to any product sold hereunder and N Design defects where Seller has complied with Buyer s design specifications III PROOF OF PURCHASE...

Page 87: ...fficiency _____ _____ Comb Air Pres intake _____ w c _____ w c Lockup Static Gas pressure Gas pressure drop ignition _____ 2 Water Inlet temperature _____ F 3 Water Outlet temperature _____ F 4 Flow t...

Page 88: ...877 728 5351 Revised October 2 2019 Released October 2 2019 Patterson Kelley 2019 All Rights Reserved 2691000099 P K Storm Installation and Owners Manual docx Page 79 Appendix A Maintenance Log Date H...

Page 89: ...oiler Altitude Derate Schedule For installations over 2 000 ft elevations a derate schedule is applied The boiler input rating must be reduced by 4 per 1 000 ft which is illustrated in the graph below...

Page 90: ...han 10 of the system volume per year and meter readings should be recorded at least monthly to ensure system losses are minimized and corrective actions shall be taken when needed Treatment programs f...

Page 91: ...nt of fresh water introduced into the system piping It can also be used to establish a rough estimate of the total system volume during the initial fill In general the annual amount of fresh water mak...

Page 92: ...the presence of suspended and dissolved solids These are typically a result of deteriorating piping fittings or legacy boiler s heat exchangers Patterson Kelley recommends installing a side stream fi...

Page 93: ...s pipe sizing Electrical Power Supply Carefully inspect the boiler s nameplate labels which describe the power supply requirements Provide an appropriate power feed to the boiler with overcurrent prot...

Page 94: ...es strainers couplings flanges etc P K STORM ST 1250 through ST 2000 Boilers Minimum Maximum Flow Rates Flow Condition Boiler Operation Flow Rate Approximate T ST 1250 ST 1500 ST 1750 ST 2000 Maximum...

Page 95: ...250 ST 1500 ST 1750 ST 2000 Mixture Flow Pressure Flow Pressure Flow Pressure Flow Pressure 0 121 GPM 18 8 ft 146 GPM 23 ft 170 GPM 20 ft 194 GPM 26 ft 10 123 GPM 19 4 ft 148 GPM 23 6 ft 172 GPM 20 5...