Patterson-Kelley P-K STORM ST-5000 Operating instructions

Patterson-Kelley 2021: All Rights Reserved.
The information in this manual is the property of Patterson-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 model boilers to within a reasonable time limit, we reserve
the right to discontinue models and replacement parts at any time or change specifications or design without notice and without incurring any obligation.
P-K STORM™GAS FIRED BOILER
w/ NURO™CONTROL SYSTEM
Natural Gas
ST-2500, ST-3000, ST-3500, ST-4000,
ST-5000, & ST-6000
Part # 2691000273
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
C.S.A Design-Certified
Complies with ANSI Z21.13/CSA 4.9
Gas-Fired Low Pressure Steam and Hot Water Boilers
Model Number:
Serial Number:
Start-Up Date:
Patterson-Kelley
155 Burson Street
East Stroudsburg, PA 18301
Telephone: [phone]
Toll Free: 877.728.5351
Fax: 570.476.724 www.pattersonkelley.com
Released: December 8, 2021
INS T ALL A TION
& OWNER ’ S
MAN U A L
INS T ALL A TION
& OWNER ’ S
MAN U A L
INS T ALL A TION
& OWNER ’ S
MAN U A L
INS T ALL A TION
& OWNER ’ S
MAN U A L
INS T ALL A TION
& OWNER ’ S
MAN U A L
INS T ALL A TION
& OWNER ’ S
MAN U A L
INS T ALL A TION
& OWNER ’ S
MAN U A L
INS T ALL A TION
& OWNER ’ S
MAN U A L
- Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
- 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.
Immediately 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.
- Installation and service must be performed by a qualified installer,
service agency or the gas supplier.
WARNING: If the information in these instructions is not followed
exactly, a fire or explosion may result causing property damage,
personal injury or death.

P-K STORMTM Gas Fired Boiler
Technical Service 1.877.728.5351
Safety
General
P-K STORM™Boilers ST-2500, ST-3000, ST-3500, ST-4000, ST-
5000, and ST-6000
All P-K STORM™Gas-Fired Boilers must be:
•Installed, operated, and serviced in accordance with
instructions contained in this manual and other supplemental
manuals.
•Installed by qualified personnel in accordance with designs
prepared by qualified facility engineers including: structural,
mechanical, electrical, and other applicable disciplines.
•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.
•Operated and serviced by experienced, qualified, and
properly trained personnel in accordance with all applicable
codes, laws, and regulations.
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.
NOTICE!
Each safety device must be
maintained and checked per the
recommended schedule. Refer to
Maintenance.
SAFETY FEATURES
It is the responsibility of the
customer to ensure external
safety provisions, such as but not
limited to: guards, safety labels,
safety controls, interlocks, lockout
devices are in place and operable.
SAFETY LABELS
The following words are used in
this manual to denote the degree
of seriousness of the individual
hazards.
Indicates an imminently
hazardous situation which,
if not avoided, will result in
death or serious injury. This
signal word is to be limited
to the most extreme
situations.
Indicates a potentially
hazardous situation which, if
not avoided, could result in
death or serious injury.
Indicates a potentially
hazardous situation which, if
not avoided, may result in
minor or moderate injury. It
may also be used to alert
against unsafe practices.
NOTICE/NOTE -NOTICE
The preferred signal word to
address practices not related to
personal injury. The safety alert
symbol is not used with this signal
word.

P-K STORMTM Gas Fired Boiler
Technical Service 1.877.728.5351
NOTICE!
The safety labels shown below are
affixed to your boiler. Although the
labels are of high quality, they may
become dislodged or unreadable
over time. Contact Patterson-Kelley
at 570.476.7261 or toll-free at
877.728.5351 for replacements.
Gas may lose its odor. Proper gas
sensing equipment and procedures
should be used for leak checks.
Failure to detect gas leaks could
result in injury or death.
Training
Proper training is the best protection against accidents. 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 injury, death, and/or property damage.
Operating and service personnel must be thoroughly familiar with
the basic construction of the P-K STORM™ST-2500, ST-3000,
ST-3500, ST-4000, ST-5000, and ST-6000 boilers, the use and
locations of the controls, the operation of the boilers, adjustment
of their various mechanisms, and all applicable safety
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
Electrical Hazards
Shock Hazard! Properly Lockout/Tagout the
electrical service and all other energy sources
before working on or near the boiler.
Shock Hazard! Do not spray water directly on
this boiler or any electrical components.
Electrical Hazard! Do not alter wiring
connections.
Crush Hazards Lifting Hazards! Use properly rated lifting
equipment to lift and position the boiler. The
load is unbalanced. Test the balance before
lifting off the floor. Do not allow personnel
beneath the lifted load. Refer to the
approximate weights in the table below.
Boiler Model
Weight in
Pounds
ST-2500
2329
ST-3000
2329
ST-3500
2772
ST-4000
2772
ST-5000
3100
ST-6000
3100
Bump Hazard from Overhead Ductwork and Piping
Injury Hazard! Install components with adequate vertical clearance.

P-K STORMTM Gas Fired Boiler
Technical Service 1.877.728.5351
Pressure Hazards
Pressure Hazard! Hot fluids. Install isolation valves on boiler water inlet and outlet.
Make sure isolation valves are closed before servicing boiler.
Pressure Hazard! Hot fluids. Annually test safety relief valve(s) for proper operation.
Do not operate boiler with faulty relief valve(s).
Slip, Fall Hazards
Tripping Hazard! Do not install piping on floor surfaces. Maintain a clear path around
the boiler.
Slip and Fall Hazard! Use a drip pan to catch water while draining the boiler. Maintain
dry floor surfaces.
Slip and Fall Hazard! Do not locate intake or exhaust terminations above a walkway;
dripping of condensate can cause icing of the walking surface. Refer to 0for more
information.
Fall Hazard! Do not stand on boiler.
Chemical Hazards
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.
Combustion Condensate –An acidic pH of
approximately 3.0 to 5.0 can be expected. Use PVC,
CPVC, or other corrosion resistant piping for drainage. Collection and disposal must be in accordance
with all applicable regulations. A condensate neutralization kit is available. Please contact your local
Patterson-Kelley representative for more information.
Burn, Fire and Explosion Hazards
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/CSA B.149. Install all required
vent lines for gas devices. Refer to 3.4 and 3.5 for more information.
Hazard from Incorrect Fuels! Possible fire, explosion, overheating, and damage. Do not
use any fuels except the design fuels for the unit.
Overfire Hazards! High pressure in gas supply could result in overfiring of this or other
devices supplied from the same source.
Fire and Explosion Hazards! Close the main gas shutoff before servicing boiler.
Fire and Explosion Hazards! Do not store or use gasoline or other flammable vapors or
liquids in the vicinity of this or any other gas fired appliance.
Burn hazard! Possible hot surfaces. Do not touch gas vent during firing operation. Use
only factory recommended vent components.
Burn Hazard! Pipes, vents, and boiler components could be hot. Do not touch piping or stack surfaces
during operation or immediately after shutdown of the boiler.
Burn Hazard! Hot flue! Use caution when servicing or draining boiler.
Fire and Explosion Hazards! Use caution when servicing burner. Propane (LPG) is heavier than air
and may linger in the combustion chamber, vent lines, or elsewhere.
Gas Leak Hazard! Make sure the burner is installed correctly and blower/transition is securely fastened
following any maintenance performed on them. These connections may leak gas if assembled
incorrectly.
Gas Leak Hazard! All threaded gas connections must be made using a pipe compound that is resistant
to liquefied petroleum gas. Do not use Teflon™tape on threaded gas piping.
Gas Leak Hazard! Check entire gas train for leaks after installation. If there is a smell of gas, shut down
the boiler and obtain immediate assistance from trained service personnel and/or your local fire
department.

P-K STORMTM Gas Fired Boiler
Technical Service 1.877.728.5351
Overfire Hazard! Possible fire and explosion from excess gas pressure. Make sure that gas inlet
pressure does not exceed 14 inches W.C.
Overfire Hazard! Possible fire and explosion. Possible malfunction of regulators and/or gas safety shut
off/control valves. Maintain all gas train components in good condition. Do not alter wiring connections.
Annual inspection by factory-trained personnel for proper set-up and operation is recommended.
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 factory trained
personnel.

P-K StormTM Gas Fired Boiler
Technical Service 1.877.728.5351
Revised: December 8, 2021
Released: December 8, 2021
Patterson-Kelley 2021
All Rights Reserved.
2691000273 P-K Storm ST2500-ST6000
Installation and Owners Manual Rev C.docx
Page v
Table of Contents
1INTRODUCTION ..........................................................................................................................IX
1.1 PURPOSE OF THIS DOCUMENT ..................................................................................................1
1.2 COMMON ABBREVIATIONS ........................................................................................................1
2SITE PREPARATION.................................................................................................................... 2
2.1 INITIAL INSPECTION UPON RECEIVING........................................................................................2
2.2 STORAGE PRIOR TO INSTALLATION............................................................................................ 2
2.3 COMPLIANCE WITH CODES........................................................................................................ 3
2.4 LOCATION SETUP.....................................................................................................................4
Lifting.................................................................................................................................. 4
Foundation .........................................................................................................................6
Clearances......................................................................................................................... 7
2.5 I NLET A IR AND E XHAUST V ENTING C ONSIDERATIONS ..................................................................8
Applicable Codes and Standards........................................................................................8
Combustion Air Inlet Planning (United States and Canada Considerations) .......................8
Category II/IV Flue Gas Exhaust Vent Planning ................................................................. 9
Venting Materials for Flue/Exhaust Systems..................................................................... 11
Required Clearances........................................................................................................ 13
2.6 GAS PIPING CONSIDERATIONS................................................................................................ 15
2.7 WATER QUALITY STANDARD ................................................................................................... 15
3INSTALLATION........................................................................................................................... 15
3.1 OVERVIEW............................................................................................................................. 15
3.2 APPLIANCE CONNECTIONS...................................................................................................... 15
Appliance Connections (ST-2500 & ST-3000).................................................................. 16
Appliance Connections (ST-3500 & ST-4000).................................................................. 17
Appliance Connections (ST-5000 & ST-6000).................................................................. 18
3.3 ELECTRICAL CONNECTIONS.................................................................................................... 19
Power Requirements........................................................................................................ 19
Three Phase Power Supply Connection........................................................................... 19
High Voltage (TB2) Terminal Block ................................................................................... 21
Low Voltage (TB1) Terminal Block.................................................................................... 23
3.4 COMBUSTIONAIR................................................................................................................... 25
Air Inlet Requirements –United States............................................................................. 25
Air Inlet Requirements - Canada....................................................................................... 26
P-K STORM™Combustion Air Requirements................................................................... 27
Direct Vent / Sealed Combustion Installations.................................................................. 27
Motorized Combustion Air Dampers................................................................................. 28
3.5 FLUE GAS /EXHAUST VENTING............................................................................................... 30
Category II or IV Venting Installation................................................................................. 30
Vent Termination............................................................................................................... 32
Venting for Multiple Boilers................................................................................................ 33
Sealed Combustion/DirectVent Systems.......................................................................... 34
Inlet Duct Connection to Boiler.......................................................................................... 38
Intake Duct Materials and Sizes ....................................................................................... 38
Category II Installations.................................................................................................... 38
Category IV Installations................................................................................................... 39
Stainless Steel Venting..................................................................................................... 39
CPVC Vent System Installation..................................................................................... 39

P-K StormTM Gas Fired Boiler
Technical Service 1.877.728.5351
Revised: December 8, 2021
Released: December 8, 2021
Patterson-Kelley 2021
All Rights Reserved.
2691000273 P-K Storm ST2500-ST6000
Installation and Owners Manual Rev C.docx
Page vi
PolyPropelene Vent System Installation ....................................................................... 40
CONDENSATE DRAIN, TRAP & DISPOSAL ............................................................... 41
3.6 REMOVING AN EXISTING BOILER ............................................................................................. 43
3.7PIPING................................................................................................................................... 44
Gas Piping Overview........................................................................................................ 44
Natural Gas Piping ........................................................................................................... 45
Pressure Testing the Gas Piping...................................................................................... 45
Boiler Water Piping........................................................................................................... 46
Boiler Water Piping (for Installer)...................................................................................... 48
3.8 WATER QUALITY .................................................................................................................... 49
3.9 PRE-START CHECKLIST.......................................................................................................... 50
3.10 SAFETY CHECKS.................................................................................................................... 50
Ignition Safety System Test .......................................................................................... 50
Low Water Cut-Out Test............................................................................................... 50
Flow Switch Test .......................................................................................................... 51
ManualReset High Temperature Limit Test..................................................................... 51
Gas Pressure Switch Tests........................................................................................... 52
3.11 FUEL/AIR ADJUSTMENTS ........................................................................................................ 53
Gas Pressure Adjustment............................................................................................. 53
Manual Control Mode for High and Low Fire Adjustment.............................................. 53
Adjusting High Fire ....................................................................................................... 55
Adjusting Low Fire........................................................................................................ 55
Checking Flame Signal................................................................................................. 55
3.12 PILOT BURNER ADJUSTMENTS (ST-6000 ONLY)...................................................................... 56
Pilot Test Hold.............................................................................................................. 56
Pilot Gas Pressure Adjustment..................................................................................... 56
Checking Pilot Flame Signal......................................................................................... 56
3.13 INITIAL NURO CONTROL SETUP AND ADJUSTMENT.................................................................. 57
Startup.......................................................................................................................... 57
Home Screen................................................................................................................ 58
Information Screen ....................................................................................................... 58
Setup Wizard................................................................................................................ 59
3.14 TYPICAL BOILER OPERATING CONDITIONS............................................................................... 59
4OPERATIONS ............................................................................................................................. 60
4.1 NURO®CONTROL PANEL....................................................................................................... 60
NURO Touch Screen Interface......................................................................................... 60
Factory Tests.................................................................................................................... 60
4.2 NORMAL LIGHTING AND SHUT-DOWN PROCEDURES ................................................................. 61
Normal Lighting Procedures ............................................................................................. 61
Normal Shut Down Procedures......................................................................................... 61
4.3 EMERGENCY SHUT-OFF ......................................................................................................... 61
5MAINTENANCE .......................................................................................................................... 62
5.1 PREVENTATIVE MAINTENANCE ................................................................................................ 62
Daily................................................................................................................................. 63
Weekly ............................................................................................................................. 63
Monthly............................................................................................................................. 63
Semi-Annually.................................................................................................................. 63
Annually or 2500 Run Hours (Whichever Comes First)..................................................... 64
5.2 CLEANING THE COMBUSTION CHAMBER................................................................................... 68

P-K StormTM Gas Fired Boiler
Technical Service 1.877.728.5351
Revised: December 8, 2021
Released: December 8, 2021
Patterson-Kelley 2021
All Rights Reserved.
2691000273 P-K Storm ST2500-ST6000
Installation and Owners Manual Rev C.docx
Page vii
5.3 AFTER REPAIRS OR MAINTENANCE.......................................................................................... 72
5.4 SEQUENCE OF OPERATIONS ................................................................................................... 73
5.5 TROUBLESHOOTING ............................................................................................................... 74
Loss of Power................................................................................................................... 74
Loss of Water Level.......................................................................................................... 74
Low Gas Pressure............................................................................................................ 74
High Gas Pressure........................................................................................................... 74
High Water Temperature................................................................................................... 74
Low Air ............................................................................................................................. 74
Flame Failure ................................................................................................................... 75
Flame Error ...................................................................................................................... 75
Flue Problem/Condensate Blockage................................................................................. 75
6PARTS/TECHNICAL SUPPORT................................................................................................. 76
6.1 TERMINAL BLOCK ASSIGNMENTS............................................................................................. 77
Terminal Block Assignments —Low Voltage (TB1) Terminal Block .................................. 77
Terminal Block Assignments —High Voltage (TB2) Terminal Block.................................. 78
6.2 WIRING DIAGRAMS................................................................................................................. 79
ST-2500-ST-4000 Natural Gas 208-240 Volt.................................................................... 79
ST-5000 Natural Gas 208-240 Volt................................................................................... 81
ST-2500-ST-4000 Natural Gas 480 Volt........................................................................... 83
ST-5000 Natural Gas 480 Volt.......................................................................................... 85
ST-6000 Natural Gas 240 Volt.......................................................................................... 87
ST-6000 Natural Gas 480 Volt.......................................................................................... 89
Control Transformer Diagrams ......................................................................................... 91
6.3 BOILER PARTS IDENTIFICATION ............................................................................................... 94
Main Boiler Assembly (ST-2500 & ST-3000) .................................................................... 94
Main Boiler Assembly (ST-3500 & ST-4000) .................................................................... 95
Main Boiler Assembly (ST-5000)...................................................................................... 96
Main Boiler Assembly (ST-6000)...................................................................................... 97
Control Panel (ST-2500-ST-4000).................................................................................... 98
Control Panel (ST-5000)................................................................................................... 99
Control Panel (ST-6000)................................................................................................. 100
Heat Exchanger Assembly ST-2500 & ST-3000............................................................. 101
Heat Exchanger Assembly ST-3500 & ST-4000............................................................. 102
Heat Exchanger Assembly ST-5000 & ST-6000 ......................................................... 103
Natural Gas Train (ST-2500-ST-4000)........................................................................ 104
Natural Gas Train (ST-5000) ...................................................................................... 105
Natural Gas Train (ST-6000) ...................................................................................... 106
Burner/Blower Assembly 240V (ST-2500-ST-4000).................................................... 107
Burner/Blower Assembly 480V (ST-2500-ST-4000).................................................... 108
Burner/Blower Assembly 240V (ST-5000 & ST-6000)................................................. 109
Burner/Blower Assembly 480V (ST-5000 & ST-6000)................................................. 110
7P-K STORM™SPECIFIC LIMITED WARRANTY....................................................................... 111
8BOILER FIRE-TEST REPORT .................................................................................................. 113
APPENDIX A –MAINTENANCE LOG.............................................................................................. 114
APPENDIX B –BOILER ALTITUDE DERATE SCHEDULE............................................................. 115
APPENDIX C –WATER QUALITY STANDARDS QUALITY STANDARDS FOR HYDRONIC
BOILERS IN MULTI-METAL SYSTEMS........................................................................................... 116

P-K StormTM Gas Fired Boiler
Technical Service 1.877.728.5351
Revised: December 8, 2021
Released: December 8, 2021
Patterson-Kelley 2021
All Rights Reserved.
2691000273 P-K Storm ST2500-ST6000
Installation and Owners Manual Rev C.docx
Page viii
APPENDIX D –BEST PRACTICES FOR NEW & RETROFIT SYSTEMS ........................................ 117
APPENDIX E –INSTALLATION AND QUICK REFERENCE ........................................................... 119
FUEL/GAS SUPPLY .......................................................................................................................... 119
ELECTRICAL/POWER SUPPLY ........................................................................................................... 119
EXHAUST VENTING .......................................................................................................................... 119
PROPYLENE GLYCOL FLOW.............................................................................................................. 122

P-K StormTM Gas Fired Boiler
Technical Service 1.877.728.5351
Revised: December 8, 2021
Released: December 8, 2021
Patterson-Kelley 2021
All Rights Reserved.
2691000273 P-K Storm ST2500-ST6000
Installation and Owners Manual Rev C.docx
Page ix
1 Introduction
This manual describes the installation and operation of
the following P-K STORM™boilers featuring NURO®
controls.
ST-2500, ST-3000, ST-3500, ST-4000, ST-5000,
& ST-6000:
Natural Gas, 208-240V (three phase)
Natural Gas, 440-480V (three phase)
Individual differences between boiler models will be
called out and defined in separate sections and the titles
of these sections will include the boiler model number. If
the boiler model numbers are not listed in the section
title, that section is common to all boiler models.
If you have any questions on the information contained
within, or do not fully and completely understand the
content, please contact Patterson-Kelley Technical
Service at 570.476.7261 or toll free at 877.728.5351.
The P-K STORM™gas-fired boiler is fully modulating
using a variable speed combustion blower, sophisticated
microprocessor controls, modulating gas safety shut off /
control valves and a unique stainless steel heat
exchanger capable of operating in a fully condensing
mode to provide maximum efficiency in a minimum
amount of space. The high-quality materials and design
of the boiler should provide years of trouble-free service
if the instructions in this manual are followed carefully.
The boiler is only a part of the complete heating system.
This boiler may be fully operational but because of poor
circulation, improper control, or other site related
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 operation of 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, fire or explosion may result causing
property damage, personal injury, or loss of
life.
Do not store or use gasoline or other
flammable vapors or liquids in the vicinity of
this or any other appliance. Installation and
service must be performed by a qualified
installer, service agency, or the gas supplier.
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.
Immediately 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.
QUE FAIRE SI VOUS SENTEZ UNE ODEUR
DE GAZ:
Ne pas tenter d’allumer d’appareils.
Ne touches à aucun interrupteur. Ne pas
vous server des téléphones dans le
bâtiment où vous vous trouvez.
Appelez immédiatement votre
fournisseur de gaz depuis un voisin.
Suivez les instructions du fournisseur.
Si vous ne pouvez rejoinder le
fournisseur de gaz, appelez le service
des incendies.
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
personal injury or death.
Installation and service must be performed
by a qualified and knowledgeable individual
who has been certified on the P-K STORM™
boiler. The features which permit this boiler
to achieve high-efficiency performance can
be misused which could result in personal
injury or death.
NOTICE! This manual covers single fuel P-K
STORM boilers (Natural Gas).
Do not store or use gasoline or other flammable
vapors and liquids in the vicinity of this or any
other appliance.
Ne pas entreposer ni utilizer d’essence ou ni
d’autres vapeurs ou liquids inflammables à
proximité de cet appareil ou de tout autre
appareil.

P-K StormTM Gas Fired Boiler
Technical Service 1.877.728.5351
Revised: December 8, 2021
Released: December 8, 2021
Patterson-Kelley 2021
All Rights Reserved.
2691000273 P-K Storm ST2500-ST6000
Installation and Owners Manual Rev C.docx
Page x
PRECAUTIONS ASSOCIATED WITH HANDLING REFRACTORY LINING MATERIAL
•This Patterson-Kelley product contains 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 (IARC)
as possibly being carcinogenic to Humans.
•AVOID breathing particles or dust from 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. Also recommended is
loose fitting, long sleeved clothing, eye protection and gloves whenever handling RCFs.
Current NIOSH Recommendations are listed on their website at
http://www.cdc.gov/niosh/homepage.html, which should be viewed before the handling or
removal of Refractory Lining Materials on this or any similar device.
•Using a SPRAY BOTTLE, saturate with WATER; but not dripping, the combustion chamber
lining to prevent dust from becoming airborne.
•Place removed RCFs into a plastic bag for disposal with normal trash.
•Wash exposed clothing (if not disposable), TWICE and DRY separately from other laundry.

P-K StormTM Gas Fired Boiler
Technical Service 1.877.728.5351
Revised: December 8, 2021
Released: December 8, 2021
Patterson-Kelley 2021
All Rights Reserved.
2691000273 P-K Storm ST2500-ST6000
Installation and Owners Manual Rev C.docx
Page 1
1.1 Purpose of this Document
It is the purpose of this Installation and Owner’s Manual is to provide complete documentation support
for P-K STORM™boilers featuring NURO controls. Patterson-Kelley is constantly seeking ways to
produce high quality HVAC products. Our operation is based on the premium quality control program
and insures that Patterson Kelley manufactures quality products.
The primary concern of all Patterson-Kelley equipment installation procedures is Safety. Safety
instructions and considerations are presented and repeated throughout the document as needed. If
you have any questions on the information contained within, or do not fully and completely 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
American National Standards Institute
ASME
American Society of Mechanical Engineers
AWG
American Wire Gauge
BTU
British Thermal Unit
CH
Comfort Heat
CO2
Carbon Dioxide
CSA
Canadian Standards Association
CSD-1
Controls and Safety Devices
CPVC
Chlorinated Polyvinyl Chloride
DHW
Domestic Hot Water
HWR
Heating Water Return / Hot Water Return (From Building)
HWS
Heating Water Supply / Hot Water Supply (To Building)
ID
Inside Diameter
MBH
Thousands of BTU / Hour
MODBUS
A serial communication protocol (not an abbreviation)
NFPA
National Fire and Protection Agency
NTC
Negative Temperature Coefficient
O2
Oxygen
OD
Outside Diameter
OEM
Original Equipment Manufacturer
SCFM
Standard Cubic Feet per Minute
SMACNA
Sheet Metal and Thermoplastic Duct Construction Manual Air Conditioning
Contractors National Association
TB<#>
Terminal Block (1, 2, 3 etc.)
VAC
Volts Alternating Current
VDC
Volts Direct Current

P-K StormTM Gas Fired Boiler
Technical Service 1.877.728.5351
Revised: December 8, 2021
Released: December 8, 2021
Patterson-Kelley 2021
All Rights Reserved.
2691000273 P-K Storm ST2500-ST6000
Installation and Owners Manual Rev C.docx
Page 2
2 Site Preparation
2.1 Initial Inspection upon Receiving
Upon receiving the boiler, inspect it for signs of shipping
damage. Some damage may be hidden. Unpack the boiler,
open the front and side doors and inspect the boiler. Verify that
the total number of pieces shown on the packing slip agrees
with those actually received.
2.2 Storage Prior to Installation
If the boiler is not installed immediately, it must be stored in a
location adequately protected from the weather, preferably
indoors. If this is not possible, then it should remain in the
shipping container and be covered by a tarpaulin or other
waterproof covering.
Installation and service must be
performed by a qualified
installer, service agency, or gas
supplier. Failure to install the
equipment in accordance with
this manual could result in an
unsafe operating condition.
L’installation et l’entretien
doivent être assures par un
installateur ou un service
d’entretien qualifié ou par le
fournisseur de gaz.
NOTICE!
Controls and other equipment that
are damaged or fail due to
weather exposure are not covered
by warranty.
The boiler is heavy and requires
additional technicians to
support and move the unit(s)
during installation. Use
extreme caution to avoid
dropping the boiler or cause
any bodily injury while lifting or
handling. When positioning
this boiler, maintain positive
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 installed on a
combustible floor; however, the
boiler must never be installed on
carpeting.
Bumping hazard from overhead
ducts! Install all components
with adequate vertical
clearances. Insufficient
clearance can restrict the
service access, increasing the
possibility of injury.
NOTICE! Note any damage, suspected potential damage,
or shortage of materials on the freight bill and immediately
notify the carrier. File all claims for shortage or damage with
the carrier. Claims for hidden damages must be filed with
your carrier within 7 days. The carton is equipped with a
“Tip (N) Tell”. If the “Tip (N) Tell” arrow point is blue, that
indicates the package has been on its side or tipped over in
transit.
NOTICE! Controls and other equipment that are damaged
or fail due to weather exposure are not covered by warranty.
If the information in these instructions are not followed
exactly, a fire or explosion may result causing property
damage, personal injury, or death.
AVERTISSEMENT
Assurez-vous de bien suivre les instructions données dans
cette notice pour réduire au minimum le risqué d’incendie
ou d’explosion ou pour éviter tout dommage materiel, toute
blessure ou la mort.
Should overheating occur or the gas supply fail to shut off,
do not turn off or disconnect the electrical supply to the
pump. Instead, shut off the gas supply at a location external
to the appliance.
En cas de surchauffe ou si l’admission de gaz ne peut être
coupée, ne pas couper ni debrancher l’alimentation
électrique de la pompe. Fermer plutôt le robinet
d’admission de gaz à l’extérieur de l’appareil.

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2.3 Compliance with Codes
Each P-K STORM™boiler with standard components complies with American National Standard/CSA
Standard ANSI Z21.13/CSA 4.9, latest edition for Gas-Fired Low Pressure Steam and Hot Water
Boilers.
The P-K STORM™ST-2500, ST-3000, ST-3500, ST-4000, ST-5000, and ST-6000 heat exchangers are
constructed and stamped in accordance with ASME Boiler and Pressure Vessel Code, Section IV for
160 psig maximum pressure and 210°F maximum temperature. Other codes or approvals which apply
will be labeled on the boiler.
ST-2500, ST-3000, ST-3500, ST-4000, ST-5000, and ST-6000
Code of Construction
(Boiler)
ASME Section IV –“H” (Latest 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 requirements of all national, state and local codes
established by the authorities having jurisdiction or, in the absence of such requirements, to the
National Fuel Gas Code, ANSI Z223.1/NFPA 54 latest edition in the U.S. In Canada, the equipment
shall be installed in accordance with the current Installation Code for Gas Burning Appliances and
Equipment, CAN/CSA-B.149, latest edition, and applicable Provincial Regulations for the class, which
should be carefully followed in all cases. Authorities having jurisdiction should be consulted before
making any installation.
Where required by local codes, 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 (a) this unit must be installed by a licensed pipe fitter/plumber,
(b) field installed gas cocks must be “T” handle type, (c) piping of condensate shall conform to the State
Plumbing Code, and (d) refer to the Massachusetts Supplement for further details.

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2.4 Location Setup
Lifting
The STORM 2500-6000 can be lifted by two methods. Lifting lugs attached to the heat exchanger,
shown in figure below, can be used to lift the unit. A variety of rigging equipment may be required to
properly lift the unit using the lifting lugs.
NOTE: Do NOT allow any rigging equipment to interfere with unit components as this can
damage the unit

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Channels running front to back below the heat exchanger, shown in the figure below, can be used to lift
the unit. A variety of lifting equipment may be required to properly lift the unit using the channels.
NOTE: Do NOT allow any lifting equipment to contact unit components as this can damage the
unit

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Foundation
The appliance must be installed level, on a housekeeping pad, to function properly. Ensure the base is
securely connected to the appliance. Use a bubble level and make sure housekeeping pad is level
before installation of appliance. There are five 3/4” holes in the base which may be used for 5/8”
anchor bolts. Two of these are located inside the cabinet and the other three are outside. The
housekeeping pad is recommended to be 4 inches but no less than 1 inch in height on the ST2500-
ST5000. On the ST6000, the housekeeping pad MUST BE 4 inches minimum.
NOTICE! The appliance may be installed on a combustible floor; however, the appliance must
NEVER be installed on carpeting.
QTY 3: 3/4” Holes
for
Anchor/Lag Bolts
(REAR)
QTY 2: 3/4” Holes
for
Anchor/Lag Bolts
(FRONT inside
cabinet)

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Clearances
If the boiler is to be installed near combustible surfaces, the minimum clearances are shown in the
illustration below. Failure to provide adequate service clearances, even with non-combustible surfaces,
may present problems during routine maintenance of the boiler. Maintain a clearance from the vent 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 National
Fuel Gas Code, NFPA 54/ANSI Z223.1, Latest Edition.
Type of Surface
Dimensions (inches)
A
B*
C†
D
E
CSA Minimum Clearances to Combustibles
18
12
0
0**
0**
Required Minimum Service Clearances
24
12
0 / 36***
18
0
Recommended Service Clearances
36
18
24 / 36***
24
6
* “B” Clearance depends upon exhaust vent configuration.
† “C” Space required for pipes, ducts, etc. in this area above the boiler.
** 18” required on either the left or right side.
*** 36” required for ST-5000 and ST-6000
Note: Failure to provide recommended service clearances may make it difficult to perform service
on the boiler(s).

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2.5 Inlet Air and Exhaust Venting Considerations
Applicable Codes and Standards
United States Installation Codes:
Canada Installation Codes:
Flue Gas Exhaust Vent Standards:
These codes and standards contain information for the venting of
gas fired appliances, including, but not limited to vent sizing,
location, clearance to combustibles, and safe installation practices.
The installation must comply with both the above Federal Codes
and with state, provincial, and local codes.
Combustion Air Inlet Planning (United States and
Canada Considerations)
Air inlet requirements for the U.S. are established by NFPA
54/ANSI Z223.1 & NFPA/ANSI 211.
Air inlet requirements for Canada are established by
CAN/CSA B149.1.
Refer to see section 3.4, for more details on combustion air inlet
requirements in the United States and Canada.
Design and installation of
venting systems should be
done only by qualified and
knowledgeable venting systems
personnel and in accordance
with vent system
manufacturer’s installation
instructions. Installing a boiler
or vent system using improper
installation methods or
materials 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 direct vent
configuration. In the US,
provisions for combustion air
must be in accordance with
NFPA 54/ANSI Z223.1, National
Fuel Gas Code, latest edition, or
applicable provisions of local
building codes. In Canada,
combustion and ventilation air
openings shall comply with
CAN/CSA B-149.1 Natural Gas
and Propane Installation Code.
For correct installation of a vent
system, read all of these
instructions and refer to the
vent manufacturer’s
instructions.
Failure to use a proper vent
system (types and materials), as
described in this manual will
void the boiler warranty and
may result in rapid deterioration
of the venting system, creating
a health or life safety hazard.
Faulty vent installation can
allow toxic fumes to be released
into living areas. This may
cause property damage, injury,
or death.
NBIC –Part I
National Board Inspection Code -
Installation
NFPA 54/ANSI Z223.1
National Fuel Gas Code
NFPA/ANSI 211
Chimneys, Fireplaces, Vents and Solid
Fuel Burning Appliances
CAN/CSA B149.1
Installation Codes for Gas Burning
Equipment
UL 441 / ULC S605
Standard for Gas Vents
UL 1738
Venting Systems for Gas-Burning
Appliances, Categories II, III and IV
ULC S636-95
Standard for Type BH Venting System
Sheet Metal and Thermoplastic Duct
Construction Manual Air Conditioning
Contractors National Association
(SMACNA)

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Category II/IV Flue Gas Exhaust Vent Planning
Several codes and standards have categorized appliances in accordance with the flue gas temperature
and pressure produced by the appliance. The applicable categories are defined as follows:
Category II: An appliance that operates with a non-positive vent static pressure and with a vent
temperature that may cause excessive condensate production in the vent.
Category IV: An appliance that operates with a positive vent static pressure and with a vent
temperature that may cause excessive condensate production in the vent.
Direct Vent: An appliance that is constructed and installed so that all air for combustion is
derived directly from outdoors and all flue gases are discharged to the outdoors.
All P-K STORM™boilers are dual-certified as Category II or IV appliances, as defined in ANSI
Z21.13/CSA 4.9, latest edition. The P-K STORM™series boilers are capable of operating with slightly
negative to slightly positive exhaust pressure. It is critical to ensure the flue vent material 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” 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 following ranges:
ST-2500 –ST-4000: +0.01” W.C. and +0.22” W.C. (Direct Vent / Sealed Combustion)
ST-2500 –ST-4000: +0.01” W.C. and +0.4” W.C. (Exhaust Only)
ST-5000 & ST-6000: +0.01” W.C. and +0.5” W.C. (Direct Vent / Sealed Combustion)
ST-5000 & ST-6000: +0.01” W.C. and +1.0” W.C. (Exhaust Only)
The vent material to be used for US and Canada is listed in the Table of Acceptable Materials for
Venting Systems located in 2.5.4.
Vent installations shall be in accordance with NFPA 54/ANSI Z223.1, the National Fuel Gas Code, or
CAN/CSA-B149.1, the Natural Gas and Propane Installation Code, or applicable provisions of the local
building codes.