Patterson-Kelley TBIG-03 User manual

INSTALLATION
OWNER’S
MANUAL
&
INSTALLATION
OWNER’S
MANUAL
&
INSTALLATION
OWNER’S
MANUAL
&
INSTALLATION
OWNER’S
MANUAL
&
INSTALLATION
OWNER’S
MANUAL
&
INSTALLATION
OWNER’S
MANUAL
&
INSTALLATION
OWNER’S
MANUAL
&
INSTALLATION
OWNER’S
MANUAL
&
GGIG-99
®

Gemini™ Twin-Fuel Gas-Fired Boiler
TABLE OF CONTENTS
1.0 INTRO UCTION ......................................... 1
2.0 ESCRIPTION............................................2
2.1 Principle of Operation.............................. 2
3.0 SAFETY ...................................................... 2
3.1 General ................................................... 2
3.2 Training................................................... 2
3.3 Safety Features....................................... 3
3.4 Safety Labels .......................................... 3
3.5 Safety Precautions .................................. 3
3.5.1 Electrical azards ......................................3
3.5.2 Burn, Fire, and Explosion azards.............3
3.5.3 Crush azards ...........................................4
3.5.4 Chemical azards ......................................4
4.0 INSTALLATION ..........................................5
4.1 General ................................................... 5
4.2 Gas Piping .............................................. 6
4.2.1 Gas Bleeds and Vents................................7
4.3 Pre-Start Check List ................................ 7
4.4 Pre-Start Safety Checks and Adjustments 7
4.4.1 Test of Ignition Safety System....................8
4.4.2 Test of Low Water Cutoff ...........................9
4.4.3 Test of igh-Limit Control ..........................9
4.4.4 Test of Gas Pressure Switch .....................9
4.4.5 Gas Pressure Adjustment ........................10
4.4.6 Leak Testing of Valves.............................10
5.0 OPERATION............................................. 13
5.1 General.................................................. 13
5.1.1 Tests ........................................................13
5.1.2 Starting System ........................................13
5.2 Lighting and Shut-Down Procedures .... 13
5.2.1 Lighting Procedures .................................13
5.2.2 Normal Shut-Down Procedures ...............14
5.2.3 Emergency Shut-Down ............................14
5.3 Switchover to Propane Operation ......... 14
7.0 MAINTENANCE........................................ 15
7.1 General................................................. 15
7.2 Sequence of Operation......................... 16
8.0 PARTS AN TECHNICAL SUPPORT ...... 17
8.1 Wiring Diagrams................................... 17
8.1.1 Wiring Diagram (Lo- i-Lo) .......................18
8.1.2 Control Logic Diagram (Lo- i-Lo) ............19
8.1.3 Wiring Diagram (On-Off)..........................20
8.1.4 Control Logic Diagram (On-Off) ...............21
It is essential to read, understand, and follow the recommenda-
tions of this manual before installing, operating, or servicing this
equipment. Failure to do so could result in serious injury,
death, and/or property damage.
The information and instructions herein pertain only to equip-
ment supplied by atterson-Kelley Company. atterson-Kelley
is not responsible for equipment supplied by others, nor for any
adverse effects such equipment might have on equipment sup-
plied by atterson-Kelley.

Introduction
Warning!
This boiler requires VA ORIZED propane or natural gas. Under
NO CIRCUMSTANCES may liquid fuel of any kind be introduced in
the boiler.
natural gas
connection
and shutoff
propane
connection
and shutoff
Figure 1-1 Twin-Fuel Gas Train
(Shows 1500/1700/1900 Series; refer to Figure 5-1 for 700/900/1200 Series)
1.0 INTRO UCTION
The twin-fuel option for the Patterson-Kelley Gem-
ini™ gas-fired boiler allows the boiler to be fired by
propane in the event that the supply of natural gas is
temporarily interrupted or restricted. The necessary
fittings, valves, piping, and controls for twin-fuel op-
eration are factory installed.
This document is a companion to the “ nstallation and
Owner’s Manual - TB G” for the standard Thermificâ
boiler. Both documents must be used together. This
companion document describes those safety, installa-
tion, adjustment, and maintenance procedures which
differ from the single-fuel model. nformation which
applies to both models is found in the main manual.
- 1 -

Geminiâ Twin-Fuel Gas-Fired Boiler
2.0 ESCRIPTION
2.1 PRINCIPLE OF OPERATION
Natural gas and propane are permanently piped to
separate connections on the boiler. Each branch of the
gas train is fitted with a regulator and a motorized gas
valve. The regulators are adjusted to properly fire the
boiler from their respective sources. Boiler and con-
trol functions are the same for both fuels.
n the event of interruption or restriction of the natural
gas supply, changeover to propane is made manually
by a selector switch on the boiler (or by a signal from
a remote switch or controller).
When the natural gas supply is reestablished, change-
over is made by restoring the selector switch to its
normal position (or by sending the appropriate signal
from the remote controller).
3.0 SAFETY
3.1 GENERAL
The Gemini™ gas-fired boiler must be:
· nstalled by qualified personnel in accordance
with designs prepared by qualified facility engi-
neers including: structural, mechanical, electrical,
and other applicable disciplines.
· Operated and serviced in accordance with a com-
prehensive safety program determined and estab-
lished by the customer and complying with all
safety provisions of this manual. Do not attempt
to operate or service the boiler until such a pro-
gram has been established.
· Operated and serviced by qualified, properly
trained personnel in accordance with all applica-
ble laws and regulations.
3.2 TRAINING
It is essential to read, understand, and follow the rec-
ommendations of this manual before installing, operat-
ing, or servicing this equipment. Failure to do so could
result in serious injury, death, and/or property damage.
Proper training is the best protection against accidents.
Operating and service personnel must be thoroughly
familiar with the basic construction of the Gemini™
boiler, the use and locations of the controls, the opera-
- 2 -

Safety
tion of the boiler, adjustment of its various mecha-
nisms, and all applicable safety precautions. f any of
the provisions of this manual are not fully and com-
pletely understood, contact the Patterson-Kelley Sales
Department at [phone] for assistance.
3.3 SAFETY FEATURES
t 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.
3.4 SAFETY LABELS
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. Con-
tact Patterson-Kelley at [phone] for replace-
ment labels.
3.5 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
he weight of the boiler, all piping, and accessories. t
3
.5.1 Electrical Hazards
· High voltage! Shock hazard. Properly lock-
out/tagout the electrical service and all other energy
sources before working on or near the machine.
· nstall a lockable disconnect switch.
3.5.2 Burn, Fire, and Explosion Hazards
General Warning Hot Surface
· Burn, fire, and explosion hazards! nstallation must
be in strict conformance to all applicable codes and
standards including NFPA 54 and ANS Z223.1, (or
in Canada, CAN-B 149). nstall all required vent
- 3 -

Gemini™ Twin-Fuel Gas-Fired Boiler
lines for gas devices. See Section 4 below.
· Hazard from incorrect fuels! Possible fire, explo-
sion, overheating, and damage. Do not use any
fuels except vaporized natural gas and propane.
Under no circumstances is liquid fuel of any kind
to be introduced in the boiler.
· Hazard from incorrect fuel connections! Possible
fire, explosion, overheating, and damage. Do not
attempt to connect the propane supply to the natu-
ral gas connection, or vice versa.
· Fire and explosion hazards! Close both the natural
gas and propane shutoffs before servicing boiler.
· Burn hazard! Possible hot surfaces. Do not touch
gas vent during firing operation. Use only factory
recommended B-vent components.
· Fire and explosion hazards! Use caution when
servicing burner. Propane is heavier than air and
may linger in the combustion chamber, vent lines,
or elsewhere.
· Gas leak hazard! Make sure all connections to
main burner are tight when reassembling the
burner. These connections cannot be tested after
burner is assembled.
· Gas leak hazard! Test motorized gas valves annu-
ally for leakage as described in Section 4.4.6.
· Gas leak hazard! All threaded gas connections
must be made using a pipe compound that is resis-
tant to propane. Do not use Teflonä tape on
threaded gas piping.
· Gas leak hazard! Check entire gas train for leaks
after installation. f there is a smell of gas, shut
down the boiler and obtain immediate assistance
from trained service personnel and/or your local
fire department.
· Overfire hazard! Possible fire and explosion from
excess gas pressure. Make sure that gas inlet pres-
sure does not exceed 14 inches W.C. to the
regulator on either the natural gas or propane sup-
ply line.
· Overfire hazard! Possible fire and explosion.
Possible malfunction of regulators and/or motorized
gas 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, ex-
plosion, 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.
3
.5.3 Crush Hazards
General Warning
· Lifting hazards! Use properly rated lifting equip-
ment to lift and position the boiler. The load is
unbalanced. Test balance before lifting 3 ft.
above the floor. Do not allow personnel beneath
the lifted load. Refer to approximate weights in
the table below:
Boiler Size Weight in Pounds
700,000 Btu 650
1,000,000 Btu 650
1,200,000 Btu 765
1,500,000 Btu 1,100
1,700,000 Btu 1,100
2,000,000 Btu 1,100
3
.5.4 Chemical Hazards
· Environmental hazard! The motorized gas valves
may contain hydraulic oil. Use safe procedures
for the disposal of all lubricants.
- 4 -

Installation
*
*
*
*
*
*
propane
connection
manual
shutoff
natural gas
connection
manual
shutoff
regulator
low gas
pressure switch
motorized gas valve
(propane)
low gas
pressure switch
motorized gas valve
motorized gas valve
(natural gas)
high gas pressure
switch
pressure tap
burner
secondary
shutoff, manual
pilot
shutoff
regulator
pilot regulator and
solenoid valve mechanical link
to control air
(Lo- i-Lo only)
Items with symbol must be
vented to outside. Refer to the
drawings packed with your
boiler for additional information.
leak test
valves
n.o. vent valve
(I.R.I. only)
Figure 4-1 Piping Schematic for the Twin-Fuel Gas Train
4.0 INSTALLATION
Gas Train Connection Sizes
Natural Gas Propane
700/1000/1200
Series
1 1/4" 1"
1500/1700/2000
Series
2" 1 1/4"
4.1 GENERAL
nstallation of the twin-fuel Gemini™ boiler is similar
to that of the single-fuel model. Refer to “Thermificâ
Gas-Fired Boiler - nstallation and Owner’s Manual -
TB G” pages 2 through 10.
The following procedures are different from those for
the single-fuel model, and are described in this Sec-
tion:
· Gas Piping
Gas Bleeds and Vents
· Pre-Start Check List
· Pre-Start Safety Checks and Adjustments
Test of gnition Safety System
Test of Low Water Cutoff
Test of High Limit Control
Test of Gas Pressure Switch
- 5 -

Gemini™ Twin-Fuel Gas-Fired Boiler
Gas Pressure Adjustment
Test of Motorized Gas Valves
4.2 GAS PIPING
Before making the gas hook-up, make sure the boiler
is being supplied only with the fuels shown on the
boiler nameplate. The boiler is designed to operate on
vaporized natural gas and propane only. Do not use
any type of liquid fuel. Do not attempt to fuel the
boiler with MAPP gas, sewage gas, coal gas, or other
fuels.
Gas train connection sizes are shown in the Gas Train
Connection table on the previous page for the different
models available.
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.).
The two gas pressure regulators supplied with the
boiler are set during a factory fire-test to provide the
proper pressure to the main burner: 6 inches W.C. in-
let pressure to the regulators for both natural gas and
propane.
The gas train components are designed to handle a
maximum inlet pressure of 14 inches W.C.(1/2 psig).
f the available gas pressure exceeds 14 inches W.C.
on either the natural gas or propane supply a suitable
intermediate gas pressure regulator of the "lock up"
type must be provided to reduce the pressure to less
than 14 inches W.C. All boilers are designed to oper-
ate at rated input with a minimum inlet pressure of 6
inches W.C. with natural gas, 6 inches W.C. with LP
gas.
shutoff
(on boiler)
union
drip leg
remote gas shutoff
(not supplied)
meter
natural gas
supply
propane
supply shutoff
(on boiler)
union
drip leg
remote gas shutoff
(not supplied)
Figure 4-2 Gas Supply Piping
(Refer to table above for connection sizes.)
nstall a sediment trap (drip leg) and a union connec-
tion ahead of the primary manual shutoff valves on the
boiler as shown in the figure above.
All gas piping must be installed in accordance with
National Fuel Gas Code, ANS Z223.1, latest edition,
and any other local codes which may apply; in Canada
gas piping must be installed in accordance with CAN-
B 149.
General Warning
Warning! All threaded connections must be made us-
ing a pipe compound that is resistant to the action of
liquefied petroleum gases. Do not use Teflonä tape
on gas line threads.
The boiler and all gas piping connections must be
pressure tested and must be checked for leaks before
being placed into service. Test with compressed air or
gas if possible.
The boiler must be disconnected at both boiler manual
- 6 -

Installation
shutoff valves (located at the end of the supplied gas
train) from the gas and propane supply systems during
any pressure testing of the system at pressures in ex-
cess of 1/2 psig (14 inches W.C.).
During any pressure testing of the gas supply piping
system at pressures equal to or less than 1/2 psig (14
inches W.C.), the boiler should be isolated from the
gas supply piping system by closing both manual
shutoff valves.
Some leak test solutions, including soap and water,
may cause corrosion. These solutions should be
rinsed off with water after testing.
4.2.1 Gas Bleeds and Vents
vent to outside air
drip leg
n.o. vent
valve (I.R.I
installations)
Figure 4-3 Schematic iagram of Bleeds and Vents
Gas vents to outdoor air must be provided for the
pressure regulators and gas pressure switches. If ap-
proved by authorities having jurisdiction, vents may
be manifolded in accordance with accepted engineer-
ing practices to minimize backpressure.
The pilot regulator is equipped with a vent limiting
device and does not require external venting!
f equipped for .R. . ( ndustrial Risk nsurers) the
normally open vent valve must be vented independ-
ently from other vented devices, as shown above.
4.3 PRE-START CHECK LIST
Before firing the boiler make sure the following items
have been completed.
1. Flue gas from the boiler is properly vented.
2. Gas connections have been made and the gas lines
purged of air.
3. Water connections are complete, and the boiler
and system have been filled and purged of air.
4. The boiler is connected to a 120 volt power source
with a lockable disconnect (customer supplied)
having adequate overload protection.
5. Combustion air openings are not obstructed in any
way and have adequate capacity.
6. The boiler is placed the proper distance from any
combustible walls, in accordance with the "Clear-
ances" section of the “ nstallation and Owner’s
Manual,” page 3.
7. Relief valves have been piped to floor drains.
4.4 PRE-START SAFETY CHECKS AN
AJUSTMENTS
Before placing the boiler in operation, perform all the
following safety checks and adjustments. This work
must be performed by qualified service personnel.
Warning! igh voltage! Shock hazard. Properly lock-
out/tagout the electrical service and all other energy
sources before working on or near the machine.
For testing control circuits only, the service power
shutoff switch (located inside the auxiliary panel at the
rear of the boiler) may be used to de-energize the sys-
tem in lieu of normal lockout/tagout procedures. Use
extreme caution when using this alternative.
- 7 -

Gemini™ Twin-Fuel Gas-Fired Boiler
service power
shutoff switch
Figure 4-4 Service Power Shutoff Switch
(located inside the auxiliary panel at the back of the boiler)
General Warning
Warning! After checking controls by manual readjust-
ment, make sure they are always returned to their
proper settings.
NEVER attempt to operate a boiler that has failed to
pass all the safety checks outlined below.
4.4.1 Test of Ignition Safety System
high limit
reset
high limit/operating
temperature
adjustments
lo-hi-lo
controller
"on"/"off"
switch
fuel
selector
switch
flame control
reset switch
propane
in-use
indicator
Figure 4-5 Lo-Hi-Lo Control Panel (faceplate opened)
high limit
reset
high limit temperature
adjustment
"on"/"off"
switch
flame control
reset switch
operating temperature
adjustment
propane in-use
indicator and
fuel selector switch
(on side)
Figure 4-5a On-Off Control Panel (faceplate opened)
The boiler is provided with an ignition safety system.
1. Open the faceplate on the control panel. Discon-
nect wire # 17 (Lo-Hi-Lo) or # 26 (On-Off) at the
terminal block on the control panel. Disconnect-
ing this wire disables the main gas valve, ensuring
that gas cannot flow during the test.
2. Turn on the circulating water pump. With the
natural gas shutoff and secondary shutoff open
and the pilot gas cock open, turn the operating
temperature control until the boiler cycles “on.”
3. Observe the operation of the boiler. After all the
safety limits on gas pressure, water flow, and tem-
perature are satisfied, the blower will run and pre-
purge the boiler. When air flow is established, the
ignition transformer and pilot will operate. Both
functions will be indicated by separate green
lights on the control panel. f a satisfactory pilot
is established, the green " gnite" light will extin-
guish and the pilot will remain on, alone, for 10
seconds. After 10 seconds, the green "Main Gas"
light will go on. (The main gas valve will not
open with the wire disconnected and gas cannot
flow to the burner). The "Pilot" will remain on,
along with the "Main Gas," for another 10 seconds
and then go out. Since the main flame cannot be
burning, at this point there will be no flame signal
and the flame safeguard programmer will assume
a "Flame Failure" and will either re-cycle through
the complete pre-purge and ignition cycle or, if in-
- 8 -

Installation
surance or local codes require, go to a "lockout”
mode. Lockout will require manual reset of the
flame safeguard.
4. After completing this test, turn off the boiler and
reconnect the wire to the main gas valve. Replace
the control panel faceplate.
4
.4.2 Test of Low Water Cutoff
The boiler is furnished with a flow-switch-type low
water cutoff in the outlet nozzle.
1. Make sure the boiler is off.
2. Turn the system pump off, stopping water flow in
the system. Do not shut the pump off while the
boiler is operating.
3. Turn the boiler back on. t should not operate,
and a red indicator for "Low Water" or "Water
Flow" should be illuminated.
Perform appropriate tests on any external probe-type
low water cutoff.
4
.4.3 Test of High-Limit Control
The boiler is furnished with a high-limit cut off.
1. With the main burner operating, turn down the
temperature setting on the "high-limit" thermostat
until the main burner shuts off. The high-limit
switch must be reset manually after testing.
This check should also be made for the "Operating
Temperature" control. (The green "Heat" indica-
tor will go out.) (See the “ nstallation and
Owner’s Manual,” page 8 for Lo-Hi-Lo units.)
2. Readjust thermostats to desired operating t
perature and set high-limit temperature, typic
20° F above operating temperature.
em-
ally
4.4.4 Test of Gas Pressure Switch
Reset
Figure 4-6 Gas Pressure Switch
The boiler is furnished with a low gas pressure switch.
1. Slowly close the manual shutoff valve (on the
natural gas supply) while the burner is operating.
The low gas pressure switch should shut down the
main burner before combustion problems are en-
countered. When the gas pressure switch opens,
the "Low Gas" or "Gas Press" indicator will illu-
minate.
2. Reopen the manual shutoff valve. The "Low Gas"
or "Gas Press" indicator should remain on until
the low gas pressure switch is reset.
- 9 -

Gemini™ Twin-Fuel Gas-Fired Boiler
4.4.5 Gas Pressure Adjustment
Increase Decrease
Figure 4-7 Regulator
The gas pressure is set initially during a factory fire-
test. A final adjustment must be made after the boiler
has been installed, as follows:
See rating plate for the minimum and maximum gas
pressure of the boiler.
Each boiler is furnished with three plugged taps in the
gas train for test gauge connections. Two taps are lo-
cated at the natural gas and propane manual shutoff
valves and are for measuring the gas supply pressure
(1/4" .P.S.). The supply pressure during main burner
operation must be greater than the minimum indicated
on the rating plate (6 inches W.C. for natural gas, 6
inches W.C. for propane). The remaining tap is lo-
cated downstream from the secondary manual shutoff
valve at the elbow where the gas line enters the back
of the cabinet and is for measuring the manifold gas
pressure (1/8" .P.S.).
f a replacement Lo-Hi-Lo actuator is required, follow
manufacturer's instructions and pre-set the "Lo" fire
setting of the actuator the same as the original actua-
tor. This must be performed by qualified service per-
sonnel.
To adjust gas pressure, first connect an appropriate
pressure-sensing device at the manifold tap, then re-
move seal cap from regulator. Turn adjusting screw
clock-wise to increase pressure, counter-clockwise to
decrease pressure. The manifold gas pressure on the
"Rating Plate," affixed to the back of the cabinet, is
provided only as a guide to the proper setting. The
manifold gas pressure indicated on the "Factory Fire-
test" label (affixed to the back of the cabinet) should
be used to achieve the proper firing rate of the
individual boiler as installed. Replace seal cap after
adjustment.
4
.4.6 Leak Testing of Valves
Annually test for by-pass leaks on all motorized gas
valves. f gas flows when the motorized gas valve is
closed it is defective.
downstream
leak test
valve
upstream
leak test
valve
motorized gas
valve (natural
gas)
motorized gas
valve (propane)
secondary
shutoff
to burner
secondary
motorized
gas valve
Figure 4-8 Leak Testing of Valves
Each branch of the gas train must be tested separately,
s follows: a
1. Open the natural gas connection manual shutoff.
Close the propane connection manual shutoff.
(Refer to Figure 4-1.)
2. Close the secondary shutoff (downstream of all
motorized valves).
3. Attach a short piece of hose to the downstream
- 10 -

Installation
leak test valve. (Refer to Figure 4-8 above.) n-
sert the free end of the hose in a cup of water.
4. Open the downstream leak test valve and check
for bubbles in the hose. f there are no bubbles the
secondary motorized gas valve is OK. f there are
bubbles, replace the valve.
5. Attach the hose to the upstream leak test valve.
6. Open the upstream leak test valve and check for
bubbles in the hose. f there are no bubbles the
natural gas motorized gas valve is OK. f there
are bubbles, replace the valve.
To test the propane branch of the gas train, open the
propane connection manual shutoff. Close the natural
gas connection manual shutoff. Then repeat steps 5 -
6 above.
- 11 -

Gemini™ Twin-Fuel Gas-Fired Boiler
natural gas
connection (2")
and shutoff
propane
connection (1 1/4")
and shutoff
main gas valve
propane
gas valve
natural gas
gas valve
pilot gas
supply
high gas pressure
switch
propane regulator
natural gas
regulator
secondary
shutoff
water
connection
low pressure
switches
(visible from side)
pressure tap
mechanical link
to air control
auxiliary panel
(service power shutoff
switch inside)
auxiliary panel
(service power shutoff
switch inside)
propane low
pressure
switch
pressure tap
secondary
shutoff
high gas
pressure
switch
main gas
valve
propane
connection (1")
and shutoff
propane
gas valve
natural gas low
pressure switch
water
connection
natural gas
gas valve
natural gas regulator
pilot gas supply
natural gas
connection (1 1/4")
and shutoff
Figure 5-1 Twin-Fuel Gas Train
(Top photo shows 1500/1700/1900 series; bottom shows 700/900/1200 series)
- 12 -

Operation
5.0 OPERATION
5.1 GENERAL
The basic operation and control functions of the Gem-
ini™ twin-fuel gas boiler are similar to the single-fuel
models.
5
.1.1 Tests
Safe lighting and other performance criteria were met
with the gas manifold and control assembly provided
on this boiler when the boiler underwent tests speci-
fied in ANS Z21.13, latest edition, or CAN 1-3.1 in
Canada. (See "Factory Firetest" label.)
5
.1.2 Starting System
Do not use this boiler if any part has been under water.
mmediately call a qualified service technician to in-
spect the boiler and to replace any part of the control
system and any gas control which has been under wa-
ter.
5.2 LIGHTING AN SHUT- OWN PROCE URES
5.2.1 Lighting Procedures
high limit
reset
high limit/operating
temperature
adjustments
lo-hi-lo
controller
"on"/"off"
switch
fuel
selector
switch
flame control
reset switch
propane
in-use
indicator
Figure 5-2 Lo-Hi-Lo Control Panel
high limit
reset
high limit temperature
adjustment
"on"/"off"
switch
flame control
reset switch
operating temperature
adjustment
propane in-use
indicator and
fuel selector switch
(on side)
Figure 5-2a On-Off Control Panel
- 13 -

Gemini™ Twin-Fuel Gas-Fired Boiler
1. Close main (natural gas and propane) and pilot
shutoffs.
2. Turn the On/Off switch to "OFF" position.
3. Wait 5 minutes.
4. Open main (natural gas and propane) and pilot
shutoffs.
5. Turn the On/Off switch to "ON" position.
6. Push reset button on flame safeguard programmer
control.
7. Push reset on low gas pressure switch (and high
pressure gas switch if applicable).
8. Check to be sure that pilot has been established.
The controller will now complete the automatic firing
sequence.
5
.2.2 Normal Shut- own Procedures
1. Close all manual gas shutoffs.
2. Turn off electric power.
5
.2.3 Emergency Shut- own
Natural gas, propane, and pilot gas shutoff valves on
the boiler must be closed immediately if an emergency
situation occurs.
f overheating occurs or the gas supply fails to shut off
at the boiler, to reduce the possibility of an electrical
arc, do not turn off or disconnect any electrical sup-
ply. nstead, shut off the gas supplies remote from the
boiler.
5.3 SWITCHOVER TO PROPANE OPERATION
Switchover from natural gas to propane is made
manually, as follows:
1. Turn the fuel selector switch located on the main
control panel from natural gas to propane.
The boiler will go through a complete shutdown
and restart procedure when the fuel source is
changed.
f the changeover is controlled by a remote signal, the
switch on the auxiliary control panel should be set at
"Automatic" for both natural gas and propane opera-
tion; operation of the remote switch will change the
fuel source.
During natural gas service interruptions or restrictions,
sufficient natural gas is usually available to operate
the pilot. n the event of complete failure of the natu-
ral gas supply, contact Patterson-Kelley at (570) 421-
7500 for assistance.
General Warning
Warning! In the event of low pressure in either the
natural gas or propane supply the higher pressure gas
could backfeed into the lower pressure line. This could
result in unsafe operation of other devices connected
to the higher pressure supply.
Always shut off the gas cock to a line which exhibits
low pressure.
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Maintenance
*
*
*
*
*
*
propane
connection
manual
shutoff
natural gas
connection
manual
shutoff
regulator
low gas
pressure switch
motorized gas valve
(propane)
low gas
pressure switch
motorized gas valve
motorized gas valve
(natural gas)
high gas pressure
switch
pressure tap
burner
secondary
shutoff, manual
pilot
shutoff
regulator
pilot regulator and
solenoid valve mechanical link
to control air
(Lo- i-Lo only)
Items with symbol must be
vented to outside. Refer to the
drawings packed with your
boiler for additional information.
leak test
valves
n.o. vent valve
(I.R.I. only)
Figure 7-1 Piping Schematic for the Twin-Fuel Gas Train
7.0 MAINTENANCE
7.1 GENERAL
Warning! igh voltage! Shock hazard. Properly lock-
out/tagout the electrical service and all other energy
sources before working on or near the machine.
For testing control circuits only, the service power
shutoff switch (located inside the auxiliary panel) may
be used to de-energize the system in lieu of normal
lockout/tagout procedures. Use extreme caution
when using this alternative.
service power
shutoff switch
Figure 7-2 Service Power Shutoff Switch
(located inside the auxiliary panel at the back of the boiler)
Maintenance of the twin-fuel gas boiler is similar to
that of the standard model. Refer to pages 11 through
14 of the “ nstallation and Owner’s Manual - TB G.”
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Gemini™ Twin-Fuel Gas-Fired Boiler
n the case of the twin-fuel boiler, the phrase “main
gas cock” or “main gas valve” as used in the “ nstalla-
tion and Owner’s Manual” applies to the manual shut-
offs for both the natural gas and propane supplies.
7.2 SEQUENCE OF OPERATION
Status (red and green) indicators located on the front
of the control panel of this boiler are specifically de-
signed to indicate the sequence of operations and the
cause of common problems. Careful observation of
indicators should provide a guide to most operational
conditions and problems.
Refer also to the wiring diagrams in Section 8.
The sequence of operation for the twin-fuel model
differs slightly from the standard model:
1. When the On/Off (main power) switch is turned
on, a green indicator marked "Power" or the am-
ber switch is illuminated. Power is applied
through a series of normally closed limit switches,
including water flow, gas pressure, and high tem-
perature, and through the operating temperature
control to the flame-safeguard programmer.
2. The water flow limit switch is closed when there
is adequate water flow through the boiler.
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. f the temperature sensed by the high-limit tem-
perature control is below the set limit, the nor-
mally closed position of the switch sends power to
the operating temperature control. Manual reset is
required following conditions exceeding high-
temperature limit. The limit series is complete
unless an external control is placed ahead of the
water flow limit (replacing the red jumper wire).
5. When heat is required, as indicated by outlet water
temperature, power is applied to Terminal 6 of the
programmer, which initiates the burner operating
sequence, and to an indicator marked "Heat."
6. The programmer first energizes Terminal 4 which
supplies power to the contactor for the blower mo-
tor and the air flow switch, which initially shows
low air flow with the "LowAir" indicator. This
indicator will remain on until sufficient air flow is
sensed.
7. A time delay of 10 seconds (standard) or 30 sec-
onds (depending on insurance or local code re-
quirements) occurs after the air proving switch
closes and the programmer signals a continuation
of the start sequence. During this time period the
combustion chamber is pre-purged to eliminate
any residual combustible gas or combustion prod-
ucts.
8. A 10-second "trial-for-ignition" period is initiated
with both Terminals 10 and 8 being energized.
Terminal 10 of the programmer powers the igni-
tion transformer and the " gnite" indicator. The
transformer output creates a spark at the igniter.
Terminal 8 powers the pilot gas valve and the in-
dicator for "Pilot."
9. When a pilot flame is detected by the flame rod, a
signal is sent to Terminal F in the programmer.
Terminal 10 is de-energized shutting off the spark
ignition and the pilot remains on for ten seconds
during the flame establishing period.
10. After the flame establishing period, Terminal 9 is
energized, which opens the motorized main gas
valve and the motorized gas valve to the fuel sup-
ply in use and lights the "Main Gas" indicator.
The boiler fires. After ten seconds, Terminal 8 is
de-energized and the pilot valve and indicator
light are extinguished.
An auxiliary panel prevents the motorized gas
valves for natural gas and propane to be open at
the same time.
Lo-Hi-Lo: When Terminal 9 is energized, the Lo-
Hi-Lo valve will be maintained in the low fire po-
sition for "low fire start" for ten seconds. f the
operating temperature control calls for high fire,
the programmer will initiate high fire (Terminal
21) at the same time the pilot valve and indicator
is de-energized.
A power failure during operation closes all motor-
ized gas valves and shuts down the boiler. When
power is restored the controller recycles to Step 1;
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Maintenance
all steps and safety checks are repeated. The mo-
torized gas valves cannot reopen in the absence of
ignition.
11. When the desired water temperature is reached,
the operating control switch opens and the pro-
grammer is de-energized at Terminal 6 and the in-
dicator for "Heat" is turned off. This action also
de-energizes Terminal 9, thus closing both main
gas valves and turning off the indicator for "Main
Gas."
12. When the water temperature is reduced by the
load on the system, the operating control switch
will close again. The operating sequence will re-
cycle to step 5, provided that the limits on water
flow, gas pressure, and high temperature are all
met.
`
8.0 PARTS AN TECHNICAL SUPPORT
Spare parts and replacement parts can be ordered from
Patterson-Kelley by calling [phone]. Ask for
the Boiler Department. The fax number is (570) 476-
7247. Refer to the parts list shown on the assembly
drawing provided with this manual.
Technical information is also available at the above
number.
Before calling, please have the model number and se-
rial number of your boiler available.
8.1 WIRING IAGRAMS
Wiring and control schematic drawings are shown on
the following pages.
- 17 -

Gemini™ Twin-Fuel Gas-Fired Boiler
8.1.1 Wiring iagram (Lo-Hi-Lo)
- 18 -