Patterson-Kelley Thermific Operating instructions

PATTERSON-KELLEY
THERMIFIC®
GAS-FIRED BOILER
Installation Date: _______________________
100 Burson Street, P.O. Box 458,
East Stroudsburg, PA 18301
elephone: [phone], Facsimile: [phone]
www.pkboilers.com
C.S.A Design-Certified
Complies with ANSI Z21.13/CSA 4.9
Gas-Fired Low Pressure Steam and Hot Water
Boilers
ASME Code, Section IV
Certified by Patterson-Kelley
C.S.A Design-Certified
Complies with ANSI Z21.13/CSA 4.9
Gas-Fired Low Pressure Steam and Hot Water
Boilers
INSTALLATION
OWNER’S
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INSTALLATION
OWNER’S
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INSTALLATION
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INSTALLATION
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MANUAL
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INSTALLATION
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INSTALLATION
OWNER’S
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INSTALLATION
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TBIG-02

Thermific®Gas-Fired Boiler Table of Contents
1.0 INTRODUCTION ................................. 1
2.0 SAFETY............................................... 1
2.1 General ......................................................1
2.2 Training......................................................1
2.3 Safety Features..........................................1
2.4 Safety Labels .............................................2
2.5 Safety Precautions.....................................2
2.5.1 Electrical Hazards .............................2
2.5.2 Burn, Fire, and Explosion Hazards ...2
2.5.3 Crush Hazards ..................................3
2.5.4 Chemical Hazards.............................3
2.5.5 Pressure Hazards .............................4
2.5.6 Slip, Fall Hazards..............................4
3.0 INSTALLATION ................................... 5
3.1 Receiving and Storage ..............................5
3.1.1 Initial Inspection ................................5
3.1.2 Storage Prior to Installation...............5
3.2 Compliance with Codes .............................5
3.3 Setup .........................................................5
3.3.1 Foundation ........................................5
3.3.2 Placement .........................................5
3.3.3 Clearances........................................6
3.4 Electrical Connections ...............................6
3.5 Combustion Air ..........................................7
3.6 Flue Venting...............................................7
3.6.1 Vent Elbows ......................................8
3.6.2 Barometric Damper...........................8
3.6.3 Barometric Damper Location ............8
3.6.4 Flue Connection................................8
3.6.5 Vent Termination...............................9
3.6.6 Removing an Existing Boiler .............9
3.7 Gas Piping .................................................9
3.7.1 Gas Supply Piping by Installer ........11
3.7.2 Gas Bleeds and Vents ....................11
3.8 Boiler Water Piping..................................11
3.8.1 Piping Design..................................11
3.8.2 Boiler Inlet and Outlet Connections 12
3.8.3 Boiler Water Piping by Installer.......12
3.8.4 Flushing and Filling.........................13
3.9 Burner and Ignition System .....................13
3.9.1 Inspection .......................................13
3.10 Pre-Start Check List...............................13
3.11 Safety Checks........................................13
3.11.1 Test of Ignition Safety System ......13
3.11.2 Test of Low Water Cut-off.............14
3.11.3 Test of High-Limit Control .............14
3.11.4 Test of Gas Pressure Switch ........14
3.12 Initial Adjustments..................................15
3.12.1 Operating Temperature Controller for
Lo-Hi-Lo Thermific®.............................15
3.12.2 Gas Pressure Adjustment.............16
3.12.3 Air Flow Adjustments ....................16
4.0 OPERATION ..................................... 19
4.1 General....................................................19
4.1.1 Control Panel Front.........................19
4.1.2 Tests ...............................................19
4.2 Lighting and Shut-Down Procedures.......19
4.2.1 Lighting Procedures........................19
4.2.2 Normal Shut Down Procedures ......20
4.2.3 Emergency Shut Off .......................20
4.3 Typical Boiler Operating Conditions ........20
5.0 MAINTENANCE ................................ 21
5.1 Maintenance and Inspection Schedule....21
5.1.1 Daily................................................21
5.1.2 Weekly ............................................21
5.1.3 Monthly (During Operation) ............21
5.1.4 Semi-Annually.................................21
5.1.5 Annually ..........................................22

Thermific®Gas-Fired Boiler Table of Contents
5.2 Cleaning the Burner.................................22
5.2.1 Semi-Annual Cleaning ....................22
5.2.2 Annual Cleaning .............................22
5.3 Removing the Exchanger ........................23
5.4 After All Repairs or Maintenance .............23
5.5 Sequence Of Operation ...........................23
5.6 Troubleshooting .......................................24
6.0 PARTS/TECHNICAL SUPPORT .......26
6.1 Wiring Diagrams ......................................27
6.1.1 On-Off .............................................28
6.1.1a On-Off IRI .....................................30
6.1.2 Lo-Hi-Lo ..........................................32
6.1.2a Lo-Hi-Lo IRI ..................................34
6.1.3 Water Cut-Off.................................. 36
6.2 Boiler Parts List ....................................... 38
6.2.1 Main Assembly ...............................38
6.2.2 Control Panel.................................. 39
6.2.3 Gas Train........................................ 40
6.2.4 Cabinet ...........................................41
7.0 LIMITED WARRANTY ....................... 42
7.1 Express Warranty .................................... 42
7.2 Warranty Disclaimer ................................42
Reorder No. 6020-V2WHPK
Improper use may
result in fire or injury.
Read instructions/safety
manual before installing,
operating or servicing boiler.
c
!
WARNING
1998 HCS, Inc. 800-748-0241
WARNING!
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 fire or explosion and serious injury, death,
and/or property damage.
The same features which permit this boiler to achieve
high-efficiency performance make it unlike most other
boilers of this general size, so it is important to under-
stand how this boiler operates.
Do not store or use gasoline or other flammable vapors
or liquids in the vicinity of this or any other appliance.
WARNING!
Installation and service must be performed by a quali-
fied installer, service agency, or 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. Immedi-
ately 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.

Thermific® Gas-Fired Boiler Introduction/Safety
Page 1
1.0 INTRODUCTION
The P-K Thermific®Gas-Fired Boiler combines a ra-
dial pre-mix fan-assisted burner with a compact, fin-
ned-tube heat exchanger to provide maximum effi-
ciency in a minimum of space. The high-quality mate-
rials and thoroughly tested design of the boiler should
provide years of trouble-free, hot-water service, if the
instructions in this manual are followed carefully.
This manual covers installation of P-K Thermific®
Boiler Series 700, 1000, 1200, 1500, 1700, and 2000.
The model numbers may be followed by a prefix or
suffix letter in some cases to indicate special features
or different options.
While details may differ slightly, basic operation is the
same for all models. Boilers may be built to operate
with natural gas or liquefied petroleum gas (propane).
Check the rating plate for correct fuel usage and gas
pressures.
The boiler is only a part of the complete heating sys-
tem. This boiler may be fully operational and yet be-
cause of poor circulation, control or other operating
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.
2.0 SAFETY
2.1 GENERAL
The Thermificgas-fired boiler must be:
•Installed by qualified personnel in accordance with
designs prepared by qualified facility engineers in-
cluding: 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. Do not attempt to operate
or service until such a program has been estab-
lished.
•Operated and serviced by qualified, properly
trained personnel in accordance with all applicable
codes, laws, and regulations.
2.2 TRAINING
Reorder No. 6020-V2WHPK
Improper use may
result in fire or injury.
Read instructions/safety
manual before installing,
operating or servicing boiler.
c
!
WARNING
1998 HCS, Inc. 800-748-0241
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 Thermific
boiler, the use and locations of the controls, the opera-
tion of the boiler, adjustment of its various mecha-
nisms, and all applicable safety precautions. If any of
the provisions of this manual are not fully and com-
pletely understood, contact the Patterson-Kelley Sales
Department toll-free at [phone] for assistance.
2.3 SAFETY FEATURES
It is the responsibility of the customer to maintain the
safety features of this machine, such as: guards, safety
labels, safety controls, interlocks, lockout devices, etc.,
in place and operable.

Thermific® Gas-Fired Boiler Safety
Page 2
2.4 SAFETY LABELS
NOTE
Make sure this union is
tight before closing cabinet
cover after servicing boiler.
Reorder No. 8032-02NHAK
c
1998 HCS, Inc. 800-748-0241
NOTE
Reorder No. 8032-01NHPK
c
When opening leak test valves,
always follow instructions in
operation and safety manual.
1998 HCS, Inc. 800-748-0241
Reorder No. 6020-V2WHPK
Improper use may
result in fire or injury.
Read instructions/safety
manual before installing,
operating or servicing boiler.
c
!
WARNING
1998 HCS, Inc. 800-748-0241
!
WARNING
C 1998 HCS, Inc. 800-748-0241 Reorder No. 5025-V1WHPK
Follow lockout/tagout
procedure when
servicing this boiler.
Electrical hazard.
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 toll-free at [phone] for
replacement labels.
2.5 SAFETY PRECAUTIONS
Provide a suitable location for the boiler, away from
normal personnel traffic, with adequate working space,
adequate clearances, proper ventilation and lighting,
with a structure sufficiently strong and rigid to support
the weight of the boiler, all piping, and accessories.
2.5.1 Electrical Hazards
!
WARNING
C 1998 HCS, Inc. 800-748-0241 Reorder No. 5025-V1WHPK
Follow lockout/tagout
procedure when
servicing this boiler.
Electrical hazard.
•Shock hazard! Properly lockout/tagout the electri-
cal service and all other energy sources before
working on or near the machine.
•Shock hazard! Boiler is not rated for wash-down
service.
2.5.2 Burn, Fire, and Explosion Hazards
General Warning
Hot Surface
Reorder No. 6020-V2WHPK
Improper use may
result in fire or injury.
Read instructions/safety
manual before installing,
operating or servicing boiler.
c
!
WARNING
1998 HCS, Inc. 800-748-0241
NOTE
Make sure this union is
tight before closing cabinet
cover after servicing boiler.
Reorder No. 8032-02NHAK
c
1998 HCS, Inc. 800-748-0241
NOTE
Reorder No. 8032-01NHPK
c
When opening leak test valves,
always follow instructions in
operation and safety manual.
1998 HCS, Inc. 800-748-0241
•Burn, fire, and explosion hazards! Installation
must be in strict conformance to all applicable
codes and standards including NFPA 54, ANSI
Z223.1 and CAN/CGA B.149. Install all required
ventlines for gas devices. Refer to Section 3.7.2
below.
•Hazard from incorrect fuels! Possible fire, explo-
sion, overheating, and damage. Do not use any
fuels except the design fuel for the unit.
•Overfire hazards! High pressure in gas or propane
supply could result in overfiring of other devices
supplied from the same source.
•Fire and explosion hazards! Close the main gas
shutoff before servicing boiler.

Thermific® Gas-Fired Boiler Safety
Page 3
•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! Hot fluids. Use caution when ser-
vicing 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 all connections to
main burner are tight when reassembling the
burner. These connections cannot be tested after
the burner is assembled.
•Gas leak hazard! All threaded gas connections
must be made using a pipe compound that is resis-
tant to liquefied petroleum. 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.
•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 regula-
tor.
•Overfire hazard! Possible fire and explosion.
Possible malfunction of regulators and/or motor-
ized gas valves. Maintain all gas train components
in good condition. Do not alter wiring connec-
tions. Annual inspection by factory-trained per-
sonnel for proper set-up and operation is recom-
mended.
•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.
2.5.3 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 595
1,000,000 Btu 595
1,200,000 Btu 685
1,500,000 Btu 990
1,700,000 Btu 985
2,000,000 Btu 1,025
•Bump hazard from overhead piping. Install piping
with adequate vertical clearance.
2.5.4 Chemical Hazards
•Environmental hazard! The motorized gas valves
may contain hydraulic oil. Use safe procedures
for the disposal of all lubricants.
•Chemical hazards from cleaning products. Use
caution when cleaning the system. The use of pro-
fessional assistance is recommended. Use safe
procedures for the disposal of all cleaning solu-
tions.

Thermific® Gas-Fired Boiler Safety
Page 4
2.5.5 Pressure Hazards
Improper use may
result in fire or injury.
Read instructions/safety
manual before installing,
operating or servicing boiler.
c
!
WARNING
1998 HCS, Inc. 800-748-0241
•Pressure hazard! Hot fluids. Install isolation
valves on boiler water inlet and outlet. Make sure
isolation valves are closed before servicing boiler.
•Pressure hazard! Hot fluids. Annually test safety
relief valve for proper operation. Do not operate
boiler with faulty relief valve.
2.5.6 Slip, Fall Hazards
Improper use may
result in fire or injury.
Read instructions/safety
manual before installing,
operating or servicing boiler.
c
!
WARNING
1998 HCS, Inc. 800-748-0241
•Tripping hazard! Do not install piping on floor
surfaces. Maintain clear path around boiler.
•Slip and fall hazard! Use drip pan to catch water
while draining the boiler. Maintain dry floor sur-
faces.
•Slip and fall hazard! Do not locate intake or ex-
haust terminations directly above a walkway;
dripping of condensation can cause icing of the
walking surface.

Thermific® Gas-Fired Boiler Installation
Page 5
3.0 INSTALLATION
3.1 RECEIVING AND STORAGE
3.1.1 Initial Inspection
Upon receiving the boiler, inspect it for signs of ship-
ping damage. Pay particular attention to the control
panel on the top of the boiler and the components
mounted on the back, which may show damage from
mishandling.
The exterior cabinet must be reasonably air-tight for
the burner to operate correctly. Leaks caused by dents
in the sheet metal or panels out of position may cause
the limit controls to show Low Air. Check to be sure
that the mixer core in the top burner is centered and
has not moved in shipment; (see Section 5.2, "Clean-
ing the Burner" for proper location). Verify that the
total number of pieces shown on the packing slip
agrees with those actually received.
Important: Note any damage or shortage on the
freight bill and immediately notify the carrier. File
all claims for shortage or damage with the carrier.
3.1.2 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.
Note: Controls and other equipment that are damaged
or fail due to weather exposure are not covered by
warranty.
3.2 COMPLIANCE WITH CODES
The P-K Thermific®Boiler with standard components
and many options complies with American National
Standard/CSA Standard ANSI Z21.13/CSA 4.9, latest
edition, Gas-Fired Low Pressure Steam and Hot Water
Boilers. The heat exchanger is constructed and
stamped in accordance with ASME Boiler and Pres-
sure Vessel Code, Section IV for 160 psig maximum
operating pressure and/or 250º F maximum operating
temperature. Other codes or approvals which apply
will be labeled on the boiler.
Installation of the boiler must conform to all the re-
quirements of all national, state and local codes estab-
lished by the authorities having jurisdiction or, in the
absence of such requirements, in the U.S. to the Na-
tional Fuel Gas Code, ANSI Z223.1/NFPA 54, latest
edition. In Canada, the equipment shall be installed in
accordance with the current Installation Code for Gas
Burning Appliances and Equipment, CAN/CGA-
B.149, and applicable Provincial Regulations for the
class, which should be carefully followed in all cases.
Authorities having jurisdiction should be consulted
before installations are made.
Where required by local codes, the installation must
conform to American Society of Mechanical Engi-
neers Safety Code for Controls and Safety Devices for
Automatically Fired Boilers (ASME CSD-1).
3.3 SETUP
3.3.1 Foundation
Provide a firm, level foundation, preferably of con-
crete.
Note: The boiler may be installed on a combustible
floor; however, the boiler must never be installed on
carpeting.
3.3.2 Placement
The boiler must be level to function properly. To as-
sist in leveling the boiler, the four (4) leg bolts (1/2"-
NC) holding the boiler to the shipping skid must be
reinstalled in the threaded legs on the bottom. The
adjustable legs are also necessary to provide adequate
floor clearance and prevent distortion on the cabinet,
(twisting, etc.) in addition to leveling.

Thermific® Gas-Fired Boiler Installation
Page 6
Adjustable Legs for Leveling and Floor Clearance
3.3.3 Clearances
If the boiler is to be installed near combustible sur-
faces, the minimum clearances shown in the table be-
low must be maintained.
Failure to provide for the service access clearances,
even with non-combustible surfaces, may cause future
problems servicing the boiler.
The boiler must be installed in a space large in com-
parison to the boiler as described in Section 6.3 of the
National Fuel Gas Code, ANSI Z223.1, latest edition.
AB
C
No pipes,
ducts, etc.
in this area.
DD
Minimum Clearances from Adjacent Walls, Ceiling, and
Obstructions
Dimensions (inches)
Type of Surface
A B C† D
Combustible Surfaces 30 24 24 24
Non-combustible Sur-
faces
30 24* 24 24**
† "C" dimension includes clearance to remove the
burner. Do not put pipes, ducts, etc. in this area above
the boiler.
* CSA minimum. Actual clearance depends upon
stacking requirements.
** Service access need be only on one side of a boiler
or row of boilers. Boilers may be installed immedi-
ately adjacent to each other. However, P-K recom-
mends this clearance between each boiler when there
is insufficient access at the rear to allow for service
and adjustment.
In Canada: The boilers are approved for installation
with zero clearance to combustible surfaces, but 24
inch service clearances are recommended.
3.4 ELECTRICAL CONNECTIONS
The boiler is wired for 120 volts, single phase, 60
hertz. The total operating amperage is indicated on the
rating nameplate. The 700 and 1000 series require less
than 8 amps; the 1200 series less than 9 amps; the
1500, 1700, 2000 series less than 12 amps. Before

Thermific® Gas-Fired Boiler Installation
Page 7
starting the boiler, check to ensure that the proper
voltage and amperage is connected to the boiler.
An external electrical disconnect (not supplied with
the boiler) with adequate overload protection is re-
quired. The boiler must be grounded in accordance
with local codes or in the absence of such require-
ments, in the U.S. with National Electrical Codes,
ANSI/NFPA No. 70 latest edition and in Canada, wire
according to the current Canadian Electrical Code.
Note: A dedicated earth ground (green wire) is re-
quired to avoid nuisance shutdowns. Do not ground
through the conduit. It is also important that proper
polarity be maintained.
3.5 COMBUSTION AIR
Combustion air must be free from dust, lint, etc. The
presence of such materials in the air supplied to the
burner could cause nuisance "Low Air" shutdowns or
premature burner failure. The boiler should not be
operated during construction while the possibility of
drywall dust, demolition dust, etc. exists.
Provisions for combustion and ventilation air must be
in accordance with Section 5.3, Air for Combustion
and Ventilation, of the National Fuel Gas Code, ANSI
Z223.1, latest edition, or applicable provisions of the
local building codes. In Canada, combustion air open-
ings shall comply with CSA 4.9. The formula is "1 sq.
in. per 1,000 Btu/hr of gas input not less than 100 sq.
in." The location shall be "neither more than 18," nor
less than 6" above the floor level.
The boiler room shall be provided with two openings
to ensure adequate combustion air and proper ventila-
tion. One opening should be 6 to 12 inches above the
floor and the other 6 to 12 inches below the ceiling,
preferably on opposite walls. The size of each open-
ing is determined by whether air is taken from inside
or outside the building. In Canada, ventilation air
openings shall be at least 10% of the cross sectional
area required for combustion air, but not less than 10
square inches. It is to be located at the highest practi-
cal point communicating with outdoors.
If air is taken directly from outside the building, each
opening should have a net free area of 1 square inch
for each 4,000 Btu per hour of total boiler input. For
instance, 300 square inches (2-1/12 square feet) are
required for 1,200,000 Btu per hour input.
When air is taken from the outdoors through a vertical
duct, 1 square inch per 4,000 Btu per hour is required.
If a horizontal duct is used, 1 square inch per 2,000
Btu per hour is required, i.e., 600 square inches for
1,200,000 Btu per hour input.
If air is taken from another interior space, each open-
ing should have a net free area of 1 square inch for
each 1,000 Btu per hour of boiler input (1,200 square
inches for a 1,200,000 Btu per hour.)
WARNING!
Under no circumstances shall the boiler room ever be
under a negative pressure. Particular care should be
taken when exhaust fans, compressors, air-handling
units or other equipment may rob air from the boiler.
The combustion air supply must be completely free of
chemical fumes which may be corrosive when burned
in the boiler. Common chemicals which must be
avoided are fluorocarbons and other halogenated com-
pounds, most commonly present as refrigerants or sol-
vents, such as freon, trichlorethylene, perchlorethyl-
ene, chlorine, etc. These chemicals, when burned,
form acids which quickly attack the boiler tubes, tube
sheets, flue collectors and the boiler stack. The result
is improper combustion and premature boiler failure.
3.6 FLUE VENTING
For boilers connected to gas vents or chimneys, vent
installations shall be in accordance with Part 7, Vent-
ing of Equipment, of the National Fuel Gas Code,
ANSI Z223.1, or applicable provisions of the local
building codes.
This boiler is certified as Category I as it is defined in
ANSI Z21.13/CSA 4.9, latest edition. This boiler is
suitable for use with Type "B" vent.
In Canada, the boiler is certified for installation with a
"Power Venter" by the Canadian Gas Association
when installed with the "listed accessories." Consult
your local distributor for information on proper selec-
tion.

Thermific® Gas-Fired Boiler Installation
Page 8
The venting system and the horizontal portions of the
venting system shall be supported to prevent sagging.
Consult your local vent supplier for correct vent sizing
and structural support requirements. Vent diameter is
dictated by the length and height of horizontal and ver-
tical portions of the vent installation and the materials
of construction. Correct sizing should provide a
slightly negative pressure (less than 0.1 inches of wa-
ter column) at the boiler flue outlet with a stack tem-
perature of 280º F.
3.6.1 Vent Elbows
The turn from horizontal to vertical should be made
with two 45º ells or with one long radius 90º ell for
best operation. Do not use "short radius" ells.
3.6.2 Barometric Damper
This boiler is certified for operation without a baro-
metric damper. However, some venting installations
may require a barometric damper for smooth opera-
tion. A barometric damper is supplied with each
boiler, and when used, should be installed according to
the following guidelines.
3.6.3 Barometric Damper Location
Boiler
Barometric
Damper
Correct Damper Location
1. We recommend that the barometric damper be
located immediately after the flue connector for
best operation. Consult vent supplier for specific
installation requirements.
2. The damper may be located in either side of the
horizontal section of stack.
3. In a multiple boiler installation, one barometric
damper must be installed with each boiler.
Be sure that the damper is mounted horizontally (never
vertically). Be sure to remove all three red stops from
the damper before start-up. The damper door should
swing freely. Carefully follow all the instructions pro-
vided with the barometric damper.
Boiler
Barometric
Damper,
(
incorrect
locations)
Incorrect Damper Locations
WARNING!
To avoid spillage into the boiler room of dangerous
flue gas containing carbon monoxide, the opening in
the damper (draft control gate) must never face
against the flow of flue gas.
3.6.4 Flue Connection
The connection from the boiler to the vent should be
as direct as possible and the upward slope of any hori-
zontal breaching should be at least 1/4 inch per linear
foot. This boiler should not be connected into any por-
tion of a mechanical draft system operating under
positive pressure. Provisions must be made for sup-
ports to prevent contact of the vent with combustible
surfaces.
Note: If the vent is erected directly behind the boiler,
make sure that the weight of the vent is not supported
by the boiler vent collar. The collar is not designed to
support the weight of the vent. Structural support and
spacing from combustible surfaces must be in accor-
dance with the vent manufacturer's requirements.

Thermific® Gas-Fired Boiler Installation
Page 9
3.6.5 Vent Termination
Correct
Listed
Termination
Typical Incorrect
(too restrictive)
Vent Termination
The minimum vent height above the flue outlet must
be five (5) feet and the vent should extend at least
three (3) feet above the roof, or at least two (2) feet
above the highest part of any structure within ten (10)
feet of the vent.
The vent must be provided with a weather cap of ap-
proved design and adequate capacity.
3.6.6 Removing an Existing Boiler
(from a common venting system)
When an existing boiler is removed from a common
venting system, the common venting system is likely
to be too large for proper venting of the appliances
remaining connected to it.
At the time of removal of an existing boiler, while the
other appliances remaining connected to the common
venting system are not in operation, the following
steps should be followed with each appliance remain-
ing connected to the common venting system placed in
operation:
1. Seal any unused openings in the common venting
system.
2. Visually inspect the venting system for proper size
and horizontal pitch and determine that there is no
blockage or restriction, leakage, corrosion or other
deficiency which could cause an unsafe condition.
3. Insofar as is practical, close all building doors and
windows and all doors between the space in which
the appliances remaining connected to the com-
mon venting system are located and other spaces
of the building. Turn on clothes dryers and any
appliances not connected to the common venting
system. Turn on any exhaust fans, such as range
hoods and bathroom exhausts, so they will operate
at maximum speed. Do not operate a summer ex-
haust fan. Close fireplace dampers.
4. Place the appliance being inspected in operation.
Follow the lighting instructions. Adjust the ther-
mostat so that the appliance will operate continu-
ously.
5. Test for spillage at the draft hood relief opening
after 5 minutes of main burner operation. Use the
flame of a match or candle or smoke from a ciga-
rette, cigar or pipe.
6. After it has been determined that each appliance
remaining connected to the common venting sys-
tem properly vents when tested as outlined above,
return doors, windows, exhaust fans, fireplace
dampers and any other gas-burning appliance to
their previous conditions of use.
Any improper operation of the common venting sys-
tem should be corrected so the installation conforms
with the National Fuel Gas Code, ANSI Z223.1.
When resizing any portion of the common venting sys-
tem, the common venting system should be resized to
approach the minimum size as determined using the
appropriate tables in Part II in the National Fuel Gas
Code, ANSI Z223.1.
3.7 GAS PIPING
Before making the gas hook-up, make sure the boiler
is being supplied with the type of fuel shown on the
boiler nameplate.
The boiler shall be installed such that the gas ignition
system components are protected from water (drip-
ping, spraying, rain, etc.) during appliance operation
and service (circulator replacement, control replace-
ment, etc.)
The gas pressure regulator supplied with the boiler is
set during a factory fire-test to provide the proper pres-
sure to the main burner, which for natural gas is based
on 7 inches W.C. inlet pressure to the regulator (11
inches W.C. for propane). The gas train components
are designed to handle a maximum inlet pressure of 14
inches water column (1/2 psig.). If the available gas
pressure exceeds 14 inch W.C., a suitable additional

Thermific® Gas-Fired Boiler Installation
Page 10
intermediate gas pressure regulator of the "lock up"
type must be provided to reduce the pressure to less
than 14 inch W.C.
WARNING!
All threaded connections must be made using a pipe
compound that is resistant to the action of liquefied
petroleum gases. Do not use Teflon tape on gas line
threads.
shutoff
(on boiler)
union
drip leg
remote gas shutoff
(not supplied)
meter
(not supplied)
natural gas
supply
by installer
Gas Piping
Note: Install a sediment trap (drip leg) and a union
connection ahead of the primary manual shutoff valve
on the boiler. Gas piping should be installed in accor-
dance with National Fuel Gas Code, ANSI Z223.1,
latest edition, and any other local codes which may
apply; in Canada see CAN/CGA-B 149.
Note: See chart below for required pipe size, based on
overall length of pipe from meter plus equivalent
length of all fittings. Approximate sizing may be based
on 1 cubic foot of natural gas per 1,000 Btu per hour
input, i.e., 900,000 Btu per hour requires about 900
cubic feet per hour. (See Typical Boiler Operating
Conditions, Section 4.3, for more information.)
Pipe Capacity for Natural Gas
Equivalent Pipe Length Maximum Capacity in Cubic Feet of Natural Gas per Hour
Pressure Drop of 0.5 inch Water Column/Equivalent Length of
Pipe (in feet)
Nominal
Iron
Pipe
Size
(Inches)
Internal
Diame-
ter
(Inches)
90º Ell
(Feet)
Tee
(Feet) 20 40 60 80 100 150 200
1-1/4 1.380 3.5 6.9 950
1-1/2 1.610 4.0 8.0 1,460 990 810
2 2.067 5.2 10.3 2,750 1,900 1,520 1,300 1,150 950 950
2-1/2 2.469 6.2 12.3 4,350 3,000 2,400 2,050 1,850 1,500 1,280
3 3.068 7.7 15.3 7,700 5,300 4,300 3,700 3,250 2,650 2,280
4 4.026 10.1 20.2 15,800 15,800 8,800 7,500 6,700 5,500 4,800

Thermific® Gas-Fired Boiler Installation
Page 11
3.7.1 Gas Supply Piping by Installer
The boiler and all gas piping connections should be
pressure-tested and must be checked for leaks before
being placed into service. Test with compressed air or
inert gas if possible.
The boiler must be disconnected at the boiler manual
shut-off valve (located at the end of the supplied gas
train) from the gas supply piping system during any
pressure testing of the system at pressures in excess of
1/2 psig (14 inch W.C.).
During any pressure testing of the gas supply piping
system at pressures equal to or less than 1/2 psig (14
inch W.C.), the boiler should be isolated from the gas
supply piping system by closing the manual shut-off.
Some leak test solutions, including soap and water,
may cause corrosion. These solutions should be
rinsed-off with water after testing.
3.7.2 Gas Bleeds and Vents
Vent to
Outside Air
Gas Pressure
Regulator
(on Boiler)
Gas Shutoff
(on Boiler Drip Leg
Gas Bleeds and Vents
The bleed vents* on the diaphragm gas valves have
been factory-piped to terminate at the burner, as re-
quired by ANSI Z21.13. This feature provides com-
bustion of any gas which leaks past a ruptured dia-
phragm during operation. Gas vents to outdoor air
must be provided for the main pressure regulator. The
pilot regulator is equipped with a vent limiting device
and does not require external venting!
* When installing per ASME CSD-1, disconnect
factory piped bleed vents and vent the diaphragm
gas valves to outdoor air (field piping.)
Gas Vents by Installer
Note: Provide a drip leg, as shown, in the vent line.
All vent lines should be pitched up at all times to pre-
vent building a trap into the vent line.
Note: The vent line connection on the gas pressure
regulator must be piped to outdoor air by the installer
in accordance with the National Fuel Gas Code ANSI
Z223.1, latest edition, Sections 2.8.4 and 2.9.7.
If a N.O. vent valve is provided, it must be vented in-
dependently.
3.8 BOILER WATER PIPING
3.8.1 Piping Design
Water Flow in System
Ideal operation of the P-K Thermific®Boiler would
consist of a 20º F temperature differential across the
heat exchanger. The operating thermostat has an ad-
justable temperature differential. Insufficient flow
may result in excessive short cycling of the boiler and
eventual damage or premature failure of the equip-
ment.
In any case, Minimum Return Water Temperature
should be greater than 130º F to avoid problems of
condensation on the outside of the heat exchanger or in
the flue passages.
Proper flow rates and return water temperature may be
achieved through a combination of primary and secon-
dary flow loops. Multiple zones and pumps may result
in different flow rates at different times. Considera-
tion must be given to all possible conditions and their
consequences.
Piping With Refrigeration Machines
When used with a refrigeration system, the boiler shall
be installed so that chilled medium is piped in parallel
with the boiler. Valves should be installed to prevent
chilled water from entering the boiler when the system
is operated in the cooling mode.

Thermific® Gas-Fired Boiler Installation
Page 12
Piping With Air Handling Units
The boiler piping system of a hot water heating boiler
connected to heating coils located in air handling units,
where they may be exposed to refrigerated air circula-
tion, must be equipped with flow control valves or
other automatic means to prevent gravity circulation of
the boiler water during the cooling cycle.
3.8.2 Boiler Inlet and Outlet Connections
Union
Isolating
Valve
Relief Valve
Drain
Union
Isolating
Valve
Boiler
Drain Strainer
Outlet
(to system)
Isolating
Valve
Inlet
(from system)
Boiler Inlet and Outlet Connections
Make water connections as the application warrants, or
at a minimum, as shown, but always in compliance
with the local requirements.
Note: Pipe unions and isolating valves must be in-
stalled in both water connections for ease of service.
The bottom connection to the boiler is the INLET and
must be used for the return from the system.
The top connection to the boiler is the OUTLET and
must be connected as the supply to the system.
3.8.3 Boiler Water Piping by Installer
Strainer
To avoid possible contamination of the boiler with
dirt, rust or sediment from the system, a strainer near
the boiler inlet is strongly recommended. Even new
systems may contain sufficient foreign material to
eventually reduce the performance of the heat ex-
changer. Adequate circulation of good clean water is
essential to maximum efficiency and long life of the
boiler.
Relief Valve and Piping
Each boiler is supplied with a pressure-relief valve
sized in accordance with ASME requirements. The
relief valve should be piped to a suitable floor drain.
Reducing couplings or other restrictions are not per-
mitted in the discharge line.
Low Water Cut-off
The boiler is furnished with a flow-switch-type low
water cut-off; no field piping is required. If the flow
switch does not sense water flow, the boiler will shut
down and a red indicator will be illuminated on the
control panel.
WARNING!
Never install a valve that can isolate the low water cut-
off from the boiler.
Installation of an external low water cutoff or manual
reset low-water switch may be required by certain
codes or in certain installations. Consult the factory
for details.
Drain Valve and Piping
The boiler is not provided with external drain connec-
tions. A drain valve should be installed near the inlet
(system return) connection to the boiler and piped to a
suitable floor drain. The boiler can be completely
drained through the bottom header by removing the
flush plug in the bottom end plate.
This plug may also be used to flush accumulated
sediment from the bottom of the boiler.

Thermific® Gas-Fired Boiler Installation
Page 13
3.8.4 Flushing and Filling
Flushing the System
Before filling the boiler, flush the system to remove
the debris. Clean and flush old piping thoroughly be-
fore installing the boiler.
Under no circumstances should the hydronic system be
flushed while the boiler is attached to the system since
the debris or corrosion products could accumulate in
the boiler and plug the boiler heat exchanger.
If the piping system attached to this unit will be
chemically cleaned, the boiler must be disconnected
from the system and a bypass installed so that the
chemical cleaning solution does not circulate through
the boiler.
Filling
To be sure that the boiler is not air-bound, open the
pressure-relief valve located at the rear of the boiler.
Leave the relief valve open until a steady flow of wa-
ter is observed. Close the valve and finish filling the
system.
3.9 BURNER AND IGNITION SYSTEM
3.9.1 Inspection
Inspect the burners to be sure nothing was damaged or
knocked loose during shipment. Make sure that the
mixer core in the top of the burner is centered in the
burner head; (see burner photo in section on "Cleaning
the Burner" Section 5.2). Inspect the pilot line, main
gas train and ignition electrode to be sure they were
not damaged during shipment or installation. Check to
see that the pilot is securely attached and that it is
properly positioned to ignite the main burner.
3.10 PRE-START CHECK LIST
Before attempting to start the boiler, make sure the
following items have been completed.
1. Flue gas from the boiler is properly vented.
2. Gas connection has been made, pressure tested for
leakage, and the line purged of air. Make sure all
required bleeds and vents have been installed.
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 disconnect having adequate overload pro-
tection.
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 Section 3.3.3.
7. Relief valves have been piped to floor drains.
3.11 SAFETY CHECKS
The following checks of safety systems must be made
before putting the boiler into normal operation.
Before firing the boiler refer to Sections 4.1 and 4.2
for information on the use of the controls, lighting, and
shut-down procedures.
WARNING!
Never attempt to operate a boiler that has failed to
pass all the safety checks described below.
WARNING!
After checking controls by manual adjustment, make
sure they are always reset to their proper settings.
3.11.1 Test of Ignition Safety System
Test the ignition system safety shutoff as follows:
1. Disconnect wire #26 (On/Off) or # 17 (Lo-Hi-Lo)
at the terminal block.
2. With the main gas cock (manual gas valve) open
and the pilot gas cock open, the burner should be
cycled on. After all the safety limits on gas pres-

Thermific® Gas-Fired Boiler Installation
Page 14
sure, water flow and temperature are satisfied, the
blower will run and pre-purge the boiler.
3. When air flow is established, the ignition trans-
former and pilot will operate. Both functions will
be indicated by separate green lights on the control
panel.
4. If a satisfactory pilot is established, the green "ig-
nite" light will extinguish and the pilot will remain
on, alone, for 10 seconds.
5. 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-
surance or local codes require, go to a "lockout"
mode. Lockout will require manual reset of the
flame safeguard.
After completing this test, turn off the boiler and re-
connect the wire to the main gas valve.
3.11.2 Test of Low Water Cut-off
The boiler is furnished with a flow-switch-type low
water cutoff in the outlet nozzle. Test as follows:
Operation of the switch can be checked by first turning
the boiler off and then turning the system pump off,
stopping water flow in the system. After turning off
the pump, turn the boiler back on. It should not oper-
ate, and a red indicator for "Low Water" or "Water
Flow" should be illuminated. Do not shut the pump
off while the boiler is operating.
Perform appropriate tests on any external probe-type
low water cutoff.
3.11.3 Test of High-Limit Control
Fire the boiler and test the high limit control as fol-
lows:
With the main burner operating, turn down the tem-
perature setting on the "high-limit" thermostat until the
main burner shuts off. The high-limit switch must be
manually reset after testing. This check should also be
made for the "Operating Temperature" control (the
green "Heat" indicator will go out) (see next section
for Lo-Hi-Lo units). Readjust thermostats to desired
operating temperature and set high-limit temperature,
typically 20º F above operating temperature.
3.11.4 Test of Gas Pressure Switch
Manual Reset
Gas Pressure Switch
The boiler is furnished with a low gas pressure switch.
The operation of this switch must be checked by
slowly closing the main gas cock while the burner is
operating. The switch should shut down the main
burner. When the gas pressure switch opens, the "Low
Gas" or "Gas Press." indicator will light. Upon re-
opening the main gas cock, the "Low Gas" or "Gas
Press." indicator should remain on until the low gas
pressure switch is manually reset.

Thermific® Gas-Fired Boiler Installation
Page 15
3.12 INITIAL ADJUSTMENTS
3.12.1 Operating Temperature Controller for
Lo-Hi-Lo Thermific®
The two stages of this boiler are operated by pro-
gramming each set point and differential into the con-
troller. The boiler will be turned on at set point 1 mi-
nus its differential and turned off at set point 1. The
Hi fire operation of the boiler will be energized at set
point 2 minus its differential and de-energized at set
point 2.
Example:
Set point 1 at 180º F with a 20º F differential, and
Set point 2 at 170º F with a 15º F differential.
Note: the set points should be adjusted for system re-
quirements.
In this example, the boiler would operate as follows:
Stage 1 energized (Boiler/Low fire turned on) at
160º F.
Stage 1 de-energized (Boiler turned off) at 180º F.
Stage 2 energized (Hi fire on) at 155º F.
Stage 2 de-energized (Hi fire off/Low fire on) at
170º F.
Contact your local P-K service representative for assis-
tance adjusting your Lo-Hi-Lo operating temperature
control to meet system requirements.
Record setting in the Programming worksheet for fu-
ture reference.
Programming Worksheet
Stage 1:
SetPt 1: (Ta) On at (Tb)
Diff 1: (Tdl) Off at (Ta)
Stage 2:
SetPt 2: (Tb) On at (Tc)
Diff 2: (Td2) Off at (Tb)
Select Set Enter
Lo-Hi-Lo Operating Temperature Controller
To adjust operating temperature controller:
1. Turn the boiler ON. The controller will begin
counting down from 210. This countdown se-
quence will last for approximately 3-1/2 minutes.
2. To override this time delay, press Select.
3. Press Select to display the current stage setpoint.
4. Press Up Arrow to increase or Down Arrow to
decrease to the desired setpoint.
5. Press Enter to enter the displayed value into mem-
ory; (you must press enter to save each value into
the controller).
6. Press Select to display the current stage switching
differential.
7. Press Up Arrow to increase or Down Arrow to
decrease to the desired switching differential.
8. Press Enter to enter the displayed value into mem-
ory (you must press enter to save each value into
the controller).
9. Repeat steps 3 through 8 to program stage 2.
10. Press Select Select (2 times) to return to stage 1
parameters. Scroll through the programming loop
a second time to confirm that the appropriate val-
ues have been entered into memory by pressing
Select.
Note: The control values programmed into memory
will not be lost because of a power failure.

Thermific® Gas-Fired Boiler Installation
Page 16
Important: After initial programming, altering the set
point for stage 1 up or down will result in a change in
set point 2 by the same number of degrees and in the
same direction. If increasing or decreasing the set
point for stage 1 results in exceeding the control limits
(-40' to +220º F) for stage 2, the control will not allow
the user to enter a value for stage 1 higher or lower
than this limit.
3.12.2 Gas Pressure Adjustment
Increase Decrease
Gas Pressure Regulator
See rating plate for the minimum and maximum gas
pressure of the boiler. Each boiler is furnished with
two plugged taps in the gas manifold for test gauge
connections. One tap is located at the main gas cock
for measuring the gas supply pressure (1/4" I.P.S.).
The supply pressure during main burner operation
must be greater than the minimum indicated on the
rating plate (4 in. W.C. for natural gas, 7 in. W.C. for
propane). The second tap is located downstream from
the last main gas control at the elbow where the gas
line enters the back of the cabinet and is for measuring
the manifold gas pressure (1/8" I.P.S.).
If a replacement Lo-Hi-Lo actuator is required, follow
manufacturers instructions and pre-set the Lo fire set-
ting of the actuator the same as the original actuator.
This must be performed by qualified service person-
nel.
To adjust gas pressure, first connect appropriate pres-
sure-sensing device at the manifold tap, then remove
seal cap from regulator. Turn adjusting screw clock-
wise to increase pressure, counter-clockwise to de-
crease pressure. The manifold gas pressure on the
"Rating Plate," on the back of the cabinet, is provided
only as a guide to the proper setting. The manifold gas
pressure indicated on the "Factory Firetest" label (af-
fixed on the back of the cabinet) should be used to
achieve the proper firing rate of the individual boiler.
Replace seal cap after adjustment.
Important: Never underfire low fire (Lo-Hi-Lo
only).
3.12.3 Air Flow Adjustments
The air flow is pre-set at the factory prior to shipment.
The air (and gas) may have to be adjusted for local
conditions.
All air flow adjustments must be performed by quali-
fied service personnel.
For initial light off, adjust the air flow until the cabinet
pressure is the same as shown on the "Factory Firetest"
labels.
Combustion measurement instrumentation must be
used to adjust the boiler for local conditions (See in-
structions below). Adjust the carbon dioxide (CO2) or
oxygen (O2) reading corresponding to approximately
50% excess air.