Performance Work Statement.pdf

27 August 2024

PERFORMANCE WORK STATEMENT (PWS)

REMOVE, FURNISH, AND INSTALL BOILER AT BUILDING 1231

LITTLE ROCK AFB, AR 72099

1. DISCRIPTION OF SERVICES

1.1. The contractor shall provide all qualified personnel, transportation, tools, equipment, materials and services required furnish, remove and install one HVAC 2-MBTU/H boiler at building 1231 on Little Rock AFB, AR 72099. The contractor shall accomplish all services below to meet the requirements of this Performance Work Statement (PWS). Work shall be in compliance with all Federal, State and local regulations, codes and license requirements for HVAC work in the State of Arkansas. Work shall be accomplished within 45 days of material arrival. Estimated delivery date of material is required to be sent to the contracting officer (CO) within 15 days of contract award.

1.2. The Government will neither supervise contractor employees nor control the method by which the contractor performs the required tasks. It shall be the responsibility of the contractor to manage its employees and to guard against any actions that are of the nature of personal services or give the perception of personal services. If the contractor feels that any actions constitute, or are perceived to constitute personal services, it shall be the contractor’s responsibility to notify the Contracting Officer (CO) immediately. These services shall not be used to perform work of a policy/decision making or management nature, (e.g., inherently governmental functions). All decisions relative to programs supported by the contractor shall be the sole responsibility of the Government.

2. SAFETY AND REGULATORY REQUIREMENTS

2.1. Building 1231 is operated by the 714th TRS Squadron. This is a Training Facility with normal operating hours - 7am to 6pm Monday – Friday. Not anticipating any weekend work needed to accomplish this project; however, the contractor may work weekends with pre-approval of the CO.

2.2. Pre-Install Requirements: Before services are commenced, the contractor shall inspect the work site and ascertain all information for the diligent performance of the service(s). The contractor shall notify the ordering agency of any conditions that prevent the suitable completion of these services to include operations that could endanger Government personnel or property and require appropriate abatement action. If the contractor discovers problems associated with the work after starting, he or she shall immediately notify the Contracting Officer (CO) for their approval if the work is to continue. Coordinate with the Government designated representative to have utilities/fire alarms etc…turned on or off during the competition of the task.

2.3. Disposal of waste: All waste disposals are the responsibility of the contractor to include any fees or permits. Recycling containers shall be provided as needed for the operation for wire, conduit, sheet metal, and small equipment. Coordinate through the government representative with Little Rock AFB Recycle Center (501-987-6611) for the delivery/pick-up of metal recycle bins. Large bulk/equipment items i.e. chillers, AHU’s, condensing units, boilers, etc. will be coordinated with the recycle center for the contractor to deliver directly to a metal recycling vendor. It’s the contractor’s responsibility to transport to said location, have it weighed. Metal vendor shall be notified, and the weight ticket should state Delivered by Little Rock AFB Recycling Center and the total weight of the object. The contractor is responsible to deliver a copy of the ticket to the government representative.

2.4. All work shall be accomplished in accordance with all regulations and State of Arkansas licensing requirement regarding HVAC installation, maintenance and repair.

2.5. Air Field Waiver: If a crane is required for any of the installation of the equipment by Federal Law an airfield waiver must be accomplished and signed off by the FAA. This takes a minimum of 60 days to complete and will delay work till completed. Contractor will need to provide the type of equipment, tonnage and full boom height to the CO or government representative within five days of contract award.

3. WORK REQUIREMENTS

3.1. DEMO – Contractor shall disconnect/remove existing Hurst boiler (Mech. Rm 129).

Contractor shall take care to remove existing Energy Management System (EMS) sensors, relays, wiring/conduit connected to existing boiler to re-utilize/connect to new boiler. Contractor shall remove/disconnect existing Grundfoss UPS 26-64F recirculation pump (BCP-1) to include piping back to the main inlet/outlet supply lines. Contractor shall electrically disconnect the pump taking care to re-utilize/connect to new pump.

3.2. Equipment & Material – Contractor will furnish one Patterson-Kelley MODU-FIRE N2000 boiler w/NURO controls, one self-contained/powered ProtoNode FPC BACnet interface, and one Grundfoss UPS 50-60F (115V) circulating pump. The contractor shall provide boiler flue piping that is compatible with existing CAT IV flue manufactured by SELKIRK Metalbestos (Model PS). All piping modifications necessary for installation of boiler & pump shall match the existing material as close as possible to include the type of insulation. All electrical materials shall meet Electrical Code and conform with existing electrical installation. Contractor shall verify and utilize the proper wire, conduit, and breakers for new equipment specifications.

3.3. Installation – Contractor shall install new boiler, BACnet controller, and re-circulating pump in accordance with manufacture specifications. Contractor shall properly connect new boiler power source to electric panel 1LO utilizing correct wire size and installing a new circuit breaker. Boiler piping modifications shall be straight, level, and properly supported. Pipe insulation shall match existing insulation to include material, covering, and markings.

Contractor will properly connect new flue to existing flue and ensure proper seal. The boiler BACnet interface shall be mounted on a wall close to existing control box – verify location with government representative prior to mounting. The contractor shall re-install all EMS sensors, relays, and wires/conduit removed from DEMO unit. The contractor shall integrate existing EMS wiring and controls with new BACnet device and ensure/verify system operation.

Contractor shall install recirculation pump in the same pipe configuration as the one removed and increase pipe diameter to 2” to include all fittings and valves. Installation shall follow all manufacturer recommendations, state and federal codes.

3.4. Final Confirmation – Contractor will utilize a certified Patterson-Kelley manufacture representative to verify/confirm contractors’ installation. Representative will check for proper pipe installation, electrical wiring, control wiring. Representative will perform an operational test with the COR present. Representative will perform a “Start-Up Combustion Analysis” with a certified/calibrated combustion analyzer. Representative will annotate test results on a document to provide to the “Manufacturer” and the Government Representative. This documentation is necessary for warranty. Contractor or Representative will need to provide Start-Up/Warranty documentation to the Government Representative upon acceptance.

3.5. Welding, Cutting and Brazing Operations: All welding, cutting, and brazing operations shall conform to the Standard for Fire Prevention in Cutting and Welding Process, NFPA 51B, and the Standard for Safeguarding Construction, Alteration, and Demolition Operations, NFPA

241. No welding, cutting, or brazing operations may begin until an Air Force Form 592, USAF Welding, Cutting and Brazing Permit, has been issued. An AF Form 592 will be issued by the Fire Department upon completion of an inspection to determine that the operation can be safely accomplished at the desired location. The responsible contractors shall notify the Fire Alarm Communication Center, at 501-987-3737 or 501-987-3228, at least one hour prior to the start of the operation. Normally an inspector will be available to issue a permit within 30 minutes from the time called. The person receiving the permit, operator performing the work or on scene supervisor shall sign in block 14 prior to beginning the work. The permit must be maintained on site for the duration of the operation. Upon completion of the work, an After Operation Inspection shall be complete to ensure that the area is in a fire safe condition. The person performing the After Operation Inspection shall sign in block 16. At the end of the day, all completed permits shall be returned to the fire department. Further information may be obtained through the Base Fire Prevention Office.

4. GOVERNMENT FURNISHED EQUIPMENT

4.1. None

5. GENERAL REQUIREMENTS

5.1. Contractor personnel and vehicles must possess appropriate passes. These shall be obtained from Installation Security Forces Pass and ID at the Vehicle Inspection Center.

5.2. The Contractor is subject to all installation fire, safety, security, and traffic regulations.

5.3. The Government contracts on the understanding that the Contractor is complying with applicable laws concerning workplace safety.

5.4. The Contractor is subject to all citations and penalties for violation of applicable workplace safety laws. The burden of compliance rests with the Contractor. Enforcement of workplace safety laws is the responsibility of the agency specified in the applicable law.

5.5. The Contracting Officer may notify the Contractor of hazards in Contractor operations that endanger Government personnel or property and require appropriate action. This provision does not constitute assumption of liability for Occupational Safety and Health compliance on the part of the Government or negate other agency responsibility for enforcement of applicable laws.

5.6. Accident prevention principles must be thoroughly integrated into all operations. Unsafe conditions and practices, as identified by the designated representative, must be corrected immediately.

5.7. Contractor Employees: While on the installation, the contractor shall not employ persons for work on this contract if such employee is identified to the contractor by the Contracting Officer as a potential threat to the health, safety, security, general well-being or operational mission of the installation and its population. Contractor personnel shall present a neat appearance and be easily recognized as contractor employees. This may be accomplished by wearing distinctive clothing bearing the name of the organization or by wearing appropriate badges containing the organization's name and the employee's name. Contractor personnel must wear issued base identification cards at all times while on the installation.

5.8. Service contracts shall require contractor employees to identify themselves as contractor personnel by introducing themselves or being introduced as contractor personnel and displaying distinguishing badges or other visible identification for meetings with government personnel. In addition, contracts shall require contractor personnel to appropriately identify themselves as contractor employees in telephone conversations and in formal and informal written correspondence.

6.0. WARRANTY

6.1. Contractor shall guarantee all workmanship and labor from defects for a period of 12 months (one year) from the date of acceptance of the work. All installed equipment and material shall follow manufacturer warranty. A warranty letter detailing the work accomplished per facility is required to be furnished to the CO or government representative upon acceptance of the work.

7.0. APPENDIXES

APPENDIX A: Commander’s Environmental Policy APPENDIX B: E603 Electrical Panel (1LO) Schedule APPENDIX C: M808B Heating Water System Flow Diagram APPENDIX D: PK Modu-Fire Installation Manual APPENDIX E: Grundfoss Installation Manual APPENDIX F: ProtoNode Installation Manual

APPENDIX A:

APPENDIX B:

APPENDIX C:

P-K MODU-FIRE FORCED-DRAFT® & GAS-FIRED BOILERS

N750-MFD, N1000-MFD, N1500-MFD, N2000-MFD, N2500-MFD & N3000-MFD

P-K MODU-FIRE FORCED-DRAFT® GAS-FIRED WATER HEATERS

W750-MFD, W1000-MFD, W1500-MFD & W2000-MFD

Part # 1004905935

MFD Boilers MFD Water Heaters

ASME Code, Section IV “H” Stamp Certified by Patterson-Kelley

ASME Code, Section IV “HLW” Stamp 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

C.S.A Design-Certified Complies with ANSI

Z21.10.3/CSA 4.3

Gas-Fired Water Heaters

C.S.A Design-Certified Complies with ANSI

Z21.13/CSA 4.9

Gas-Fired Low Pressure Steam and Hot Water Boilers

C.S.A Design-Certified Complies with ANSI

Z21.10.3/CSA 4.3

Gas-Fired Water Heaters

Model Number:

Serial Number:

Start-Up Date: ___________________________ Patterson-Kelley 155 Burson Street East Stroudsburg, PA 18301 Telephone: 570.476.7261 Toll Free: 877.728.5351 Fax: 570.476.7247 www.pattersonkelley.com

Released: February 2023 Patterson-Kelley 2023: All Rights Reserved.

INSTALLATION

& O W N E R’S

MANUAL

INSTALLATION

& O W N E R’S

MANUAL

INSTALLATION

& O W N E R’S

MANUAL

INSTALLATION

& O W N E R’S

MANUAL

INSTALLATION

& O W N E R’S

MANUAL

INSTALLATION

& O W N E R’S

MANUAL

INSTALLATION

& O W N E R’S

MANUAL

INSTALLATION

& O W N E R’S

MANUAL

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 appliances 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.

- 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.

APPENDIX D:

P-K MFD Gas Fired Appliance Technical Service 1.877.728.5351

Safety

General All P-K MODU-FIRE FORCED-DRAFT® Gas-Fired Boilers and Water Heaters must be:

• Installed, operated, and serviced in accordance with the instructions contained in this manual and any 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 appliance, 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 appliance, all piping, and accessories.

NOTICE!

Each safety device must be maintained and checked per the recommended schedule. Refer to Section 5.2.

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

Is the preferred signal word to address practices not related to personal injury. The safety alert symbol is not used with this signal word.

NOTICE!

The safety labels shown below are affixed to your appliance. 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 MODU-FIRE Forced-Draft gas-fired boilers and water heaters, the use and locations of the controls, the operation of the equipment, 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 appliance.

Shock Hazard! Do not spray water directly on this appliance 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 appliance. 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.

750 & 1000 1500 2000 2500 & 3000

750 Lbs. 920 Lbs. 935 Lbs. 1200 Lbs.

Bump Hazard from Overhead Ductwork and Piping

Injury Hazard! Install components with adequate vertical clearance.

Pressure Hazards

Pressure Hazard! Hot fluids. Install isolation valves on appliance water inlet and outlet. Make sure isolation valves are closed before servicing the appliance.

Pressure Hazard! Hot fluids. Annually test safety relief valve(s) for proper operation. Do not operate the appliance with faulty relief valve(s). Contact the water supplier or local plumbing inspector on how to correct this situation. Do not plug the relief valve.

Slip, Fall Hazards Tripping Hazard! Do not install piping on floor surfaces. Maintain a clear path around the appliance.

Slip and Fall Hazard! Use a drip pan to catch water while draining the appliance. 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 Section 2.5.5.

Fall Hazard! Do not stand on the appliance.

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.

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 Section 3.4 and Section 3.5.

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 the appliance.

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 appliance components could be hot. Do not touch piping or stack surfaces during operation or immediately after shutdown of the appliance.

Burn Hazard! Hot flue! Use caution when servicing or draining the appliance.

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 appliance 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 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 appliance. The firing rate must be adjusted only by factory-trained personnel.

Revised: March 1, 2023 Released: March 1, 2023

Patterson Kelley 2023 All Rights Reserved.

1004905935 P-K MFD 750-3000 Installation and Owners Manual Rev H.docx

Page v

Table of Contents 1 INTRODUCTION ....................................................................................... VIII

1.1 REFERENCE TABLE –MODU-FIRE FORCED DRAFT “MFD” MODELS

1.2 PURPOSE OF THIS DOCUMENT

1.3 COMMON ABBREVIATIONS

2 SITE PREPARATION

2.1 INITIAL INSPECTION UPON RECEIVING

2.2 STORAGE PRIOR TO INSTALLATION

2.3 COMPLIANCE WITH CODES

2.3.1 MFD Series: Boiler Specific Certifications

2.3.2 MFD Series: Water Heater Specific Certifications

2.3.3 Installation Codes

2.4 LOCATION SETUP

2.4.1 Foundation

2.4.2 Clearances

2.5 INLET AIR AND EXHAUST VENTING CONSIDERATIONS

2.5.1 Applicable Codes and Standards

2.5.2 Combustion Air Inlet Planning (United States and Canada Considerations)

2.5.3 Category II/IV Flue Gas Exhaust Vent Planning (MFD Boilers & Water Heaters)

2.5.4 Venting Materials for Flue/Exhaust Systems

2.5.5 Required Clearances

2.6 GAS PIPING CONSIDERATIONS

2.7 WATER QUALITY STANDARD

3 INSTALLATION

3.1 OVERVIEW

3.2 APPLIANCE CONNECTIONS

3.2.1 Appliance Connections (750 & 1000 Sizes)

3.2.2 Appliance Connections (1500 & 2000 Sizes)

3.2.3 Appliance Connections (N2500-MFD & N3000-MFD)

3.3 ELECTRICAL CONNECTIONS

3.3.1 Power Requirements

3.3.2 High Voltage (TB2) Terminal Block (208-240VAC)

3.3.3 Low Voltage (TB1) Terminal Block (120VAC -or- 208-240VAC)

3.4 COMBUSTION AIR

3.4.1 Air Inlet Requirements – United States

3.4.2 Air Inlet Requirements - Canada

3.4.3 MFD Combustion Air Requirements

3.4.4 Direct Vent / Sealed Combustion Installations

3.4.5 Motorized Combustion Air Dampers

3.5 FLUE GAS / EXHAUST VENTING

3.5.1 Category II or IV Vent Installation (MFD Boilers and Water Heaters Only)

3.5.2 MFD Boilers & Water Heaters: Acceptable Category II/IV Vent Configurations

3.5.3 Venting for Multiple Appliances

3.6 REMOVING AN EXISTING BOILER OR WATER HEATER

3.7 PIPING

3.7.1 Gas Piping Overview

3.7.2 Natural Gas Piping

3.7.3 Propane Gas Piping

Revised: March 1, 2023 Released: March 1, 2023

Patterson Kelley 2023 All Rights Reserved.

1004905935 P-K MFD 750-3000 Installation and Owners Manual Rev H.docx

Page vi

3.7.4 Pressure Testing the Gas Piping

3.7.5 Sample Piping Diagram – MFD Series Boilers

3.7.6 Sample Piping Diagram – MFD Series Water Heaters

3.7.7 Water Piping Accessories & Connections (for Installer)

3.8 WATER QUALITY

3.9 PRE-START CHECKLIST

3.10 SAFETY CHECKS

3.10.1 Ignition Safety System Test

3.10.2 Manual Reset High Temperature Limit Test

3.10.3 Low Gas Pressure Switch Test

3.10.4 High Gas Pressure Switch Test

3.10.5 Low Water Cut-out Test (If Applicable)

3.11 BURNER ADJUSTMENT

3.11.1 Inlet Gas Test Port

3.11.2 Manual Control Mode for High and Low Fire Adjustment

3.11.3 Adjusting High Fire Combustion

3.11.4 Adjusting Low Fire

3.11.5 Checking Flame Signal

3.12 INITIAL NURO CONTROL SETUP & ADJUSTMENT

3.12.1 Startup

3.12.2 Home Screen

3.12.3 Information Screen

3.12.4 Setup Wizard

4 OPERATIONS

4.1 NURO TOUCHSCREEN CONTROL SYSTEM

4.1.1 Power On/Off Switch

4.1.2 NURO Touch Screen Interface and Control Panel

4.1.3 Factory Tests

4.2 NORMAL LIGHTING AND SHUT-DOWN PROCEDURES

4.2.1 Normal Lighting Procedures

4.2.2 Normal Shut Down Procedures

4.3 EMERGENCY SHUT-OFF

5 MAINTENANCE

5.1 PREVENTATIVE MAINTENANCE

5.1.1 Daily Preventative Maintenance

5.1.2 Weekly Preventative Maintenance

5.1.3 Monthly Preventative Maintenance

5.2 MAINTENANCE AND INSPECTION SCHEDULE

5.2.1 Semi-Annually

5.2.2 Annually

5.3 CLEANING THE BURNER & COMBUSTION CHAMBER

5.4 AFTER REPAIRS OR MAINTENANCE

5.5 SEQUENCE OF OPERATIONS

5.6 TROUBLESHOOTING

5.6.1 Loss of Power

5.6.2 Loss of Water Flow

5.6.3 Low Gas Pressure

5.6.4 High Gas Pressure

5.6.5 High Water Temperature

Revised: March 1, 2023 Released: March 1, 2023

Patterson Kelley 2023 All Rights Reserved.

1004905935 P-K MFD 750-3000 Installation and Owners Manual Rev H.docx

Page vii

5.6.6 Low Air

5.6.7 Flame Failure

5.6.8 Flame Error

5.6.9 Flue Problem

6 PARTS/TECHNICAL SUPPORT

6.1 TERMINAL BLOCK ASSIGNMENTS AND WIRING DIAGRAMS

6.1.1 Terminal Block 208-240VAC

6.1.2 Terminal Block 120VAC

6.1.3 Terminal Block Assignments — High Voltage (TB2) Terminal Block (208-240VAC)

6.1.4 Terminal Block Assignments — High Voltage (TB2) Terminal Block (120VAC)

6.1.5 Terminal Block Assignments — Low Voltage (TB1) Terminal Block (120VAC -or- 208-

240VAC)

6.1.6 MFD NURO 208-240VAC Wiring Diagram

6.2 PARTS IDENTIFICATION

6.2.1 Main Assembly

6.2.2 NURO Control Panel

6.2.3 Heat Exchanger Assembly (Sizes 750 through 2000)

6.2.4 Heat Exchanger Assembly (Sizes 2500 & 3000)

6.2.5 Gas Train, Burner & Blower Assembly (Sizes 750 through 2000)

6.2.6 Gas Train, Burner & Blower Assembly (Sizes 2500 & 3000)

7 MODU-FIRE FORCED DRAFT® SPECIFIC LIMITED WARRANTY

8 FIRE-TEST REPORT

APPENDIX A – MAINTENANCE LOG

APPENDIX B –ALTITUDE DERATE SCHEDULE

APPENDIX C –WATER QUALITY STANDARD FOR HYDRONIC BOILERS IN

MULTI-METAL SYSTEMS

APPENDIX D – BEST PRACTICES FOR NEW & RETROFIT SYSTEMS

APPENDIX E – INSTALLATION AND QUICK REFERENCE

FUEL/GAS SUPPLY

ELECTRICAL/POWER SUPPLY

EXHAUST VENTING

HYDRONICS/WATER FLOW (MFD 750 - 1000 SIZES)

APPLIANCE CONNECTIONS (MFD 750 - 1000 SIZES)

HYDRONICS/WATER FLOW (MFD 1500 - 2000 SIZES)

APPLIANCE CONNECTIONS (MFD 1500 - 2000 SIZES)

HYDRONICS/WATER FLOW (N2500-MFD & N3000-MFD)

APPLIANCE CONNECTIONS (N2500-MFD & N3000-MFD)

PROPYLENE GLYCOL FLOW

Revised: March 1, 2023 Released: March 1, 2023

Patterson Kelley 2023 All Rights Reserved.

1004905935 P-K MFD 750-3000 Installation and Owners Manual Rev H.docx

Page viii

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.

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 appliance. The features which permit this appliance to achieve high-efficiency performance can be misused which could result in personal injury or death.

If you cannot reach your gas supplier, call the fire department.

1 Introduction This manual describes the installation and operation of P-K MODU- FIRE Forced Draft “MFD” series boilers and water heaters featuring NURO controls:

MFD Boilers Category II or IV Venting See Section 1.1 for modulation

ANSI Z21.13 / CSA 4.9

ASME “H” Stamp 160 PSI Maximum Pressure 250°F Maximum Temperature

MFD Water Heaters Category II or IV Venting See Section 1.1 for modulation

ANSI Z21.10.3 / CSA 4.3

ASME “HLW” Stamp 160 PSI Maximum Pressure 210°F Maximum Temperature

Individual differences between each model will be called out and defined in separate sections and the titles of these sections will include the applicable model number. If model numbers are not listed in the section title, that section is common to all 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 MODU-FIRE Forced Draft gas-fired appliance is fully modulating using a variable speed combustion blower, sophisticated microprocessor controls, modulating gas safety shut off / control valves and a time tested copper finned-tube heat exchanger. The high-quality materials and state of the art design should provide years of trouble-free service if the instructions in this manual are followed carefully.

This appliance is only a part of the complete hydronic or domestic water system. This appliance may be fully operational and yet 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.

While details may differ slightly, basic operation is the same for all models. Most models may be built to operate with natural gas or liquefied petroleum gas (propane). Check the rating plate for correct fuel type and gas pressures.

Revised: March 1, 2023 Released: March 1, 2023

Patterson Kelley 2023 All Rights Reserved.

1004905935 P-K MFD 750-3000 Installation and Owners Manual Rev H.docx

1.1 Reference Table –MODU-FIRE Forced Draft “MFD” Models

Model Number

Vent Category

Max Input

Rating (Btu/hr)

Min Input Rating (Btu/hr)

Effective Turndown

Ratio

Max Output Rating (Btu/hr)

Efficiency

Recovery Rating

(GPH)

40°F to 140°F

MFD Boilers: ASME “H” Stamp & ANSI Z21.13 / CSA 4.9

N750-MFD II or IV 750,000 150,000 5:1 637,500 85% N/A N1000-

MFD

II or IV 1,000,000 166,000 6:1 850,000 85% N/A

N1500-

MFD

II or IV 1,500,000 250,000 6:1 1,275,000 85% N/A

N2000-

MFD

II or IV 2,000,000 335,000 6:1 1,700,000 85% N/A

N2500-

MFD*

II or IV 2,500,000 500,000 5:1 2,200,000 85% N/A

N3000-

MFD*

II or IV 3,000,000 500,000 6:1 2,640,000 85% N/A

MFD Water Heaters: ASME “HLW” Stamp & ANSI Z21.13 / CSA 4.9

W750-MFD II or IV 750,000 150,000 5:1 637,500 85% 772.5 W1000-

MFD

II or IV 1,000,000 166,000 6:1 850,000 85% 1030

W1500-

MFD

II or IV 1,500,000 250,000 6:1 1,275,000 85% 1545

W2000-

MFD

II or IV 2,000,000 335,000 6:1 1,700,000 85% 2060

**NOTE: Models N2500-MFD & N3000-MFD are only approved for use with Natural Gas.

All other models can be ordered for Natural Gas or Propane Gas.

Revised: March 1, 2023 Released: March 1, 2023

Patterson Kelley 2023 All Rights Reserved.

1004905935 P-K MFD 750-3000 Installation and Owners Manual Rev H.docx

1.2 Purpose of this Document

The purpose of this Installation and Owner’s Manual is to provide comprehensive documentation support for the P-K MODU-FIRE Forced Draft series of gas fired boilers and water heaters featuring NURO controls. This manual discusses requirements for all installations as well as recommended best practices for installation, operation and maintenance.

The primary concern of all Patterson-Kelley equipment installation procedures is safety. Safety instructions and considerations are presented and repeated throughout the document as required. 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.

1.3 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

MFD MODU-FIRE Forced-Draft Series Boiler or Water Heater

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

Revised: March 1, 2023 Released: March 1, 2023

Patterson Kelley 2023 All Rights Reserved.

1004905935 P-K MFD 750-3000 Installation and

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.

The appliance is heavy and requires additional technicians to support and move the unit(s) during installation. Use extreme caution to avoid dropping the appliance or cause any bodily injury while lifting or handling. When positioning this appliance, 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 appliance may be installed on a combustible floor; however, the appliance 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.

2 Site Preparation

2.1 Initial Inspection upon Receiving

Upon receiving the appliance, inspect it for signs of shipping damage. Some damage may be hidden. Unpack the appliance, open the front and side doors and inspect the appliance. Verify that the total number of pieces shown on the packing slip agrees with those actually received.

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.

2.2 Storage Prior to Installation

If the appliance 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.

NOTICE! Controls and other equipment that are damaged or fail due to weather exposure are not covered by warranty.

Revised: March 1, 2023 Released: March 1, 2023

Patterson Kelley 2023 All Rights Reserved.

1004905935 P-K MFD 750-3000 Installation and Owners Manual Rev H.docx

2.3 Compliance with Codes

MFD Series

Boilers

MFD Series

Water Heaters

Code of Construction ASME Section IV – “H”

(Latest Edition)

ASME Section IV – “HLW”

(Latest Edition)

CSA/ANSI Specification

ANSI Z21.13 / CSA 4.9

(Latest Edition)

ANSI Z21.10.3 / CSA 4.3

(Latest Edition)

Maximum Allowable

Working Pressure

160 PSIG 160 PSIG

Maximum Allowable Design Temperature

250°F 210°F

Maximum Setpoint 220°F 190°F

Hi-limit Setpoint 240°F 197°F

Suitable for Potable Water? NO YES

2.3.1 MFD Series: Boiler Specific Certifications

The “N Series” MODU-FIRE Forced-Draft boilers with standard components comply with American National Standard/CSA Standard ANSI Z21.13/CSA 4.9, latest edition. The heat exchanger is not suitable for use with potable water and is constructed and “H” stamped in accordance with ASME Boiler and Pressure Vessel Code, Section IV for 160 psig maximum pressure and 250°F maximum temperature. Other codes or approvals which apply will be labeled on the boiler.

2.3.2 MFD Series: Water Heater Specific Certifications

The “W Series” MODU-FIRE Forced-Draft water heaters with standard components comply with American National Standard/CSA Standard ANSI Z21.10.3/CSA 4.3, latest edition. The heat exchanger is suitable for use with potable water and is constructed and “HLW” 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 water heater.

NOTE: The appliance should be located in an area where leakage of the tank or connections will not result in damage to the area adjacent to the appliance or to lower floors of the structure.

When such locations cannot be avoided, it is recommended that a suitable drain pan, adequately drained, be installed under the appliance. The pan must not restrict combustion air flow.

NOTE: If a water heater is installed in a closed water supply system, such as one having a backflow preventer in the cold water supply line, means shall be provided to control thermal expansion. Contact the water supplier or local plumbing inspector on how to control this situation.

Revised: March 1, 2023 Released: March 1, 2023

Patterson Kelley 2023 All Rights Reserved.

1004905935 P-K MFD 750-3000 Installation and Owners Manual Rev H.docx

2.3.3 Installation Codes

Installation of the boiler or water heater 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.

Note: For tube type circulating water heaters installed only with a pressure relief valve, the separate storage vessel must have a temperature and pressure relief valve installed. This relief valve shall comply with the Standard for Relief Valves for Hot Water Supply Systems, ANSI Z21.22 • CSA 4.4.

(Also see Clauses 4.21.4 and 4.21.5.)

Revised: March 1, 2023 Released: March 1, 2023

Patterson Kelley 2023 All Rights Reserved.

1004905935 P-K MFD 750-3000 Installation and Owners Manual Rev H.docx

2.4 Location Setup

2.4.1 Foundation

Provide a firm, level foundation, preferably made of concrete. The MODU-FIRE Forced Draft boilers and water heaters must be level and upright to function properly. There are 3/4” holes at the four corners of the structural steel c-channel base for anchoring and leveling as shown below. Once the appliance is installed on the foundation and furnished with anchor/lag bolts, use a bubble level and adjust the four anchor nuts until the appliance is secure and level.

NOTICE! The appliance may be installed on a combustible floor; however, the appliance must NEVER be installed on carpeting.

NOTICE! This appliance is certified for INDOOR use only!

3/4” Hole for Anchor/Lag Bolts

(Rear Right Corner)

3/4” Hole for Anchor/Lag Bolts

(Front Right Corner)

3/4” Hole for Anchor/Lag Bolts

(Front Left Corner)

3/4” Hole for Anchor/Lag Bolts (Rear Left Corner)

Revised: March 1, 2023 Released: March 1, 2023

Patterson Kelley 2023 All Rights Reserved.

1004905935 P-K MFD 750-3000 Installation and Owners Manual Rev H.docx

2.4.2 Clearances

If the boiler or water heater is to be installed near combustible surfaces, there must be twenty-four (24”) inches minimum clearance. Failure to provide adequate service clearances, even with non-combustible surfaces, may present problems during routine maintenance of the appliance. The appliance must be installed in a space large in comparison to the appliance 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 24 24 24 24 24

Clearance to Non-Combustible Surfaces 0 0 0 0 0

Recommended Service Clearances 36 24* 24 24** 24**

† “C" dimension includes clearance to remove the burner. Do not put pipes, ducts, etc. in area above the appliance.

*CSA minimum. Actual clearance depends upon venting requirements.

** Left & Right-Side service access (“D” & “E” Dimension”) are needed to view the appliance’s runout & safety warning labels, and access the electrical junction box.

Note: Failure to provide recommended service clearances may make it difficult to perform service on the appliance(s).

Revised: March 1, 2023 Released: March 1, 2023

Patterson Kelley 2023 All Rights Reserved.

1004905935 P-K MFD 750-3000 Installation and

Design and installation of venting systems should be done only by qualified and knowledgeable venting systems personnel and in accordance with the vent system manufacturer’s installation instructions. Installing an appliance or vent system using improper installation methods or materials can result in serious injury or death due to fire or asphyxiation.

Before connecting an appliance to a venting system, it must be determined whether the appliance 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 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.

2.5 Inlet Air and Exhaust Venting Considerations

2.5.1 Applicable Codes and Standards

United States Installation Codes:

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

Canada Installation Codes:

CAN/CSA B149.1 Installation Codes for Gas Burning Equipment

Flue Gas Exhaust Vent Standards:

UL 441 / ULC S605 Standard for Gas Vents ULC S636 Standard for Type BH Gas Venting Systems

UL 1738

Venting Systems for Gas-Burning Appliances, Categories II, III and IV

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.

2.5.2 Combustion Air Inlet Planning (United States and

Canada Considerations)

Air inlet considerations for the United States 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 Section 3.4 for more details on combustion air inlet requirements in the United States and Canada.

Revised: March 1, 2023 Released: March 1, 2023

Patterson Kelley 2023 All Rights Reserved.

1004905935 P-K MFD 750-3000 Installation and Owners Manual Rev H.docx

2.5.3 Category II/IV Flue Gas Exhaust Vent Planning (MFD Boilers & Water Heaters)

Several codes and standards, e.g. NFPA 54/ANSI Z223.1 categorize appliances in accordance with the flue gas temperature and pressure produced by the appliance, which are defined as follows:

MODU-FIRE Forced Draft Boilers & Water Heaters

Category II: An appliance that operates with a non-positive vent static pressure and with a vent gas 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 gas 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.

MODU-FIRE Forced-Draft series boilers are dual-certified as Category II or IV appliances, as defined in ANSI Z21.13/CSA 4.9, latest edition. MODU-FIRE Forced-Draft series water heaters are also dual-certified as Category II or IV appliances, as defined in ANSI Z21.10.3/CSA 4.3, latest edition. The MFD series boilers and water heaters 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:

+0.01” W.C. and +1.5” W.C. (MFD Sizes 750 through 2000) +0.01” W.C. and +1.0” W.C. (MFD Sizes 2500 & 3000).

The vent material to be used for US and Canada is listed in the Table of Acceptable Materials for Venting Systems located in Section 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.

Vent Sizing for Category II / IV Operation (MFD Boilers & Water Heaters Only)

The vent must be sized in accordance with the ASHRAE Systems and Equipment handbook (Chapter

30) or according to the vent manufacturer’s recommendations. When using manufactured venting systems, consult your vent supplier for correct sizing and structural support requirements.

MFD Appliance Size Exhaust Pressure Stack Temperature

CO2

Natural Gas

CO2

Propane Gas

750/1000/1500/2000 1.5” W.C. 325 °F (gross) 8.7% 10.0%

2500/3000 1.0” W.C. 325 °F (gross) 8.4% N/A

Revised: March 1, 2023 Released: March 1, 2023

Patterson Kelley 2023 All Rights Reserved.

1004905935 P-K MFD 750-3000 Installation and Owners Manual Rev H.docx

2.5.4 Venting Materials for Flue/Exhaust Systems

MODU-FIRE Forced-Draft series boilers and water heaters are dual-certified as Category II or IV appliances, which vent with a gas temperature that is likely to cause condensation in the vent.

Therefore, any venting system used with a MFD series boiler or water heater MUST comply with the requirements for Category II or IV venting systems as specified in the latest edition of NFPA 54/ANSI Z223.1 in the US or the latest edition of CAN/CSA B-149.1 in Canada.

The use of plastic venting materials including CPVC, PVC, PolyPropylene, etc. is PROHIBITED! Failure to comply with this warning could result in injury or death due to failed flue material.

The venting materials listed below are intended for the venting of gas burning appliances only.

Do not use these venting materials for venting liquid or solid fuel (such as oil, kerosene, wood, or coal) appliances.

Maintain clearances to combustibles as listed in the vent manufacturer’s installation instructions or as set forth in the codes and standards listed in this section. Do not use these vent pipes for incinerators of any sort.

As per ANSI Z21.13b-2012 * CSA 4.9b-2012:

The use of cellular core PVC, cellular core CPVC, or Radel® as venting materials is prohibited.

The use of plastic vent pipe is prohibited.

Table of Acceptable Venting Materials for MFD Appliances

Product Series Category Country Type B AL29-4C 316L SS PVC CPVC PP

MFD Boilers II, IV US No Yes Yes No No No

MFD Water Heaters II, IV US No Yes Yes No No No

MFD Boilers II, IV Canada No Yes Yes No No No

MFD Water Heaters II, IV Canada No Yes Yes No No No

Note 1: Ensure this flue material is suitable for Category I applications.

The venting materials listed are intended for the venting of gas burning appliances only.