P K Compact Manual Rev C Jan 2020

P-K COMPACT® (All models)
1004905925
(Rev C Jan-2020)
P-K COMPACT®
Semi-Instantaneous Water Heater
(Steam and Water)
ASME Code, Section VIII

Certified by Patterson-Kelley
Installation Date: _______________________
Patterson-Kelley
155 Burson Street
East Stroudsburg, PA 18301
Telephone: (570) 476-7261
Toll free: (877) 728-5351
www.pattersonkelley.com
© 2020 Patterson-Kelley, All Rights Reserved

P-K COMPACT®
TABLE OF CONTENTS
INTRODUCTION.............................................................................................. 4
SAFETY ......................................................................................................... 6
2.1 General ............................................................................................................................ 6
2.2 Training ............................................................................................................................ 6
2.3 Safety Features ................................................................................................................ 6
2.4 Safety Labels ................................................................................................................... 7
2.5 Safety Precautions ........................................................................................................... 7
INSTALLATION................................................................................................ 9
3.1 Receiving and Storage ..................................................................................................... 9
3.2 Compliance with Codes ................................................................................................... 9
3.3 Placement ........................................................................................................................ 9
3.4 Electrical Connections ................................................................................................... 10
3.5 Heating Media Piping ..................................................................................................... 10
3.6 Additional Piping ............................................................................................................ 16
3.7 Water Quality & Other Considerations ........................................................................... 17
3.8 Setting the Temperature Control .................................................................................... 18
3.9 Pre-Start Check List ....................................................................................................... 24
OPERATION ...................................................................................................26
4.1 Initial Startup .................................................................................................................. 26
4.2 Shut Off Procedures....................................................................................................... 27
MAINTENANCE ..............................................................................................28
5.1 Maintenance and Inspection Schedule .......................................................................... 28
5.2 Service Tips & Troubleshooting ..................................................................................... 29
5.3 Cleaning/Inspecting the Tubes ...................................................................................... 31
5.4 Replacing the Tube Bundle ............................................................................................ 32
5.5 Servicing the Control Valve ............................................................................................ 33
5.6 Servicing the Integral Circulator ..................................................................................... 33
5.7 Recommended Spare Parts ........................................................................................... 34
5.8 After All Repairs or Maintenance ................................................................................... 34
P-K COMPACT® DIMENSION DIAGRAMS .....................................................35
6.1 P-K COMPACT® Horizontal Steam-to-Water Dimensions ............................................. 35
6.2 P-K COMPACT® Horizontal Boiler Water-to-Water Dimensions ................................... 36
6.3 P-K COMPACT® Vertical Steam-to-Water Dimensions ................................................. 37
6.4 P-K COMPACT® Vertical Boiler Water-to-Water Dimensions ....................................... 38
PARTS/TECHNICAL SUPPORT .....................................................................39
7.1 Schematic Diagrams ...................................................................................................... 40
P-K COMPACT® SPECIFIC LIMITED WARRANTY ........................................49
FIELD STARTUP INFORMATION...................................................................51
Revised: January 3, 2020 © Patterson Kelley 2020 1004905925 P-K Compact Manual (Rev C Jan-
Released: January 3, 2020 All Rights Reserved. 2020).docx
Page 2
P-K COMPACT®
Page 3
P-K COMPACT®
INTRODUCTION
This manual covers installation, operation, and maintenance of the P-K COMPACT® semi-
instantaneous water heater. While details may differ slightly, basic operation is the same for all
models. The P-K COMPACT® water heater is built to operate using steam or boiler water as the
heating medium.
The P-K COMPACT® water heater is only a part of the complete hot water supply system. The P-K
COMPACT® water heater may be fully operational and yet, because of poor circulation, controls, heat
source failure, or other operating conditions, may not deliver hot water as desired. Additional
equipment such as steam or hot water boilers, temperature sensors, pumps, flow switches or valves
will be required for satisfactory operation of any system. Patterson-Kelley cannot be held responsible
for the design or operation of such systems and a qualified engineer or contractor must be consulted.
P-K COMPACT® water heaters are completely packaged, ready to connect to services.
A standard P-K COMPACT® water heater A standard P-K COMPACT® water heater
configured for use with boiler water includes the configured for use with steam includes the
following trim: following trim:
• Shell insulated and covered with a • Shell insulated and covered with a
reinforced PVC jacket reinforced PVC jacket
• Boiler water control valve • Steam control valve
• Dual temperature limit system • Dual temperature limit system
• Circulation pump • Circulation pump
• Dial thermometer • Dial thermometer
• Relief valve • Relief valve
• Steam pressure gauge
• Steam trap
Page 4
P-K COMPACT®
SAFETY
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
serious injury, death, and/or property damage.
Installation and service must be performed by a qualified and

knowledgeable installer or service agency.
2.1 GENERAL
The P-K COMPACT® semi-instantaneous water heater must be:
Installed, operated, and serviced in accordance with instructions contained in this manual.
Installed 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 the unit until such a program has
been established.
Operated and serviced by qualified and knowledgeable personnel in accordance with all applicable
codes, laws, and regulations.
2.2 TRAINING
Proper training is the best protection against

accidents. Operating and service personnel must
be thoroughly familiar with the basic construction
and operation of the P-K COMPACT® semi-
instantaneous water heater, and all applicable
safety precautions. If any of the provisions of this
manual are not fully and completely understood,
contact the Patterson-Kelley Technical Service Department at (877) 728-5351. Please have the serial
number of the unit available. The serial number is located on the name plate attached to the main
flange. The serial number is also stamped into the tube-sheet of the bundle.
2.3 SAFETY FEATURES

It is the responsibility of the customer to maintain the safety features of this water heater such as
guards, safety labels, safety controls, interlocks and lockout devices.
Page 6
P-K COMPACT®
2.4 SAFETY LABELS

The following signal 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! - 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.
The safety labels shown below are affixed to the unit and dual language labels may also be affixed to
the unit. Although the labels are of high quality, they may become dislodged or unreadable over time.
Contact Patterson-Kelley for replacement labels.
2.5 SAFETY PRECAUTIONS

Provide a suitable location for the P-K COMPACT® water heater, 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 P-K COMPACT® water heater, all piping and
accessories.
Proper lockout/tagout procedures must be employed whenever

this unit is serviced.
2.5.1 Electrical Hazards
Shock hazard! Properly lockout/tagout the
electrical service and all other energy sources
before working on or near the water heater.
Shock hazard! Water heater is not rated for wash-
down service.
Page 7
P-K COMPACT®
2.5.2 Burn Hazards

Burn hazard! Possible hot surfaces. Do not touch the steam or hot water inlet pipes
during operation.
Burn hazard! Valve and piping should be insulated according to valve manufacturer’s
specifications to prevent contact with hot surfaces.
General Warning Burn hazard! Contains hot fluids. Allow P-K COMPACT® water heater to cool before
servicing or draining the water heater.
2.5.3 Crush Hazards
Lifting hazards! Use properly rated lifting equipment to lift and

position the P-K COMPACT® water heater. The load is Model Weight
unbalanced. Test balance before lifting 3 ft. above the floor. PK06 680 lbs
Do not allow personnel beneath the lifted load. The PK08 780 lbs
approximate weights of the P-K COMPACT® water heater PK10 1270 lbs
General Warning
models are listed in the chart at the right. Weights may vary PK12 1550 lbs
based on options and component selection.
2.5.4 Pressure Hazards

Pressure hazard! Contains hot fluids under pressure. Install isolation valves on
steam or boiler water inlet and outlet. Make sure isolation valves are closed before
servicing the P-K COMPACT® water heater.
Pressure hazard! Contains hot fluids under pressure. Test the relief valve as
recommended by the manufacturer during operation and after any prolonged period
General Warning of inactivity. Do not operate the water heater with a faulty relief valve.
2.5.5 General Hazards

Tripping hazard! Do not install piping on floor surfaces. Maintain clear path around
the P-K COMPACT® water heater.
Slip and fall hazard! Use a drip pan to catch water while draining the P-K
COMPACT® water heater. Maintain dry floor surfaces.
General Warning Bump hazard from overhead piping. Install piping with adequate vertical clearance.
Page 8
P-K COMPACT®
INSTALLATION
3.1 RECEIVING AND STORAGE
3.1.1 Initial Inspection
Upon receipt of this P-K COMPACT® semi-instantaneous water heater, please inspect the unit for any
damage. The P-K COMPACT® water heater was thoroughly inspected and tested prior to shipment.
Note any damage or shortage on the freight bill and file all claims for shortage or damage with the
carrier.
3.1.2 Storage Prior to Installation
If the P-K COMPACT® water heater 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.
3.2 COMPLIANCE WITH CODES

The P-K COMPACT® semi-instantaneous water heater is constructed and stamped in accordance with
ASME Boiler and Pressure Vessel Code, Section VIII. Other codes or approvals which apply will be
labeled on the P-K COMPACT® water heater.
Installation of the P-K COMPACT® water heater must be performed by qualified personnel. The
installation must conform to all national, state or provincial and local code requirements established by
the authorities having jurisdiction as well as specific instructions in this manual. Authorities having
jurisdiction should be consulted before installations are made.
3.3 PLACEMENT
Provide a firm, level foundation, preferably of concrete. The P-K COMPACT® water heater should be
secured to the building floor or mounting pad. Four holes are provided in the base for attachment to
the foundation. Note: Seismic anchorage information is available upon request. Contact your local
sales representative for more information.
The P-K COMPACT® water heater is top-heavy. Proper rigging techniques should be followed while
moving heavy equipment to avoid injury.
The P-K COMPACT® water heater must be plumb and level to function properly.
The P-K COMPACT® water heater should be placed with at least 10” headroom above it to permit
removal of the relief valve.
All P-K COMPACT® steam water heaters should be placed to permit gravity flow of condensate to the
condensate return system (see Section 3.5.2).
Page 9
P-K COMPACT®
3.4 ELECTRICAL CONNECTIONS

All field wiring connections for power and controls are in the junction box on the front of the P-K
COMPACT® water heater. The wiring label is attached to the inside front door of the control box. An
external electrical disconnect (not supplied with the water heater) with adequate overload protection is
required. The water heater must be grounded in accordance with national, state or provincial, and
local codes.
Connect the system to the correct voltage. The P-K COMPACT® water heater requires 120V AC, 15A
service with ground (H, N, G) supplied from a suitable circuit breaker or fused disconnect. The
circulation pump has a 120V constant speed fractional HP motor that operates continuously when the
power to the unit is on.
NOTICE! Do not operate the pump without water in the unit! Do not turn on power before filling
with water! Failure to do so can cause damage to the pump.
3.5 HEATING MEDIA PIPING

Install unit using steam or boiler water as listed on the unit. The steam or boiler water piping should be
appropriately sized and include a strainer, isolation valves and over pressure protection where
required. A self–contained, pneumatic or electric steam or boiler water control valve is required.
Connection to the valve should be made according to the installation diagrams in this manual.
Only steam or hot water heating media is to be used.
3.5.1 Steam Piping

Steam supply piping should be sized to deliver the correct volume of steam at sufficient pressure to the
control valve. Consideration should be given to steam pressure, steam volume, and supply line
pressure drop. The control valve should be mounted directly to the steam bonnet on the base of the
unit with no pipe runs between the control valve and the steam bonnet.
The steam supply, including a strainer and isolation valves, must be connected to the inlet of the
steam control valve. The strainer protects the control valve from any foreign materials carried through
the steam line. A drip leg with a condensate trap should be installed in the steam line just before the
steam valve to prevent condensate from collecting in the line. Condensate in the line may impact the
valve at such a velocity that damage to the valve could occur. A blow down valve on the wye strainer
is recommended for periodic cleaning of the strainer.
NOTICE! When installing the wye strainer in the horizontal steam piping configuration, the boss
must be in the same plane as the pipe. DO NOT point the screen at a downward angle!
Strainer Boss
Correctly installed Incorrectly Installed

Steam Wye Strainer Steam Wye Strainer
Page 10
P-K COMPACT®
3.5.2 Condensate Piping

Proper condensate drainage from the tubes of the P-K COMPACT® water heater is needed to avoid:
• Possible tube rupture
• Damage to steam traps
• Damage to the temperature control valve
• Erratic water temperature control
The P-K COMPACT® water heater requires the rapid removal of condensate that accumulates as the
heat energy from the steam is transferred into the domestic hot water. A properly sized steam trap is
supplied loose for field installation and must be piped to the condensate connection of the unit.
Condensate connection
Steam Inlet Connection
(vertical units)
The condensate connection Vertical COMPACT Stand

is at the bottom rear of the
bonnet. (refer to the bonnet
drawing at the right.) Bottom View of Steam Bonnet
NOTICE! The condensate must be drained from the P-K COMPACT® water heater into a receiver
or piping vented to atmosphere.
NOTICE! Do not attempt to lift condensate above the condensate outlet without a condensate
pump. Failure to comply will cause erratic temperature control and may result in premature tube
bundle failure.
Page 11
P-K COMPACT®
Vertical Configuration (Standard)
bundle failure.
The figure above illustrates proper piping for removal of the condensate, both in the inlet steam pipe
and from the condensate outlet for the standard (vertical) P-K COMPACT® water heater configuration.
The inlet steam pipe has an Auxiliary Steam Trap to remove any condensate that forms in the steam
supply line. This trap protects the valve and the unit from damage during operation. All condensate is
shown draining vertically downward by gravity.
The temperature control valve regulates the steam flow according to the requirements of the domestic
water flow. This regulation is accomplished by varying the orifice size of the valve while maintaining a
pressure drop across the orifice, which results in reduced pressure in the tube bundle. The reduced
pressure is not sufficient to lift the condensate above the trap level. Therefore, the condensate must
be drained from the P-K COMPACT® water heater by gravity to a floor drain or condensate return
system.
Page 12
P-K COMPACT®
Horizontal Configuration
8 5 8 5
10 0 10 0
House Recirculation
Steam Supply
Piped to drain
Cold Water Inlet
Hot Water
Piped to vented return

Piped to drain
®
Horizontal P-K COMPACT Piping Diagram
bundle failure.
The figure above illustrates proper piping for removal of the condensate, both in the inlet steam pipe
and from the condensate outlet for the horizontal P-K COMPACT® water heater configuration. The
inlet steam pipe has an Auxiliary Steam Trap to remove any condensate that forms in the steam
supply line. This trap protects the valve and the unit from damage during operation. All condensate is
shown draining vertically downward by gravity.
The temperature control valve regulates the steam flow according to the requirements of the domestic
water flow. This regulation is accomplished by varying the orifice size of the valve while maintaining a
pressure drop across the orifice, which results in reduced pressure in the tube bundle. The reduced
pressure is not sufficient to lift the condensate above the trap level. Therefore, the condensate must
be drained from the P-K COMPACT® water heater by gravity to a floor drain or condensate return
system.
Page 13
P-K COMPACT®
3.5.3 Boiler Water Piping

The boiler water supply & return piping should be sized to deliver sufficient hot water to the P-K
COMPACT® water heater without excessive pressure drop throughout its capacity range. The boiler
water supply piping should include isolation valves, strainer, pressure gauges and a drain valve as
illustrated in the piping diagrams below.
When using a two-way valve, the boiler water passes through the valve
and then through the tube bundle. On a three-way valve the valve is mounted such that the
common port (AB) faces away from the water heater.
The systems illustrated below depict two-way and three-way control valve arrangements.
The three-way control valve arrangement is recommended for boiler water applications but is not
mandatory. Use of a three-way control valve provides continuous flow through the water heater
“zone”, so that flow through the boiler is not upset when the water heater receives a call for heat.
Two-way control valves should be used only when the P-K COMPACT® water heater is piped as a
zone on the heating loop. Note that a bypass is recommended when using two-way valves to avoid
“deadhead” operation of the boiler water loop. Flow through the bypass must be adjusted to provide
sufficient flow to the P-K COMPACT® water heater at maximum capacity. When two or more water
heaters are piped in parallel, it is important that the boiler water flow is balanced through all units.
Page 14
P-K COMPACT®
3.5.4 Domestic Water Connections

NOTICE! Domestic hot water piping may be required to be separated from domestic cold-water
piping by means of an approved backflow preventer. Please refer to state and local for specific
details.
Properly sized water service lines should be connected to the heater. The domestic water piping
should include isolation valves to assist in servicing the equipment. Patterson-Kelley strongly
recommends using a circulated hot water system as illustrated below. This type of system will deliver
hot water to fixtures quickly and help to reduce the overall water usage.
When two or more heaters are piped in parallel, it is important that the piping systems are balanced to
assure the full combined capacity is realized. The branches for the building recirculation line should
also be balanced to ensure equal flow.
10 10
5 5
15 15
0 0
House Recirculation Hot Water
Cold Water Section VII RV Section VII RV

piped to drain piped to drain
Steam 10 10
Supply
5 5
15
15
0 0
Hi- Limit Hi- Limit

to drain Steam to drain
Supply
Compact Compact
Water Water
Heater Heater
10 10
5 5
15
15
0
0
Strainer* Strainer*
Condensate Return
(Drain by gravity to
vented receiver)
* Y-Strainer should be installed on it’s side

MULTIPLE UNIT PIPING on all horizontal pipe configurations.
Page 15
P-K COMPACT®
3.6 ADDITIONAL PIPING

3.6.1 Relief Valves
PRV
A Pressure and Temperature Relief Valve PTRV
(PTRV), sized to relieve the full capacity of the
water heater, is installed on the connection
provided on top of the P-K COMPACT® water Pipe to
heater. In addition, in accordance with ASME Drain Pipe to
and NBIC requireme Drain
nts, a Pressure Relief Valve (PRV) is shipped

loose and must be installed downstream from the To System
Tee
pressure temperature relief valve. The drawing to
the right illustrates the configuration for this
installation. The relief valve(s) must be piped to Tee
a drain. Decreasing the discharge pipe size or
installing any restrictions or isolation valves in the discharge piping is not permitted by code.
Failure to pipe to a drain could cause a hazardous condition as well as

flooding of the equipment room.
3.6.2 Over Temperature Control System

The high temperature limit control is located inside the control panel on each P-K COMPACT® water
heater. The high temperature limit control should be set 15°F above the desired operating
temperature. When the high temperature limit trips, the over temperature control system is activated.
The over temperature control system has three functions:
First, a ½” solenoid valve, located adjacent to the hot water outlet, opens and dumps hot water into a
drain. The solenoid valve discharge must be piped to a drain. This prevents high temperature water
from entering the hot water supply to the building. Second, as the hot water dumps to the drain, cold
water is forced to fill the system, which reduces the water temperature inside the unit. Third, the over
temperature control system isolates the steam or boiler water supply as follows:
• Pneumatic of Self-Contained: A second solenoid valve closes and cuts off the pressure
signal to the control valve, forcing the valve to close.
• Electric: The power circuit to the control valve opens, forcing the valve to close.
Failure to pipe to a drain could cause a hazardous condition as well as

flooding of the equipment room.
The over temperature control system should not be used as the operating
temperature control. Refer to Section 3.8 for adjusting the operating temperature control.
Page 16
P-K COMPACT®
3.6.3 Integral Circulator Pump

All P-K COMPACT® water heaters feature a lead-free bronze circulator pump which maintains a
constant water flow over the tube bundle. This prevents the water from stagnating inside the water
heater, maintains an accurate temperature reading at all times, and “primes” the domestic hot water
system by maintaining a constant outlet temperature. The standard recirculation pump configuration is
not intended to function as a building recirculation pump, however, the “NY Trim” recirculation pump
configuration does provide accommodations for building recirculation flow. Contact your local sales
representative for more information.
Do not run the pump dry as seal damage may occur. The system must
be filled with water and all the air must be vented from the unit before starting the pump.
The integral circulator pump is designed to provide years of trouble free service. It is recommended
that periodic inspections be made to check for potential problems with the pump. If any leakage or
evidence of leakage is present, repair or replace the pump accordingly.
3.7 WATER QUALITY & OTHER CONSIDERATIONS

The water hardness should be between 1 grain and 6 grains per gallon (17 ppm and 103 ppm). If the
water hardness exceeds these levels, water softening may be required to prevent premature tube
bundle failure.
NOTICE! Do not use deionized water with a P-K COMPACT® water heater.
Air elimination from the domestic water is extremely important in any hot water system. Ensure that
automatic air vents are installed in areas of piping that are prone to trap pockets of air.
Water hammer occurs when there are dramatic fluctuations of the water pressure inside the domestic
hot water system and can be heard throughout the domestic water piping. This can occur when the
hot water fixtures open and close too quickly, forcing the water pressure to surge momentarily. This
can also occur when the pressure reducing valve for the makeup water opens and closes too quickly,
which also forces the pressure to surge momentarily. If the domestic water system features these
types of fixtures or pressure reducing valves and water hammer is occurring, water hammer arrestors
or an expansion tank may be required to dampen the pressure spikes.
NOTICE! Water hammer can lead to premature failure of the tube bundle and baffles. Consider
including water hammer arrestors or an expansion tank to dampen the spikes in water pressure.
Page 17
P-K COMPACT®
3.8 SETTING THE TEMPERATURE CONTROL

The P-K COMPACT® water heater is available with pneumatic, self-contained or electrically operated
temperature control valves, which are described in the following sections:
3.8.1 Pneumatic Temperature Control
Read instructions and understand operation before operating or making

adjustments to the pneumatic temperature control system.
The pneumatic temperature control system (below) controls the air operated control valve (not shown)
on the P-K COMPACT® water heater. Note that this system does not require instrument quality air.
Over-temperature
15 15 Protection
10 20 10 20
Solenoid Valve
5 25 Pneumatic 5 25
Temperature
0 30 0 30
Controller
25
PSIG
Air
Supply
Combination
Pressure
Regulator and Temperature 3-15
Water Trap Adjustment Dial PSIG
Pneumatic Air Signal
Temperature to Control
Valve
Control System
The pneumatic temperature control system regulates the air pressure to the control valve based on the
outgoing domestic water temperature. The air pressure is delivered to a diaphragm on the valve body,
opening the valve. A spring return closes the valve when the air pressure is reduced or removed.
There is a manually operated dial on the front of this temperature control. To increase the domestic
water temperature, turn the dial clockwise. Turn the dial counterclockwise to decrease the domestic
water temperature.
The pilot system comes pre-assembled, with a solenoid valve that interrupts the supply of compressed
air to the diaphragm in an over-temperature condition (Section 3.6.2).
Temperature Control Set-Up
For initial valve adjustment, turn the pneumatic temperature control dial counterclockwise until it is fully
closed and apply the air pressure (0.5 CFM at 25 psi). Slowly increase the temperature dial until the
thermometer at the outlet indicates the desired water temperature.
NOTICE! Wait several cycles for the temperature to stabilize before making additional changes.
NOTICE! Do not adjust the sensitivity screw on the pneumatic temperature control system!
Page 18
P-K COMPACT®
3.8.2 Self-Contained Temperature Control
Read instructions and understand operation before operating or making

adjustments to the self-contained temperature control system.
The self-contained temperature control system (below right) does not require compressed air or an
electronic signal to operate. The pilot system shown comes pre-assembled, with a solenoid valve that
interrupts the steam supply during an over-temperature condition (Section 3.6.2).
The self-contained pilot is actuated by a
hermetically-sealed system of bellows, capillary
tube and bulb assembly. The bulb is installed in
the upper portion of the P-K COMPACT® water
heater and measures the domestic hot water
outlet temperature. As the water temperature
rises around the bulb, the volatile liquid (or gas)
inside the bulb, capillary and bellows expands
and transmits a force moving the valve stem
downward, restricting the steam supply.
Conversely, as the water temperature around the

bulb decreases, the liquid (or gas) contracts,
allowing the regulating spring to compress the
bellows and move the valve stem upwards,
increasing the steam supply. The regulator can
easily be adjusted to any point within its
temperature range (75°F – 165°F standard) by
simply rotating the adjustment wheel with the
metal rod tethered to the pilot housing.
Temperature Control Set-Up

Provide a domestic water load equal to the rated
capacity of the water heater by opening sufficient
hot water fixtures or taps in the system. Then,
open the heating medium isolation valve to allow
steam or boiler water to flow into the water
heater. Monitor the outlet temperature by
watching the dial thermometer on the top of the
P-K COMPACT® water heater. To increase the
temperature set point, turn the adjustment wheel
bushing to match the desired outlet temperature.
It is very important to wait several minutes after
each adjustment to monitor the system and
response of the P-K COMPACT® water heater to
the system conditions. Then, open the heating
medium isolation valve in small increments to
allow steam to flow into the water heater and ride gradually.
Page 19
P-K COMPACT®
3.8.3 Electronic Temperature Control
Read instructions and understand operation before operating or adjusting

the digital temperature control system.
A digital temperature controller (right) positions the valve in LOVE CONTROLS
SERIES 16B
0126
response to outlet water temperature. The controller uses a type J °F
PV
thermocouple to monitor the domestic hot water outlet temperature.
0140
°
A 4-20 milliamp signal drives the electronic valve actuator. SV C
The default screen is shown. PV - the top number (red) - is the AT OUT1 OUT2 ALM
temperature of the water in the P-K COMPACT® water heater and
SV - the lower number (green) - is the setpoint.
The index button changes the parameters displayed on the

screen. The PV line lists the parameter name and the SV line lists
the parameter value.
Press the enter button to store any value after it is changed.
The up and down buttons are used to change the values of the parameters.
Controller Operation
To change the setpoint, press the up or down buttons to change SV to the desired value. Once the
desired value is displayed, press the enter button to store the value.
The temperature control starts in the operation mode. The following table lists the operating
parameters, their factory default settings, and a description of the parameters function. Parameters
are accessed by repeatedly pressing the index key until the desired parameter is displayed.
Parameter Default Value Description of Parameter Function

Home Screen 120°F Setpoint temperature of outlet water
= Setpoint
r-S RUN Run – Stop output control.
Must be in run for control to operate
SP 0 Sets the number of digits to the
right of the decimal point
AL1H 20 Alarm 1 High Set Point,
Alarms at setpoint + AL1H value
LoC Off Set front panel security,
Off = no security, On = settings are locked
OUt1 ### Output value of controller, 0 – 100%
Page 20
P-K COMPACT®
3.8.3.1 LOVE Control Settings: Electric Actuators
Press and Hold Right Button - #1
Parameter Description Value

At Auto Tune OFF
R-5 Select Run – Stop Output Control RUN
SP Number of digits to the right of the decimal 0
AL-IH Alarm 1 High Set Point 20
LOC Set front panel security lock OFF
OUt Display the % output value for output 1 (0-100%)
Press and Hold Left Button - #3

CNPt Temperature Input Selection J
tPur Temperature Units F
tP-H Scale Height Limit 220
tP-L Scale Low Limit 25
CtrL Control Mode Pcd
S-HC Heat/Cool Selection HeAt
ALA1 Alarm 1 Setting 2
SALA System Alarm Setting OFF
COSH Communications Write Function Feature ON
C-SL Communications protocol language rtu
C-no Controller Address: Set from 1 to 247 1
bP5 Baud Rate Setting 1
Len Communication Data Length 8
PRt4 Communication Parity Bit EVEN
StoP Communication Stop Bit 1
Press #1 & #2 Together - #2

At Auto Tune OFF
PCd1 Selection of PID profile 119
SU1 Target Set Value associated with each PID 119
profile
Factory Settings:

PI Proportional Band Setting 20.0 (Proportional Band)
CI Integral time (reset time) 30.0 (Integral Band)
dI Derivative time (rate time) 0.0 (Derivative Band)
Page 21
P-K COMPACT®
3.8.4 Electric Control Valves Setup

The electric control valve MUST open when the hot water demand increases and close when the hot
water demand decreases.
If power is removed or an over-temperature condition occurs, the control

valve MUST fail in the closed position. This MUST be verified prior to placing the unit in service.
Watson McDaniel Valve Actuators:
NOTICE! A linear trim valve is typically the preferred type for steam to water heaters provided the
valve is properly sized. For water to water applications or when valve is oversized, equal
percentage valves are the preferred type.
All of the Watson McDaniel valves have a manual override control knob on the top of the valve
actuator
• A handwheel is supplied in order to operate the actuator in case of power loss or during
installation work such as mounting onto a valve or setting the limit positions.
• The handwheel is permanently engaged and turns during motor operation of the device series
PSL201‐210 and PSL214.
• The actuators PSL320 ‐ 325 have a handwheel which has to be engaged for manual operation.
The button on the cover has to be depressed to engage the handwheel
Do not exceed the adjusted electrical stroke limits by handwheel.

The mechanical limits must be set accordingly. If these instructions are not observed, it may result
in malfunction or damage to the actuator.
Do not operate the handwheel using excessive force. If these instructions

are not observed, it may result in malfunction or damage to the actuator.
Watson McDaniel Terminal connections are shown below:
Page 22
P-K COMPACT®
Siemens Valve Actuators:

All of the Siemens valves have a manual override control knob on the top of the valve actuator. The
knob must be set to “Auto” for the valve to function normally. There are three styles of actuators:
MXG/MXF, MVP and MVF. Each actuator style is slightly different in its setup configuration.
During the initial equipment startup, check the DIP switches to verify correct positioning. The DIP
switches are found inside the valve actuator’s housing. The following pictures illustrate the correct
positioning for the various valve actuators.
MXG and MXF

The MXG and MXF series actuators have 3 DIP switches labeled “1 2 3” and the ON position is
marked. These actuators have a similar setup which is shown in the image and table below:
Switch Function OFF ON Factory Setting

1 Valve Response Type Linear Equal Percent ON
Control Signal Range 0-10 VDC 2-10 VDC or ON
2
4-20 mA
3 Input Selector 0/2-10 VDC 4-20 mA ON
MVP
The MVP series actuators have no configurable components. Do not change the factory wiring.
MVF
The MVF series actuators have 3 DIP switches labeled “1 2 3” and the ON/OFF positions are marked
as shown in the image below and described in the table on the next page:
1 2 3
ON
OFF
Page 23
P-K COMPACT®
Switch Function OFF ON Factory Setting

1 Type of Control Signal Voltage milliAmps ON
0-10 VDC or 2-10 VDC or ON
2 Control Signal Range
0-20mA 4-20 mA
Vlog: Equal Vlin: Linear OFF
3 Valve Response Type
Percentage
3.9 PRE-START CHECK LIST

Before attempting to startup the P-K COMPACT® water heater for the first time, make sure the
following items have been completed.

 Ensure the P-K COMPACT® water heater is installed with the proper clearances and is firmly
anchored to the floor or support structure (Section 3.3).
 For steam-to-water units, refer to Section 3.5.1 to verify the steam piping is installed correctly
and Section 3.5.2 to verify the condensate drain piping and return system is installed correctly.
Ensure the steam and condensate piping are the proper size to handle the full design load
conditions. IMPORTANT: Ensure the steam isolation valve is fully closed before starting up
the P-K COMPACT water heater.
o Patterson-Kelley recommends a strainer on the inlet steam piping to keep foreign debris
out of the control valve. If the strainer is installed in a horizontal pipe, verify the strainer
basket is in the 3 o’clock or 9 o’clock position (Section 3.5.1).
o Verify that any condensate lift is provided by a condensate pump (Section 3.5.2).
 For boiler water-to-water units, refer to Section 3.5.3 to verify the boiler water piping is installed
correctly. Ensure the boiler water piping is the proper size to handle the full design load
conditions. IMPORTANT: Ensure the boiler water isolation valve(s) are fully closed before
starting up the P-K COMPACT water heater.
 Refer to Section 3.5.4 to verify the domestic water piping is installed correctly, and the P-K
COMPACT® water heater and domestic system have been completely filled with water and all
the air has been purged. Ensure the domestic water piping is the proper size to handle the full
design load conditions.
 Many domestic hot water systems require the use of a thermostatic mixing valve, which blends
the domestic hot water supply from the unit and the cold makeup water. If applicable, verify the
thermostatic mixing valve is installed and adjusted properly.
 Refer to Section 3.6.1 to verify the relief valve(s) have been installed correctly, and their
discharge piping is routed to a safe location at a floor drain. Ensure the discharge piping does
not reduce in size below the nominal outlet of the relief valve(s).
Page 24
P-K COMPACT®
 Refer to Section 3.6.2 to verify the discharge piping from the over temperature solenoid is
routed to a safe location at a floor drain. Ensure the discharge piping does not reduce in size
below the nominal outlet of the solenoid valve.
 Ensure there are no flammable liquids, materials or hazardous fumes present in the
environment.
 Remove all tools and unused parts that could interfere with normal operation of the P-K
COMPACT® water heater.
 Ensure that all panels, covers and guards are properly installed.
 The P-K COMPACT® water heater must be connected to a 120 volt / 60 Hz / 1 Ph power
source with proper polarity, a dedicated earth ground, and an electrical disconnect having
adequate overload protection (15 amps) according to the National Electrical Code (NFPA 70,
latest edition). Refer to Sections 7.1.1 through 7.1.6 for power and control wiring diagrams for
the different control valve offerings on the P-K COMPACT® water heater.
Page 25
P-K COMPACT®
OPERATION
The P-K COMPACT® semi-instantaneous hot water heater produces domestic hot water and is
configured to use either steam or boiler water as a heating media. A control valve regulates the
amount of steam or boiler water introduced into the tubes of the heat exchanger bundle.
The domestic water is rapidly heated as it is directed over the outside of the tubes by segmental
baffles. The circulation pump maintains proper water velocity across the tubes, allowing the P-K
COMPACT® water heater to maintain a high rate of heat transfer. Constant circulation produces
extremely high performance and precise temperature control, while mitigating scale formation in all but
the harshest hard water conditions.
The P-K COMPACT® water heater incorporates a small storage volume in order to provide the
anticipator temperature control sufficient time to respond to changing load conditions. The anticipator
temperature control is located in this storage section directly above the tube bundle.
4.1 INITIAL STARTUP

NOTICE! Do not turn on power or operate the pump until the unit is completely filled with water!
 Refer to Section 3.9 and verify all items on the Pre-Start Check List are complete.
 Open any isolation valves in the cold water makeup system, and allow the system to
completely fill with water.
 Manually open the lever on the PTRV and allow any entrained air to escape. Once water starts
to discharge from the PTRV, close the lever (Section 3.6.1).
 Before turning on the P-K COMPACT® water heater and operating the recirculation pump,
carefully check the following:
o Is the pump primed with water?
o Has the air been purged from the domestic water system?
o Is the domestic system clean and free of foreign debris?
o Does the power source agree with data on the pump motor’s nameplate?
o Is overload protection provided?
 Turn on the P-K COMPACT® water heater with the ON/OFF switch on the control panel.
(Continued on Next Page)
Page 26
P-K COMPACT®
 After turning on the P-K COMPACT® water heater, the recirculation pump will energize.
Carefully check the following:
o Is the motor rotation correct?
o Does the pump appear to be vibrating excessively?
o Does the pump operation sound smooth?
o If any of the above situations occur, immediately remove power from the P-K
COMPACT® water heater and correct before proceeding.
 Manually provide a load roughly equivalent to the full design load conditions by opening fixtures
such as faucets, showers and other hot water appliances.
 Slowly open the isolation valve on the steam supply or boiler water supply piping.
 Refer to Section 3.8 to setup and adjust the temperature setpoint:
o Section 3.8.1 for Pneumatic Temperature Control
o Section 3.8.2 for Self-Contained Temperature Control
o Section 3.8.3 for Electronic Temperature Control
NOTICE! The outlet temperature setpoint is not pre-set at the factory. The thermostat inside the
control panel serves as a high limit and MUST not be used to set the desired operation
temperature.
 Manually reduce the load to approximately ½ the full design load conditions by closing half of
the fixtures such as faucets, showers and other hot water appliances. Verify the P-K
COMPACT® water heater maintains the desired setpoint at the reduced load conditions.
 After verifying operation of the P-K COMPACT® water heater at full and reduced load
conditions, return the domestic hot water system to its normal state by closing the fixtures.
4.2 SHUT OFF PROCEDURES
4.2.1 Normal (short term) Shutdown

Simply move the ON/OFF switch on the control panel to the “OFF” position. This removes power from
the circulation pump and forces the control valve to close.
4.2.2 Extended Shutdown

For extended shut-downs, follow the following procedure:
1. Turn off power to the P-K COMPACT® water heater by moving the ON/OFF switch on the
control panel to the “OFF” position.
2. Isolate the heating media (steam or boiler water) by manually closing the isolation valve(s).
3. Open the drain valve on the heating media side to drain any remaining condensate or boiler
water out of the tube bundle and bonnet.
4. Isolate the water heater by manually closing the isolation valves on the inlet and outlet
domestic water connections.
5. Remove the drain pipe cap, or open the drain valve to drain the unit of all domestic water.
Page 27
P-K COMPACT®
MAINTENANCE
Service must be performed by an experienced and knowledgeable service

agency, such as an authorized P-K representative or qualified installer.
Proper lockout/tagout procedures must be employed when servicing this

unit.
A hazard analysis should be performed by the end user to ensure the safety of their employees and/or
service technicians. All weekly, monthly and annual maintenance checks should be performed by
experienced and knowledgeable personnel.
5.1 MAINTENANCE AND INSPECTION SCHEDULE
Label all wires prior to disconnection when servicing the controls. Wiring
errors can cause improper and dangerous operation.
The sections below provide guidance for daily, monthly and annual maintenance tasks.
5.1.1 Daily
On a daily schedule, Patterson-Kelley recommends the following inspections:
 Observe the operating temperature and general conditions.
 Determine the cause of any illuminated red indicators, unusual noises or operating conditions
and make the necessary corrections.
 Check and drain the air/water separator in the compressed air supply (pneumatic units only).
5.1.2 Monthly
In addition to the recommended daily inspections, perform the following actions on a monthly basis:
 Verify that the outlet water temperature matches the desired setpoint.
 Inspect and clean the Y-strainer in the steam or boiler water piping. Make sure to follow all
proper Lockout/tagout procedures for all energy sources.
5.1.3 Annually
In addition to the recommended daily and monthly service, perform the following on a yearly basis:
 Check all joints and pipe connections for tightness.
 Inspect the discharge piping for the relief and dump valves for blockage. Verify this piping is
unobstructed to the drain.
 Test the safety relief valve in accordance with the manufacturer’s recommendations (see relief
valve tag).
 Perform a solenoid dump valve test. Turn down the high limit control by reducing the
temperature setting below the operating temperature. Verify that the solenoid valve opens.
Page 28
P-K COMPACT®
5.2 SERVICE TIPS & TROUBLESHOOTING
Do not override or place “jumpers” on any limit device or factory setting.
Isolate and de-energize all energy sources prior to maintenance. Steam

or hot water could be released and may cause injury.
NOTICE! Consult the appropriate component manufacturer’s instructions prior to servicing.
Note that a linear trim valve is typically the preferred type for steam-to-water units, provided the control
valve is properly sized. For boiler water-to-water applications or when the control valve is oversized,
equal percentage valves are the preferred type. Improperly applied control valve types can result in
poor temperature control or erratic outlet temperatures.
Corrective Action(s)
Symptom
Steam-to-Water Boiler Water-to-Water
Check for proper operation of the Check for proper operation of the
temperature control. temperature control.
Check for proper rotation of integral Check for proper rotation of integral
circulation pump. circulation pump.
Check for flow of circulator pump. Check for flow of circulator pump.
(Be sure water is flowing through the (Be sure water is flowing through the
recirculation pipe) recirculation pipe)
1. Erratic Check valves in pipe line must be Check valves in pipe line must be
temperature control operational. operational.
Check for condensate lift and Check for proper boiler water flow.
drainage.
Check for proper steam pressure.
Check condensate traps for proper
operation.
Corrective Action(s)
Symptom
Steam-to-Water Boiler Water-to-Water
Check the setting of the temperature Check the setting of the temperature
control. control.
Check for dirt or foreign materials in Check for dirt or foreign materials in
2. Domestic water bleed ports on self-contained steam bleed ports on self-contained steam
temperature is too piloted valves. piloted valves.
high or too low.
Check for proper spring tension on Check for proper spring tension on
air operated valves. air operated valves.
Check temperature sensing element Check temperature sensing element
for malfunction. for malfunction
Page 29
P-K COMPACT®
Check for proper steam pressure. Check for proper boiler water
Check for proper air pressure on temperature and flow rate.
pneumatic valves. Check for proper air pressure on
Check condensate trap for proper pneumatic valves
operation. Shut down unit – Remove billet and
Remove bonnet and inspect steam inspect boiler water side of tubes for
side of tubes for scale or fouling (See scale or fouling (See Section 5.3).
Section 5.3). Shut down unit – Remove tube
Remove tube bundle and inspect bundle and inspect domestic water
domestic water side of tubes for side of tubes for scale or fouling
scale or fouling (See Section 5.4). (See Section 5.4).
Check for fouling of steam pilot and Check to be sure heater design
self-contained valves due to carry rating is not being exceeded (See
over of steam treatment compounds design specifications for this P-K
(steam heated units). COMPACT® water heater).
Check to be sure heater design
rating is not being exceeded (See
design specifications for this P-K
COMPACT® water heater).
Check for proper condensate
drainage.
Do not attempt to lift condensate
above the tube bundle.
3. Banging or
Check for back pressure of
pinging in heater
condensate line. (Condensate
(steam only)
should flow by gravity to a vented
receiver.)
Check condensate traps for proper
installation and orientation.
Page 30
P-K COMPACT®
5.3 CLEANING/INSPECTING THE TUBES

It is not necessary to disconnect the domestic water piping to inspect and/or service the heating
medium side of the tube bundle - the shell remains installed and in place.
1. Remove power from P-K COMPACT® water heater by turning the ON/OFF switch “OFF”.
2. Follow all proper lockout/tagout procedures.
3. Isolate the steam or boiler water supply by manually closing the isolation valve(s).
4. Isolate the domestic water system by manually closing the domestic cold water and domestic
hot water supply isolation valve(s).
5. Close recirculation line valve (if applicable).
6. Disconnect the flange or union in the steam or boiler water supply and return lines.
7. Carefully remove the nuts one-by-one from the bottom of the tube bundle flange and
disconnect piping as needed to remove the steam bonnet (Cast Iron) or boiler water billet
(Carbon Steel).
To avoid injury, ensure that all appendages are free and clear from
underneath the steam bonnet or boiler water billet when removing. The steam bonnet or boiler
water billet may be too heavy to be lifted by a single person and this operation may require
additional support or mechanical assistance (hydraulic bottle jack, manual jack, etc.).
8. After the steam bonnet or boiler water billet is removed, the tubes are now visible for
inspection. If there is a leaking tube, plug the tube as a temporary fix using either driven or
expansion type tube plugs.
9. If the tubes are fouled, clean either chemically or mechanically, as appropriate. Exercise
caution to avoid damaging the tubes.
10. Reassembly is the reverse of removal. If replacing the steam bonnet or boiler water billet, be
sure to use new gaskets supplied by Patterson-Kelley.
Page 31
P-K COMPACT®
5.4 REPLACING THE TUBE BUNDLE
The heat exchanger tube bundle is heavy and may cause injury if
improperly handled. Removal of the heat exchanger should be performed only by knowledgeable
and experienced personnel. Use appropriate rigging procedures. These procedures must be
established by end user prior to installation and operation of equipment. Owner must perform
internal hazard analysis.
To remove the tube bundle, refer to the following steps:

1. Remove power from P-K COMPACT® water heater by turning the ON/OFF switch “OFF”.
2. Follow all proper lockout/tagout procedures.
3. Isolate the steam or boiler water supply by manually closing the isolation valve(s).
4. Isolate the domestic water system by manually closing the domestic cold water and domestic
hot water supply isolation valve(s).
5. Close recirculation line valve (if applicable).
6. Disconnect the flange or union in the steam or boiler water supply and return lines.
7. Carefully remove the nuts one-by-one from the bottom of the tube bundle flange and
disconnect piping as needed to remove the steam bonnet (Cast Iron) or boiler water billet
(Carbon Steel) as described in Section 5.3.
underneath the steam bonnet or boiler water billet when removing. The steam bonnet or boiler
water billet may be too heavy to be lifted by a single person and this operation may require
additional support or mechanical assistance (hydraulic bottle jack, manual jack, etc.).
8. Carefully remove the nuts one-by-one from the top of the tubesheet studs, and carefully lower
the tube bundle to the floor.
underneath the tube bundle when removing. The tube bundle is too heavy to be lifted by a single
person and this operation may require additional support or mechanical assistance (hydraulic bottle
jack, manual jack, etc.).
9. Reinstall the existing bundle or install the new bundle in the same orientation as the original
bundle. The word “TOP” is stamped into the side of the tubesheet. “Top” MUST be facing
toward the front of the unit (vertical configuration) or top of the unit (horizontal configuration) for
proper operation. Failure to do so will cause erratic temperature control, as well as premature
tube bundle failure. Follow the procedures above in reverse order to reinstall the bundle. Be
sure to use new gaskets supplied by Patterson-Kelley.
Page 32
P-K COMPACT®
5.5 SERVICING THE CONTROL VALVE

Several different types of control valves are supplied with the P-K COMPACT® water heater and each
has unique service procedures. It is important to read the manual for the specific valve on the unit to
determine the exact service procedure. These individual manuals are available from Patterson-Kelley
upon request.
5.6 SERVICING THE INTEGRAL CIRCULATOR
The circulator requires minimal maintenance. However, periodic inspections should be made to
ensure the pump is functioning properly (See Section 3.6.3).
5.6.1 Seal Replacement (if necessary):
1) De-energize the system following proper lock out/tag out procedures.
2) Ensure that the system has been allowed to cool before removing the pump.
3) If isolation flanges are installed, close the valves on the suction and discharge sides of the
pump. If no valves have been installed on the pump, drain the system prior to pump removal.
4) Loosen the conduit box cover screw and remove the cover. The electrical supply wires to the
pump need to be disconnected. Mark or label the wires so you can install them in their proper
location when reinstalling the pump.
5) Remove the four capscrews that hold the motor housing to the pump body and separate the
housing from the pump body. The volute does not need to be removed from the piping.
6) Place the pump on a flat work surface, insert a screwdriver into one of the endplate ventilation
slots until it engages one of the rotor cooling fins. Hold the rotor with the screwdriver and rotate
the impeller clockwise. The impeller is molded around a metal hub with a left hand thread.
7) Remove the impeller from the shaft.
8) Next, remove the seal assembly from the shaft by sliding it off the shaft sleeve. Clean the seal
seat with a clean rag and inspect for grooving or cracks. If it shows no grooving or cracks, it
may be cleaned and reused.
a. If the seat seal is to be replaced, the face plate must be removed from the motor
housing. Remove it by gently prying it away from the housing.
b. Remove the seat seal and cup. Lubricate the cup with soapy water and install new
parts in the face plate
recess. Reposition the face
plate on the motor housing.
Gently tap the face plate
evenly around its diameter to
drive it into the recess
provided in the motor
housings.
9) Clean the shaft and sleeve before
installing the new seal.
10) Slide the carbon seal head onto the
shaft sleeve until it contacts the seal
seat.
Page 33
P-K COMPACT®
11) Slide the new “O-ring” and back-up ring along the shaft sleeve until they fit inside the counter
bore in the seal head. Place the seal spring between the back-up ring and the seal cage while
positioning the seal cage flush with the end of the sleeve.
12) Place the small end of the spring against the back-up ring. The three driving legs of the seal
cage should engage the three slots on the seal head.
13) While holding the rotor assembly with the screwdriver, thread the impeller onto the shaft in a
counter clockwise direction. Tighten the impeller with light hand pressure. Take care to avoid
bending a rotor cooling fin or damaging the shaft sleeve.
14) Clean the recess in the pump body and install a new body gasket.
15) Install the pump in the body and secure with four capscrews. Apply torque evenly in a
crisscross pattern in 40 in-lb increments to a torque of 80 in-lb.
16) Rewire the pump to the unit following the labels used when disconnecting the pump.
17) Reinstall the conduit box cover and secure with the cover screw. If isolation flanges were
installed, open the valves, otherwise refill the system with water.
18) Ensure all the air has vented out of the unit and the pump’s rotor has been wetted. Follow the
Initial Start-Up instructions in Section 4.1.
Before operating the pump, carefully check:

Is the pump primed? Has the air been purged from the system?
Is the pump motor’s rotation correct?
Is the system clean and free of debris?
5.7 RECOMMENDED SPARE PARTS

 Circulator Pump: bearing and seal assembly.
 Dial Thermometer
 Temperature sensor – T/C for electric controls only or pilot for self-contained valves
 Relief Valve
 Thermostat for over-temperature control
 Solenoid valve: 3-way for pneumatic, 2-way for self-contained.
 Replacement tube bundle
 Tube bundle gaskets
 Steam trap cage unit (if used)
 Pressure gauge (for steam)
NOTICE! When ordering parts, always mention the Serial Number, part name and model and the
size of the part needed.
5.8 AFTER ALL REPAIRS OR MAINTENANCE
1. Follow "Pre-Start Check List" (Section 3.9)

2. Turn on the P-K COMPACT® water heater and verify integral circulator operation.
3. Verify operation, setpoint, and domestic water temperature (Section 4.1)
Page 34
P-K COMPACT®
P-K COMPACT® DIMENSION DIAGRAMS

6.1 P-K COMPACT® HORIZONTAL STEAM-TO-WATER DIMENSIONS
Page 35
P-K COMPACT®
6.2 P-K COMPACT® HORIZONTAL BOILER WATER-TO-WATER DIMENSIONS
Page 36
P-K COMPACT®
6.3 P-K COMPACT® VERTICAL STEAM-TO-WATER DIMENSIONS
Weight
Model A A1 A2 B B1 D E F G I J K L M
(lbs)
PK06S 1-½ 69-1/8 X 2 31-1/8 22-1/4 18- 1/8 8 12 15 20 78 85 ¾ 630
PK06D 1-½ 69-1/8 X 2 31-1/8 20-5/8 16-½ 8 12 15 20 78 85 ¾ 650
PK08S 2 69-¼ X 3 31-3/8 22-1/2 18 8-¾ 13-¾ 15 20 78 84 1-½ 730
PK08D 2 69-¼ X 3 31-3/8 21-1/2 17 8-¾ 13-¾ 15 20 78 84 1-½ 760
PK10S 2-½ 72-¾ X 3 31-1/2 22-5/8 17 12 14-¾ 19 24 81-½ 89 2 990
PK10D 2-½ 72-¾ X 3 31-1/2 21-5/8 16 12 14-¾ 19 24 81-½ 89 2 1040
PK12S 4 X 85-½ 5 41-3/8 29 23 11-¼ 18 29 34 97-¾ 101 2 1200
PK12D 4 X 85-½ 5 41-3/8 27-7/8 27-7/8 11-¼ 18 29 34 97-¾ 101 2 1300
Dimensions in Inches Rough-in Dimensions Only
Seismic Support Stand Available
1. PK12 Units inlet and outlet connections are ANSI 150# Flanged.
2. Single Wall Unit Represented. See chart for different dimensions between single and double wall.
3. Pressure only relief valve shipped loose and must be installed by contractor in field as shown.
4. A2 is Outlet height for PK12 Compacts.
Page 37
P-K COMPACT®
6.4 P-K COMPACT® VERTICAL BOILER WATER-TO-WATER DIMENSIONS
Model WEIGHT
A A1 A2 B B1 D E F G
Number (lbs)
PK06S 1-1/2 69-1/8 X 2 31-1/8 15 20 78 85 630
PK06D 1-1/2 69-1/8 X 2 31-1/8 15 20 78 85 650
PK08S 2 69-1/4 X 3 31-3/8 15 20 78 84 730
PK08D 2 69-1/4 X 3 31-3/8 15 20 78 84 760
PK10S 2-1/2 72-3/4 X 3 31-1/2 19 24 81-1/2 89 990
PK10D 2-1/2 72-3/4 X 3 31-1/2 19 24 81-1/2 89 1040
PK12S 4 X 85-1/2 5 41-3/8 29 34 97-3/4 101 1200
PK12D 4 X 85-1/2 5 41-3/8 29 34 97-3/4 101 1300
Dimensions in Inches Rough-in Dimensions Only
Seismic Support Stand Available
1. PK12 Units inlet and outlet connections are ANSI 150# Flanged.
2. Single Wall Unit Represented. See chart for different dimensions between single and double wall.
3. Pressure only relief valve shipped loose and must be installed by contractor in field as shown.
4. A2 is Outlet height for PK12 Compacts.
Page 38
P-K COMPACT®
PARTS/TECHNICAL SUPPORT
Spare parts and replacement parts can be ordered from your local representative. For assistance in
determining part numbers, call your local rep or Patterson-Kelley at (877) 728-5351. Refer to the parts
list shown on the assembly drawing provided with this manual. Factory direct replacement parts must
be used to ensure that the water heater operates correctly. When ordering replacement parts please
have the Serial Number of your P-K COMPACT® water heater available.
Use of Non-Factory-Authorized replacement parts are not recommended

for this equipment. All control components are engineered for safety and are designed to work with
each of the other components. Use of non-factory-authorized replacement parts could jeopardize
the functionality of the safety features and the performance of the equipment.
Technical information is also available at the above number or at the Patterson-Kelley website
www.pattersonkelley.com.
Page 39
P-K COMPACT®
7.1 SCHEMATIC DIAGRAMS
The image below is representative of a standard (vertical) steam-to-water Compact with no control
valve. Detailed as-built drawings of the P-K COMPACT® water heaters can be supplied by your local
Patterson-Kelley representative.
PTRV
Relief Valve Solenoid Dump
Valve
Hot Water
Outlet
Control Panel
Circulator Pump
Cold Water
Inlet
Tube Bundle
Steam Inlet Vacuum Breaker
Page 40
P-K COMPACT®
The image below is representative of a horizontal boiler water-to-water Compact with electric control
valve. Detailed as-built drawings of the P-K COMPACT® water heaters can be supplied by your local
Patterson-Kelley representative
Control Panel
PTRV
Boiler Relief Valve
Tube Bundle Water Inlet
Hot Water
Outlet
Cold Water Solenoid Dump

Inlet Valve
Circulator Pump
Page 41
P-K COMPACT®
7.1.1 Wiring Diagram for Pneumatic & Self-Contained Temperature Control
Page 42
P-K COMPACT®
7.1.2 Wiring Schematic for Pneumatic & Self-Contained Temperature Control w/ Alarm Relay
Page 43
P-K COMPACT®
7.1.3 Wiring Schematic for Pneumatic & Self-Contained Temperature Controls w/ Alarm Relay
& Local Alarm
Page 44
P-K COMPACT®
7.1.4 Wiring Schematic for Electric Temperature Control (Siemens MXG/MXF/MVF Actuators)
Page 45
P-K COMPACT®
7.1.5 Wiring Schematic for Electric Temperature Control (Siemens M3P Actuators)
Page 46
P-K COMPACT®
7.1.6 Wiring Schematic for Electric Temperature Control (Watson McDaniel Actuators)
Page 47
P-K COMPACT®
7.1.7 Tube Bundle Types
Single Wall Double Wall

Tube Bundle Tube Bundle
Page 48
P-K COMPACT®
P-K COMPACT® SPECIFIC LIMITED WARRANTY
Subject to the terms and conditions herein and the Terms and Conditions of Sale (as defined herein), Patterson-Kelley
(“Seller”) provides to the purchaser of the product (“Buyer”) non-prorated warranties for the following components of the P-K
COMPACT®, when operated in accordance with the conditions stated herein, against the indicated failures and for the
indicated periods commencing on the date of shipment or, if a start-up report is furnished to Seller, on the start-up date shown
on the report furnished to Seller (the “Warranty Period”), provided that startup is completed within six (6) months of shipment
and the start-up report is furnished to Seller within thirty (30) days of startup (this “Specific Limited Warranty”):
• tube bundle assembly for 10 years against failure due to thermal shock or mechanical failure,
• pressure vessel for 20 years against leakage and
• Anticipator® temperature control (self-contained and pneumatic control) for 20 years against any failure.
The Exclusions and limitations of liability set forth in the Terms and Conditions of Sale (as defined herein) apply to this
Specific Limited Warranty. Capitalized terms used but not defined herein have the meanings ascribed to them under Seller’s
terms and conditions of sale for the product, which can be found at http://pattersonkelley.com/warranty.php (the “Terms and
Conditions of Sale”). This Specific Limited Warranty is transferrable to the owner that utilizes the product(s) purchased
hereunder for its intended use at the original installation site (the “Original Owner”). This Specific Limited Warranty is non-
transferable to anyone who subsequently receives or purchases products from the Original Owner. If the Original Owner did
not purchase the product directly from Seller, the Original Owner should contact the reseller from whom it purchased the
product for a copy of the Terms and Conditions of Sale attached to the Order Acknowledgement received by the original
purchaser of the product from Seller.
I. REMEDY
Seller’s obligations under this Specific Limited Warranty is limited to repairing or, if in Seller’s judgment it seems more
appropriate, to furnishing without charge (installation not included), FCA Seller’s factory (Incoterms 2010), a similar part to
replace any part which after examination shall, to Seller’s own satisfaction be determined to have been defective at the time it
was shipped. In the event that a replacement is provided by Seller, the defective item will become the property of Seller.
Transportation to Seller’s facility or other designated facility for repairs of any products or party alleged defective shall, in all
events, be at Buyer’s sole risk and cost. This warranty applies only if the original installer and Seller (Attention: Patterson-
Kelley, 155 Burson Street, East Stroudsburg, PA 18301) receive, within the Warranty Period, an immediate written notice,
providing a detailed description of all claimed defects, upon discovery of such defects together with proof of purchase (invoice
or Order Acknowledgment) and a copy of the start-up report for the affected product. Seller may seek reimbursement of any
costs incurred by Seller where the product is found to be in good working order, or when it has been determined that this
Specific Limited Warranty does not apply as per the exclusions set forth below. The remedies available to Buyer set forth
herein are exclusive remedies, and all other remedies, statutory or otherwise, including but not limited to the right of
redhibition, are waived by Buyer. Buyer acknowledges that the exclusion of remedies is neither unreasonable nor
unconscionable. Buyer shall indemnify and hold Seller harmless against, any claim due to any injury or death to any person
or damage to any property resulting in whole or in part from any modification or alteration Buyer makes to any product sold
hereunder.
II. EXCLUSIONS
To the full extent permitted by law, Seller shall have no liability for and the Warranties do not cover:
(A) any product which has been altered or repaired by other than Seller's personnel;
(B) deterioration or failure of any product due to
(i) abrasion, corrosion, erosion or fouling,
(ii) misuse,
(iii) modification not authorized by Seller in writing or
(iv) improper installation, lack of or improper maintenance or operation;
(C) equipment not furnished by Seller, either mounted or unmounted, or when contracted for by a party or parties other than
Seller to be installed or handled;
(D) the suitability of any product for any particular application;
(E) the design or operation of owner’s plant or equipment or of any facility or system of which any product may be made a
part;
(F) any damage to the product due to abrasion, erosion, corrosion, deterioration, abnormal temperatures or the influence of
foreign matter or energy;
(G) the performance of any product under conditions varying materially from those under which such product is usually tested
under industry standards at the time of shipment;
Page 49
P-K COMPACT®
(H) leakage or other malfunction caused by:
(i) defective installations in general and specifically, any installation which is made
(a) in violation of applicable state or local plumbing, housing or building codes or
(b) contrary to the written instructions furnished with the product,
(ii) adverse local conditions in general and, specifically, sediment or lime precipitation in the tubes, headers and/or
shells or corrosive elements in the water, heating medium or atmosphere, or
(iii) misuse in general and, specifically, operation and maintenance contrary to the written instructions furnished with
the unit, disconnection, alteration or addition of components or apparatus, not approved by Seller, operation with
heating media, fuels or settings other than those set forth on the rating plate or accidental or exterior damage;
(I) production of noise or odors;
(J) discoloration or rusty water caused by piping, fittings, valves, pumps or other sources outside of the P-K COMPACT®;
(K) damage to surrounding area or property caused by leakage or malfunction;
(L) costs associated with the replacement and/or repair of the unit including: any freight, shipping or delivery charges, any
removal, installation or reinstallation charges, any material and/or permits required for installation, reinstallation or repair,
charges to return the P-K COMPACT® or components;
(M) INCIDENTAL, SPECIAL OR CONSEQUENTIAL DAMAGES, SUCH AS LOSS OF THE USE OF PRODUCTS,
FACILITIES OR PRODUCTION, INCONVENIENCE, LOSS OF TIME OR LABOR EXPENSE INVOLVED IN REPAIRING OR
REPLACING THE ALLEGED DEFECTIVE PRODUCT;
(N) any claim due to any injury or death to any person or damage to any property resulting in whole or in part from any
modification or alteration Buyer makes to any product sold hereunder; and
(O) design defects where Seller has complied with Buyer’s design specifications.
III. PROOF OF PURCHASE
Proof of purchase (invoice or Order Acknowledgement) and a copy of the start-up report for the affected product must be
provided to Seller when requesting service under this Specific Limited Warranty.
IV. ORDER OF PRECEDENCE
The Standard Limited Warranty set forth in the Terms and Conditions of Sale, (b) this Specific Limited Warranty and (c) any
applicable Extended Limited Warranty exclusively govern and control Seller’s and Buyer’s rights and obligations regarding the
warranty of the products. In case of any inconsistency, conflict, or ambiguity between the Standard Limited Warranty, this
Specific Limited Warranty and any applicable Extended Limited Warranty (collectively, the “Warranty Documents”), the
documents shall govern in the following order: (w) any applicable Extended Limited Warranty; (x) this Specific Limited
Warranty; (y) the Standard Limited Warranty and (z) other provisions in the Terms and Conditions of Sale. Information
identified in one Warranty Document and not identified in another shall not be considered a conflict or inconsistency. No
sales representative, agent, or employee of Seller or any reseller in the chain of sale of the product is authorized to make any
modification, extension, or addition to this Specific Limited Warranty, unless agreed to in writing by Seller.
Page 50
P-K COMPACT®
FIELD STARTUP INFORMATION
Installed Location
______________________________
______________________________
______________________________
Type of Building ______________________________
Serial Number ______________________________
Contractor/Installer ______________________________
Contractor/Startup ______________________________
Domestic Water Supply

Rating: _____________ GPM supply
from _____________ °F. to _____________ °F
Hardness GR or PPM (Select)
Heating Medium
Steam Line Pressure _____________ P.S.I.G.

Or
Boiler Water _____________ GPM supply
at _____________ °F. to _____________ °F
Submit to: Patterson-Kelley

155 Burson Street
East Stroudsburg, PA 18301
Attention: Customer Service
Email: pkcboilersales@spx.com
Fax: (570) 476-7247
Page 51

P K Compact Manual Rev C Jan 2020

Uploaded by

Copyright:

Available Formats

P K Compact Manual Rev C Jan 2020

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

P K Compact Manual Rev C Jan 2020

Uploaded by

Copyright:

Available Formats

P-K COMPACT® (All models)

ASME Code, Section VIII

Installation Date: _______________________

© 2020 Patterson-Kelley, All Rights Reserved

It is essential to read, understand, and follow the recommendations of

Installation and service must be performed by a qualified and

Proper training is the best protection against

2.3 SAFETY FEATURES

2.4 SAFETY LABELS

indicates an imminently hazardous situation which, if not avoided, will

indicates a potentially hazardous situation which, if not avoided, could

indicates a potentially hazardous situation which, if not avoided, may result

2.5 SAFETY PRECAUTIONS

Proper lockout/tagout procedures must be employed whenever

2.5.2 Burn Hazards

Lifting hazards! Use properly rated lifting equipment to lift and

2.5.4 Pressure Hazards

2.5.5 General Hazards

3.2 COMPLIANCE WITH CODES

3.4 ELECTRICAL CONNECTIONS

3.5 HEATING MEDIA PIPING

Only steam or hot water heating media is to be used.

3.5.1 Steam Piping

Correctly installed Incorrectly Installed

3.5.2 Condensate Piping

The condensate connection Vertical COMPACT Stand

Vertical Configuration (Standard)

Piped to vented return

3.5.3 Boiler Water Piping

3.5.4 Domestic Water Connections

House Recirculation Hot Water

Cold Water Section VII RV Section VII RV

Hi- Limit Hi- Limit

* Y-Strainer should be installed on it’s side

3.6 ADDITIONAL PIPING

nts, a Pressure Relief Valve (PRV) is shipped

Failure to pipe to a drain could cause a hazardous condition as well as

3.6.2 Over Temperature Control System

Failure to pipe to a drain could cause a hazardous condition as well as

3.6.3 Integral Circulator Pump

3.7 WATER QUALITY & OTHER CONSIDERATIONS

3.8 SETTING THE TEMPERATURE CONTROL

Read instructions and understand operation before operating or making

3.8.2 Self-Contained Temperature Control

Read instructions and understand operation before operating or making

Conversely, as the water temperature around the

Temperature Control Set-Up

3.8.3 Electronic Temperature Control

Read instructions and understand operation before operating or adjusting

The index button changes the parameters displayed on the

Press the enter button to store any value after it is changed.

Parameter Default Value Description of Parameter Function

Parameter Description Value

Press and Hold Left Button - #3

Parameter Description Value

Press #1 & #2 Together - #2

Parameter Description Value

Parameter Description Value

3.8.4 Electric Control Valves Setup