Harsco Industrial P-K DURATION II D2DW-30(S/D), P-K DURATION IID2DW-80(S/D) Installation & Owner's Manual
P-K Duration II D2DW-30&D2DW-80
Rev. 1.00 (10/1/2015)
P-K DURATION II™
D2DW-30(S/D) & D2DW-80(S/D)
(S-Simplex D-Duplex)
INSTANTANEOUS INDIRECT
DOMESTIC HOT WATER SYSTEM
Model #:_______ Serial #______________________
Start-Up Date: _______________________
Harsco Industrial, Patterson-Kelley
155 Burson Street
East Stroudsburg, PA 18301
Telephone: 570.476.7261
Toll Free: 877.728.5351
Facsimile: 570.476.7247
www.harscopk.com
©2015 Harsco Industrial, Patterson-Kelley PN: 1004905970
Printed: 11/11/2015
P-K DURATION II ™ Indirect Domestic Water Heating System
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1 ..... INTRODUCTION ................................................................................................................................................ 4
2 ..... SAFETY .............................................................................................................................................................. 4
2.1 General ............................................................................................................................................. 4
2.2 Training ............................................................................................................................................. 5
2.3 Safety Features ................................................................................................................................ 5
2.4 Safety Labels .................................................................................................................................... 5
2.5 Safety Precautions ........................................................................................................................... 6
3 ..... INSTALLATION .................................................................................................................................................. 7
3.1 Receiving and Storage ..................................................................................................................... 7
3.2 Compliance with Codes .................................................................................................................... 8
3.3 Setup ................................................................................................................................................ 8
3.4 Mechanical Connections .................................................................................................................. 9
3.5 Electrical Connections .................................................................................................................... 15
3.6 Pre-Start Check List ....................................................................................................................... 16
3.7 Safety Checks ................................................................................................................................. 16
4 ..... OPERATION ..................................................................................................................................................... 17
P-K DURATION II ™ Indirect Domestic Water Heating System
4.1 LOVE Controller.............................................................................................................................. 17
4.2 Setup of the Electric Valve ............................................................................................................. 18
5 ..... MAINTENANCE ............................................................................................................................................... 19
5.1 Maintenance and Inspection Schedule .......................................................................................... 19
5.2 Troubleshooting .............................................................................................................................. 19
6 ..... PARTS/TECHNICAL SUPPORT ..................................................................................................................... 21
6.1 RECCOMENDED SPARE PARTS ................................................................................................. 21
6.2 Wiring Diagram ............................................................................................................................... 22
6.3 Models ............................................................................................................................................ 23
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P-K DURATION II ™ Indirect Domestic Water Heating System
1 INTRODUCTION
This manual describes the installation and operation of the P-K Duration II Semi-instantaneous indirect domestic
hot water system. It is important to note that the P-K Duration II is designed to operate in conjunction with a
complete hydronic system and does require an external source of hot boiler water. The available boiler water
temperature will have a profound impact on the performance and capacity of the P-K Duration II, and it must
always exceed the desired domestic hot water supply temperature.
If you have any questions on the information contained within, or do not fully and completely understand the
content, please contact Harsco Industrial, Patterson-Kelley Technical Service at 570.476.7261 or toll free at
877.728.5351.
The P-K Duration II system is only a part of a complete water heating system. This add-on package may be fully
operational and yet because of poor circulation, control, or other operating characteristics not deliver hot water to
the desired location. Additional equipment such as pumps, flow switches, balancing valves, and check valves
may be required for satisfactory operation of any system. Harsco Industrial, Patterson-Kelley cannot be
responsible for the design or operation of such systems and a qualified engineer or contractor must be consulted.
2 SAFETY
2.1 GENERAL
The P-K Duration II instantaneous indirect domestic hot water system must be:
Installed, operated, and serviced in accordance with instructions contained in this manual and other
supplemental manuals.
Installed by qualified personnel in accordance with designs prepared by qualified facility engineers including:
structural, mechanical, electrical, and other applicable disciplines.
Operated and serviced in accordance with a comprehensive safety program determined and established by
the customer. Do not attempt to operate or service until such a program has been established.
Operated and serviced by experienced, qualified, and properly trained personnel in accordance with all
applicable codes, laws, and regulations.
NOTICE! Each safety device must be maintained and checked per the recommended schedule. Refer to
Section 3.7 of this manual.
The P-K Duration II is a dynamic system that is designed to heat domestic hot water to
a wide range of temperatures. The P-K Duration II system is capable of heating water to scalding temperatures.
Refer to your local codes for guidelines on compliance for domestic hot water systems. A thermostatic mixing
valve or other device may be required to prevent scalding.
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2.2 TRAINING
Proper training is the best protection against accidents. Factory training sessions are available to qualified
individuals who are sponsored by the local Harsco Industrial, Patterson-Kelley representative.
Operating and service personnel must be thoroughly familiar with the basic construction of the P-K Duration II
system, the location and operation of the controls, 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
Harsco Industrial, Patterson-Kelley Technical Service at 570.476.7261 or toll free at 877.728.5351.
2.3 SAFETY FEATURES
It is the responsibility of the customer to maintain the safety features, such as but not limited to: guards, safety
labels, safety controls, interlocks, lockout devices and pressure relief valves.
P-K DURATION II ™ Indirect Domestic Water Heating System
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.
2.4 SAFETY LABELS
The following words are used in this manual to de-note 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.
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Model
Weight in Pounds
D2DW-30S Simplex
950 lbs.
D2DW-30D Duplex
1590 lbs.
D2DW-80S Simplex
1005 lbs.
D2DW-80D Duplex
1700 lbs.
Hot Surface
General Warning
General Warning
P-K DURATION II ™ Indirect Domestic Water Heating System
2.5 SAFETY PRECAUTIONS
Provide a suitable location for the P-K Duration II system, 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 Duration II system, all piping, and accessories.
2.5.1 Electrical Hazards
Shock hazard! Properly lockout/tag out the electrical service and all
other energy sources before working on or near the P-K Duration II.
Shock hazard! Do not spray water directly on this system or on any
electrical components.
Electrical hazard! Do not alter wiring connections.
2.5.2 Burn, Fire, and Explosion Hazards
Burn hazard! Possible hot surfaces. Pipes and internal components could be hot.
Do not touch piping or internal components during operation or immediately after
shutdown of the boiler.
Burn hazard! Hot fluids. Use caution when servicing or draining the P-K Duration
II system.
Isolation valves are provided on all inlets and outlets for your convenience. Close
the applicable isolation valves and allow the P-K Duration II to cool down to
ambient temperature before servicing.
The P-K Duration II is a dynamic system that is designed to heat domestic hot water to
a wide range of temperatures. The P-K Duration II system is capable of heating water to scalding temperatures.
Refer to your local codes for guidelines on compliance for domestic hot water systems. A thermostatic mixing
valve or other device may be required to prevent scalding.
2.5.3 Crush Hazards
Lifting hazards! Use properly rated lifting equipment to lift and position the P-K
Duration II system. The load is unbalanced. Test balance before lifting 3 ft. above
the floor. Do not allow personnel beneath the lifted load. Refer to approximate
weights in the table.
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General Warning
General Warning
General Warning
P-K DURATION II ™ Indirect Domestic Water Heating System
2.5.4 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.
2.5.5 Pressure Hazards
Pressure hazard! Hot fluids. Isolation valves are provided on all inlets and outlets for
your convenience. Make sure all isolation valves are closed before servicing.
Pressure hazard! Hot fluids. Annually test safety relief valve for proper operation.
Do not operate with faulty relief valve(s).
2.5.6 Slip, Fall Hazards
Tripping hazard! Do not install piping on floor surfaces. Maintain clear path around
the P-K DURATION II™ system.
Slip and fall hazard! Use drip pan to catch water while draining. Maintain dry floor
surfaces.
Fall hazard! Do not stand on the P-K DURATION II™ system.
3 INSTALLATION
Installation and service must be performed by a qualified installer, service agency,
or gas supplier.
3.1 RECEIVING AND STORAGE
3.1.1 Initial Inspection
Upon receiving the P-K Duration II system, inspect it for signs of shipping damage. Since some damage
may be hidden, unpack the product, open the front, and side doors to inspect. 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.
3.1.2 Storage Prior to Installation
If the P-K Duration II system 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.
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Clearance Dimensions
A
24”
B
18”
C
36”
B
P-K DURATION II ™ Indirect Domestic Water Heating System
3.2 COMPLIANCE WITH CODES
The brazed plate heat exchanger is constructed and stamped in accordance with ASME Boiler and Pressure
Vessel Code, Section VIII, Division 1 for 219 psig maximum operating pressure. However, certain components in
the domestic piping have a maximum pressure rating of 150 psig. Therefore, the domestic side pressure must
never exceed 150 psig.
The pressure-only relief valve in the domestic piping is constructed and stamped in accordance with ASME Boiler
and Pressure Vessel Code, Section VIII with a standard 150 psig set pressure.
3.3 SETUP
3.3.1 Foundation and Placement
Provide a firm, level foundation, preferably of concrete. The P-K Duration II system must be level to function
properly. Consult with a certified Professional Engineer regarding any seismic anchoring requirements.
3.3.2 Clearances
Since the P-K Duration II instantaneous indirect domestic hot water system is designed to operate in potentially
remote mechanical rooms, it requires sufficient clearance for service and operation.
3.3.2.1 Clearance Figure
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A B D
C
A
B
C
D
Simplex Model
Duplex Model
3.4 MECHANICAL CONNECTIONS
The P-K Duration II system is designed to provide substantial domestic hot water capacity in a 32” wide x 64” long
footprint and requires four (4) piping connections to operate as seen below:
A. DHW Supply (2” Sweat Ball Valve)
B. DHW Return (2” Sweat Ball Valve)
3.4.1 Connection Figure
P-K DURATION II ™ Indirect Domestic Water Heating System
C. Boiler Water Inlet (2” NPT Ball Valve/Grooved)
D. Boiler Water Outlet (2” NPT Ball Valve/Grooved)
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