Harsco Industrial P-K SONIC SC-3000, P-K SONIC SC-4000 Installation & Owner's Manual

revised June 12, 2014

1004905898

InstallatIon

owner’s

P-K SONIC™ GaS FIred BOIler

SC-3000/SC-4000 Natural Gas/Propane/dual Fuel

C.S.A Design-Certied

Complies with ANSI Z21.13/CSA 4.9

Gas-Fired Low Pressure Steam and Hot Water Boilers

ASME Code, Section IV Certied by Patterson-Kelley

manual

InstallatIon

owner’s

manual

InstallatIon

owner’s

manual

InstallatIon

owner’s

manual

InstallatIon

owner’s

C.S.A Design-Certied Complies with ANSI Z21.13/CSA 4.9

CERTIFIED

Part Number

Model Number:

Serial Number:

Start-Up Date:

Harsco Industrial, Patterson-Kelley 155 Burson Street East Stroudsburg, PA 18301

Telephone: 570.476.7261 Toll Free: 877.728.5351

Fax: 570.476.7247 www.harscopk.com

SONIC201

Gas-Fired Low Pressure Steam and Hot Water Boilers

manual

InstallatIon

owner’s

manual

InstallatIon

owner’s

manual

InstallatIon

owner’s

manual

InstallatIon

owner’s

manual

Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351

Gas Fired Boiler

Installation and Operation Best Practices

Gas

•Use a lock-up type regulator.

•Minimum gas inlet pressure 4.5" wc

•Maximum gas inlet pressure 14" wc

Electrical

•Verify power requirements to boiler.

•Check all electrical connections for tightness as connections may come lose during

shipping.

Venting

•Maintain exhaust pressure from -.04" wc to +.22" wc

Hydronics

•Maximum Flow:

SC-4000 384 gpm, SC-3000 285 gpm

•Minimum Flow @ Ignition: SC-4000 98 gpm,

SC-3000 72 gpm

•Minimum Flow: SC-4000 76 gpm, SC-3000 57 gpm

•Boiler is provided with two (2) relief valves - a Section VIII and a Section IV. Both

must be installed as per ASME and local code requirements. A reference to potential installation arrangement is discussed in Section 3.7.3 of this manual.

Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351

Gas Fired Boiler

TABLE OF CONTENTS

Table of ConTenTs

1 InTroduCTIon 4 2 s

afeTy 5

2.2 Safety Precautions 5

2.3 Training 6

2.4 Hazard Warnings 6

2.4.1 Electrical Hazards 6

2.4.2 Crush Hazards 6

2.4.3 Bump Hazards 6

2.4.4 Pressure Hazards 6

2.4.5 Slip, Fall Hazards 6

2.4.6 Chemical Hazards 7

2.4.7 Burn, Fire and Explosion Hazards 7

3 InsTallaTIon 8

3.1 Receiving and Storage 8

3.2 Compliance with Codes 8

3.3 Setup 8

3.3.1 Foundation 8

3.3.2 Placement 8

3.3.3 Clearances 8

3.4 Electrical Connections 9

3.4.1 The Power Input Junction Box 9

3.4.2 High Voltage (TB2) Terminal Block 10

3.5 Inlet Air and Exhaust Venting 11

3.5.1 Applicable Codes and Standards 11

3.5.1.1 Gas Vent Categories 12

3.5.1.2 Venting Materials for Flue/Exhaust Systems 12

3.5.2 Combustion Air Materials and Sizes 13

3.5.2.1 Air Inlet Requirements — United States 14

3.5.2.2 Air Inlet Requirements – Canada 14

3.5.3 Flue Venting 15

3.5.3.1 Vent Sizing 15

3.5.3.2 Required Clearances 16

3.5.3.3 Flue Connection 17

3.5.3.4 Vent Termination 17

3.5.4 Venting for Multiple Boilers 17

3.5.5 Sealed Combustion/Direct Vent Systems 18

3.5.5.1 Inlet Duct Connection to Boiler 18

3.5.5.2 Intake Duct Materials and Sizes 18

3.5.6 Removing an Existing Boiler 18

3.6 Gas Piping 19

3.6.1 Gas Supply Piping by Installer 19

3.7 Boiler Water Piping 20

3.7.1.2 Piping with Air Handling Units 20

3.7.1.1 Piping with Refrigeration Lines 20

3.7.2 Boiler Inlet and Outlet Connections 20

3.7.3 Boiler Water Piping by Installer 21

3.7.4 Flushing and Filling 21

3.8 Pre-Start Checklist 22

3.9 Safety Checks 22

3.9.1 Test of Ignition Safety System 22

3.9.2 Test of Low Water Cut-out 22

3.9.3 Test of High-Limit Control 23

3.9.4 Test of Gas Pressure Switches 23

3.10 Initial Adjustments 23

3.10.1 Operating Temperature Controller 23

3.10.2 Boiler Set Point 24

3.10.3 Other CH Parameters 24

3.10.4 Other Parameters 24

3.10.5 Additional Menu Items 24

3.10.6 Service Menu 25

3.11 Fuel/Air Adjustment 25

3.11.1 Gas Pressure Adjustment 25

3.11.2 Combustion Setup and Adjustment 25

4 operaTIon 27

4.1 General 27

4.1.1 Control Panel Front 27

4.1.2 Factory Tests 27

4.2 Normal Lighting and Shut-Down Procedures 27

4.2.1 Lighting Procedures 27

4.2.2 Normal Shut Down Procedures 27

4.3 Emergency Shut Off 27

4.4 Typical Boiler Operating Conditions 27

5 MaInTenanCe 28

5.1 Maintenance and Inspection Schedule 28

5.1.1 Daily 28

5.1.2 Weekly 28

5.1.3 Monthly 28

5.1.4 Semi-Annually 28

5.1.5 Annually 29

5.2 Cleaning the Burner 29

5.3 Removing the Heat Exchanger 29

5.4 After Repairs or Maintenance 29

5.5 Sequence of Operation 30

5.6 Troubleshooting 30

5.6.1 Loss of Power 30

5.6.2 Loss of Water Level 30

5.6.3 Low Gas Pressure 31

5.6.4 High Gas Pressure 31

5.6.5 High Water Temperature 31

5.6.6 Low Air 31

5.6.7 Flame Failure 31

5.6.8 Flame Error 31

5.6.9 Stack Problem 31

5.7 Manual Reset Error Codes 32

5.8 Auto-Reset Error Codes 33

6 parTs/TeChnICal supporT 34

6.1 Wiring Diagrams 34

6.1.1 Terminal Block Assignments – Power Block 34

6.1.2 Terminal Block Assignments — High Voltage Circuit (TB2) 34

6.1.3 Terminal Block Assignments — Low Voltage Circuit (TB1) 35

6.1.4 SC-3000 & SC-4000 Transformer Diagram 36

6.1.5 SC-3000/SC-4000 Boiler Wiring Diagrams 40

6.1.5.1 SC-3000/SC-4000 Dual Fuel 240 Volt 40

6.1.5.2 SC-3000/SC-4000 Dual Fuel 480 Volt 42

6.1.5.3 SC-3000/SC-4000 240 Volt 44

6.1.5.4 SC-3000/SC-4000 480 Volt 46

6.2 Boiler Parts List 48

6.2.1 Main Assembly 48

6.2.2 Control Panel 49

6.2.3 SC-3000/SC-4000 Heat Engine 50

6.2.4 SC-3000 Gas Train 50

6.2.5 SC-4000 Gas Train 51

7 lIMITed WarranTy 52 a

ppendIx 1: MaInTenanCe log 54

ppendIx 2: boIler alTITude deraTe sChedule 55

ulTI-MeTal sysTeMs WaTer QualITy sTandards 56

Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351

SAFETY

Gas Fired Boiler

Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351

INTrOdUCTION

Gas Fired Boiler

WARNING: If the information in this manual is not followed

exactly, a re or explosion

may result causing property damage, personal injury or loss of life.

It is essential to read, understand, and follow the recommendations of this manual before installing, operating, or servicing this equipment.

WARNING

Installation and service must be performed by a qualied and knowledgeable individual who has been certied on the

P-K Sonic™

Boiler. The same features which permit this boiler to achieve highefciency performance make it unlike most other boilers of this general size, so it is important to understand how this boiler

operates.

WARNING

• 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 re department.

WhAt tO DO IF yOu smell GAs:

Do not store or use gasoline

or other ammable vapors or liquids in the vicinity of this or

any other appliance.

Installation and service must be performed by a qualied installer, service agency, or the

gas supplier.

WARNING

Improper use may result in fire or injury.

Read instructions/safety manual before installing, operating or servicing boiler.

WARNING

AVERTISSEMENT

Improper installation, adjustment, alteration, service, or maintenance can cause property damage, personal injury or loss of life.

Read and understand the installation and Owner’s manual provided with this boiler. Installation and service must be performed by experienced and knowledgeable personnel who have been trained on this series boiler.

Une installation, un réglage, un changement ou un entretien inappropriés peuvent causer des dommages matériels, des blessures corpoeiles ou la mort.

Lire et bien comprendre le Manuel d’installation et du propriétaire fourni avec cette chaudière. L’installation et le service dolvent être effectués par un personnel expérimenté et compétent qui a reçu une formation sur la chaudière de cette série.

1 InTroduCTIon

This manual describes the installation and operation of P-K SONIC™ boilers. Natural gas, propane, and dual fuel (natural and propane) units are described. It also includes 208/3/60, 240/3/60, or 480/3/60 voltages for the 3 and 4 million BTUH input boilers. Information for operation with other fuels is included in the various sections of this manual as applicable. 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 SONIC™ gas red boilers are fully modulating using variable

speed combustion blowers, sophisticated microprocessor controls, modulating gas safety shut off/control valves and a unique stainless steel heat exchanger capable of operating in a fully condensing mode to provide maximum efciency in a minimum amount of space.

While details may differ slightly, basic operation is the same for all models. Check the rating plate for correct fuel usage and gas pressures.

The boiler is only a part of the complete heating system. This boiler may be fully operational and yet because of poor circulation, control, or other operating characteristics not deliver heat to the desired location. Additional equipment such as temperature sensors, pumps, ow switches, balancing valves, and check valves will 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 qualied engineer or contractor must be consulted.

2.1 general

the sC-3000 and sC-4000 gas-red boilers must be:

• Installed, operated, and serviced in accordance with instructions contained in

this manual and other supplemental manuals.

• Installed by qualied personnel in accordance with designs prepared by qualied 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, qualied, and properly trained personnel in accordance with all applicable codes, laws, and regulations.

2.2 safeTy preCauTIons

Provide a suitable location for the boiler, away from normal personnel trafc, with adequate working space, adequate clearances, proper ventilation and lighting, with a structure sufciently strong and rigid to support the weight of the boiler, all piping, and accessories.

2 safeTy

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.

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.

noTICe!

Each safety device must be maintained and checked per the recommended schedule. Refer to Section 5.1 of this manual.

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, in place and operable.

safeTy labels

The following words are used in this manual to denote the degree of seriousness of the individual hazards.

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/noTe - noTICe

WARNING

CAUTION

Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351

SaFeTY

Gas Fired Boiler

Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351

SaFeTY

Gas Fired Boiler

2.4.2 Crush hazards lifting hazards! Use properly rated lifting equipment to lift and position

the boiler. The load is unbalanced. Test balance before lifting off the oor. Do not allow personnel beneath the lifted load. Refer to approximate weights in the table.

2.4.5 slip, Fall hazards tripping hazard! Do not install piping on oor surfaces. Maintain clear path around boiler.

slip and fall hazard! Use drip pan to catch water while draining the boiler.Maintain dry oor surfaces. slip and fall hazard! Do not locate intake or exhaust terminations directly above a walkway; dripping

of condensation can cause icing of the walking surface.

(See section 3.5)

Fall hazard! Do not stand on boiler.

2.4.4 Pressure hazards Pressure hazard! Hot uids. Install isolation valves on boiler

water inlet and outlet. Make sure isolation valves are closed before servicing boiler.

Pressure hazard! Hot uids. Annually test safety relief valve for proper operation. Do not operate boiler with faulty relief valve.

2.4.1 electrical hazards shock hazard! Properly lockout/tagout the electrical service

and all other energy sources before working on or near the boiler.

shock hazard! Do not spray water directly on this boiler or on any electrical components.

electrical hazard! Do not alter wiring connections.

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 re or explosion and serious injury, death, and/or property damage.

Operating and service personnel must be thoroughly familiar with the basic construction of the

SC-3000 and SC-4000 boilers, the use and locations

of the controls, the operation of the boilers, 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.

2.4 hazard WarnIngs

2.3 TraInIng

Boiler size Weight in Pounds

SC-3000 1,850 lbs

SC-4000 1,900 lbs

Gas may lose its odor. Proper gas sensing equipment and procedures should be used for leak checks.

WARNING

AVERTISSEMENT

Improper installation, adjustment, alteration, service, or maintenance can cause property damage, personal injury or loss of life.

Une installation, un réglage, un changement ou un entretien inappropriés peuvent causer des dommages matériels, des blessures corpoeiles ou la mort.

CAUTION

ATTENTION

Burn hazard.

Some components are hot to the touch.

Allow time to cool after shutdown and do not touch during operation.

Risque de brûlures.

Certains composants sont très chauds.

Allouer un temps de refroidissement après l’arrêt et ne pas toucher pendant le functionnement.

AVERTISSEMENT

WARNING

Electrical Hazard.

Contact may cause electrical shock and injury.

Follow lockout/tagout procedure when servicing.

Risque électrique.

Un contact causera un choc électrique et des blessures.

Suivre les procédures de verrouillage/signalisation lors de l’entretien.

WARNING

Improper use may result in fire or injury.

Read instructions/safety manual before installing, operating or servicing boiler.

The safety labels shown below are afxed to your boiler. Although the labels are of high quality, they may become dislodged or unreadable over time. Contact Harsco Industrial, Patterson-Kelley at 570.476.7261 or toll-free at

877.728.5351 for replacements.

noTICe!

2.4.6 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.

Combustion Condensate – an acidic pH of approximately 3.0 to 5.0 can be expected. Use

PVC, CPVC, or other corrosion

resistant piping for drainage. Collection and disposal must be in accordance with all applicable regulations. A condensate neutralization kit is available. Please contact your local Harsco Industrial, Patterson-Kelley representative for more information.

General Warning

2.4.7 Burn, Fire and explosion hazards

Burn, re, 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 3.6

hazard from incorrect fuels! Possible re, explosion, overheating, and damage. Do not use any fuels except the design fuels for the unit.

Overre hazards! High pressure in gas supply could result in overring of this or other devices supplied from the same source.

Fire and explosion hazards! Close the main gas shutoff before servicing boiler. Fire and explosion hazards! Do not store or use gasoline or other ammable vapors or liquids in the

vicinity of this or any other gas red appliance.

Burn hazard! Possible hot surfaces. Do not touch gas vent during ring operation. Use only factory recommended vent components.

Burn hazard! Pipes, vents, and boiler components could be hot. Do not touch piping or stack surfaces during operation or immediately after shutdown of the boiler.

Burn hazard! Hot ue! Use caution when servicing or draining boiler. Fire and explosion hazards! Use caution when servicing burner. Propane (

LPG) is heavier than air and may linger

in the combustion chamber, vent lines, or elsewhere. Gas leak hazard! Make sure 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 liqueed

petroleum gas. Do not use Teon™ tape on threaded gas piping. Gas leak hazard! Check entire gas train for leaks after installation. If there is a smell of gas, shut down the boiler

and obtain immediate assistance from trained service personnel and/or your local re department.

Overre hazard! Possible re and explosion from excess gas pressure. Make sure that gas inlet pressure does not exceed 14 inches wc.

Overre hazard! Possible re 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.

Overre and underre hazards! Possible re, explosion, overheating, and component failure. Do not attempt to adjust ring rate of the boiler. The ring rate must be adjusted only by factory trained personnel.

General Warning

WARNING

Improper use may result in fire or injury.

Read instructions/safety manual before installing, operating or servicing boiler.

Hot Surface

2.4.3 Bump Hazard from overhead ductwork and piping.

Install components with adequate vertical clearance.

General Warning

Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351

INSTallaTION

Gas Fired Boiler

Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351

INSTallaTION

Gas Fired Boiler

3.2 CoMplIanCe WITh Codes

The boiler with standard components and with many options complies with American National Standard/

CSA Standard ANSI Z21.13/CSA 4.9,

latest edition, Gas-Fired Low Pressure Steam and Hot Water Boilers.

The heat exchanger is constructed and stamped in accordance with

ASME Boiler and Pressure Vessel Code, Section IV (160 psig maximum

operating pressure) and Section VIII.

Installation of the boiler 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 installations are made.

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 tter/plumber, (b) eld 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.

3.3.1 Foundation

Provide a rm, level foundation, preferably of concrete. Lifting the front of the boiler slightly will allow the boiler to be rolled off the shipping skid onto the concrete foundation. Once in position, the wheel bolts may be removed allowing the wheels to recess up into the boiler. The base will sit at on the provided foundation. If the boiler is to be pulled out for maintenance, the wheels may be left attached.

3.3 seTup

The boiler must be level to function properly. Six 9/16” holes in the base may be used for 3/8” seismic anchors.

3.3.2 Placement

Bumping hazard from overhead ducts! Install all components with adequate vertical clearances.

The wheels provided with this boiler are for positioning purposes only. When positioning this boiler, 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.

Installation and service must be performed by a qualied installer, service agency, or gas supplier.

WARNING

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

The boiler may be installed on a combustible oor; however, the boiler must never be installed on carpeting.

noTICe!

oTICe!

3 InsTallaTIon

3.1.2 storage Prior to Installation

If the boiler is not installed immediately, it must be stored in a location

adequately protected from the weather, preferably indoors. If this is not

possible, then it should remain in the shipping container and be covered

by a tarpaulin or other waterproof covering.

3.1.1 Initial Inspection

Upon receiving the boiler, inspect it for signs of shipping damage. Some

damage may be hidden. Unpack the boiler, open the front and side doors

and inspect the boiler. Verify that the total number of pieces shown on the

packing slip agrees with those actually received.

3.1 reCeIvIng and sTorage

3.4 eleCTrICal ConneCTIons

The SC-3000 and SC-4000 boilers are available as either 208-240 VAC, three phase, 60 hertz or 440-480VAC, three

phase, 60 hertz electrical service. Refer to sections 6.1.4, 6.1.5 and 6.2.2 for proper wiring and conguration of the electrical connections. The total operating amperage is indicated on the rating nameplate. Each

SC-3000 or

SC-4000 boiler requires less than 20 Amps. Before starting the boiler, check to ensure that the proper electrical

service is connected to the boiler.

An external electrical disconnect (not supplied with the boiler) is required. The boiler electrical service must be installed and grounded in accordance with local codes or in the absence of such requirements, in the U.S. with National Electrical Codes,

ANSI/NFPA No. 70 latest edition or, in Canada, to the Canadian Electrical Code, Part I,

CSA C22.1, latest edition. Installed conduit must not block openings and must allow the side doors to be opened.

3.3.3 Clearances

If the boiler is to be installed near combustible surfaces, the minimum clearances shown in the pictures and table below must be maintained. Failure to provide for the service access clearances, even with non-combustible surfaces, may cause future problems servicing the boiler. Maintain a clearance from the vent to combustible

† “C” Space required for pipes, ducts, etc. in this area above the boiler.

* “B” Clearance depends upon exhaust vent conguration.

** Do not put pipes, ducts, vents, etc in this space. Electrical conduit must be installed vertically so that the side doors can be opened. NOTE - Annual maintenance items can be accessed from the front of the boiler.

Type of Surface Dimensions (inches)

A B C† D

Combustible Surfaces Minimum Clearances

30 12* 24 12

Recommended Clearances for Service Access

30 12* 24 12**

surfaces of 24” or as specied in the vent manufacturer’s listed installation instructions. The boiler must be installed in a space large in comparison to the boiler as described in the National Fuel Gas Code,

ANSI Z223.1, latest edition.

The main power connections are connected to the over current safety device rated for a 20 Amp 3 phase circuit (for either

208-240 or 480 VAC) and ground terminal located in the main power connection box. This box is located

at the lower front left side of the boiler. The power connection has four points of contact: Terminals 1, 3, 5 and G. Connect the three wires supplying the three phase power to terminals 1, 3 and 5. Connect the main boiler ground

wire to G.

The internal control transformer may be pre-wired from the factory for operation with

240 VAC. If 208 VAC three

phase power is used, the internal control transformer must be wired for operation at this lower voltage. The wire

in terminal

X3 on the load side of the internal control transformer must be moved to terminal X4. This supplies the

120 VAC power to the controls from the 208 VAC main voltage. Refer to Sections 6.1.4 and 6.1.5 for proper wiring

and conguration of the internal control transformer.

3.4.1 the Power Input Junction Box

Figure 3.3.3

Table 3.3.3

→

←

→

←

→

←

→

←

Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351

INSTallaTION

Gas Fired Boiler

DhW Pump Relay w/ Delay Off – This output is enabled when there is

a call for

DHW When the call for heat is removed, the output remains enabled for the post pump time parameter

within the

DHW settings. This output provides 120 VAC, 0.5 Amp service to TB2-12. The neutral for this circuit is

provided on

TB2-5.

Circ Pump Relay w/ Delay Off – This output is enabled when there is a call for heat. When the call for heat is removed, the output remains enabled for the post pump time parameter within the CH settings. This output provides

120 VAC, 0.5 Amp service to TB2-13. The neutral for this circuit is provided on TB2-6.

Damper Relay – This output is enabled when the call for heat is enabled. This output provides

120 VAC service

TB2-14. The neutral for this circuit is provided on TB2-7. This circuit is for pilot duty only.

master Alarm Relay –

This is a dry set of contacts that are normally open and will close in the event of an alarm

output from the boiler control, connecting

TB2-15 and TB2-16.

Flame Detected Relay – This is a dry set of contacts that are normally open and will close whenever the boiler control is reading a ame, connecting

TB2-17 and TB2-18.

Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351

INSTallaTION

Gas Fired Boiler

3.4.2 high Voltage (tB2) terminal Block

3.4.3

low Voltage (tB1) terminal Block

enable/Disable –

TB1-1 and TB1-2 are used for enabling the boiler (factory installed jumper). Closing this circuit

allows the boiler to run. Opening this circuit prevents the boiler from running. This circuit is energized by the boiler.

It has a

24 VAC potential. Devices connected to these terminals must be rated for 24 VAC Note: this circuit will be

changed by certain C

h modes and Cascade master modes. * Note 1

external Interlock –

TB1-3 and TB1-4 are used for attachment of an additional eld safety device to the boiler

control circuit (factory installed jumper). Closing this circuit allows the boiler to run. Opening this circuit prevents the boiler from running. This circuit is energized by the boiler with a

5V potential. Devices connected to these terminals

must be rated for

5V.

Outdoor temp sensor –

TB1-5 and TB1-6 are connected to the outdoor temperature sensor. The temperature

control must be programmed to run an outdoor air schedule. The outdoor air sensor and programming help are available from the local Harsco Industrial, Patterson-Kelley Representative. This circuit is energized by the boiler

with a

5V potential. The temperature sensor must be a NTC having 12k @ 77°F.

DhW stat/sensor –

TB1-7 and TB1-8 are connected to the DHW temperature sensor or thermostat. This circuit is

energized by the boiler with a

5V potential. The temperature sensor must be a NTC having 12k @ 77°F.

header temp sensor –

TB1-9 and TB1-10 are connected to the header temperature sensor. This circuit is

energized by the boiler with a

5V potential. The temperature sensor must be a NTC having 12k @ 77°F.

DhW Flow switch –

TB1-11 is energized by the boiler with a 5V potential. This circuit connects through a ow

switch on the domestic side of a domestic hot water system. The ow switch should close upon ow to provide a closed circuit back to

TB1-12.

Analog Input – Remote signal for controlling the boiler. The boiler can be operated in a remote setpoint or a remote ring rate control mode. Input

0-10 VDC+ signal on TB1-13 only. The 0 VDC- Analog Input is provided on

TB1-14. The temperature control must be programmed to run with the analog input. * Note 1

mODBus® – TB1-17 and TB1-18 are used for connecting a MODBUS® building management system. *Note 1

Cascade –

TB1-19 and TB1-20 are used to connect between boilers that are part of a Master/Member Network. Up

to 24 boilers may be connected together. * Note 1

*NOTE 1 - Refer to ENVI® Control Advanced Users Guide (Part # 1004905953) for more information.

The high voltage (

TB2) terminal

block contains

120 VAC output pilot

duty. Do not connect any

120 VAC

supply voltage to the high voltage (

TB2) terminal block. Connecting a

120 VAC supply voltage to

TB2 can

result in serious injury or death.

Be sure to check the nameplate on the boiler before connecting electrical supply.

CAUTION

A dedicated earth ground (green wire) is required to avoid nuisance shutdowns. Do not ground through the conduit.

noTICe!

WARNING

The SC-3000 and SC-4000 boiler may be supplied from the factory as

either

208–240 VAC or 440-480 VAC. Refer to Sections 6.1.4 and 6.1.5 for

proper wiring and conguration of the internal control transformer.

Codes

united states:

NFPA 54/ANSI Z223.1 National Fuel Gas Code NFPA/ANSI 211 Chimneys, Fireplaces, Vents and Solid Fuel Burning Appliances

Canada:

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

sTandards

UL 1738 Venting Systems for Gas-Burning Appliances, Categories II, III, and IV ULC S636-95 Standard for Type BH Venting Systems Sheet Metal and Thermoplastic Duct Construction Manual Air Conditioning Contractors National Association (SMACNA)

These codes and standards contain information for the venting of gas red 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.

3.5 InleT aIr and exhausT venTIng

3.5.1 Applicable Codes and standards

Refer to sections 6.1.4, 6.1.5 and 6.2.2 for proper wiring and conguration of the electrical connections.

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INSTALLATION

Gas Fired Boiler

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Gas Fired Boiler

Design and installation of venting systems should be done only by qualied and knowledgeable venting systems personnel and in accordance with vent system manufacturer’s installation instructions. Installing a boiler or vent system using improper installation methods or materials can result in serious injury or death due to re or asphyxiation.

WARNING

Before connecting a boiler to a venting system, it must be determined whether the boiler is to be installed in a conventional or direct vent conguration. In the US, provisions for combustion and ventilation air must be in accordance with

NFPA 54/ANSI

Z223.1, National Fuel Gas Code,

latest edition, or applicable provisions of the local building codes. In Canada, combustion and ventilation air openings shall comply with

CAN/CSA B-149.1

Natural Gas and Propane Installation Code.

WARNING

The venting materials listed 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.

This boiler is not certied for use with PVC venting. Use of PVC venting may result in vent

failure and possible serious injury or death.

WARNING

For correct installation of vent system, read all of these instructions and refer to vent manufacturer’s instructions.

Failure to use a proper vent system (types and materials), as described in this manual will void the boiler 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, serious bodily injury or death.

WARNING

Boiler size Nom.

vent

size

stainless Vent Adapter

Vent adapter size

Boiler Combustion Air inlet

Combustion air N.C.

motorized

Damper

length

SC-3000 10” 2640000133

10” 12” 1004906946 12”

SC-4000 10” 2640000133 10” 12” 1004906989 14”

Required stainless steel Vent Adapters and Category II motorized Dampers

This table is for information only. Combustion air dampers and vent

adapters are listed for use of design and may or may not be specic to

your application.

The optional, but required for Category II venting, normally-closed

motorized combustion air damper operates on 120

VAC and features an

end limit switch wired into the boiler’s external interlock circuit. Upon a

call for heat, the boiler’s combustion air damper relay will energize and

drive the damper open. Once the damper reaches the fully-open position,

the end limit switch makes contact and closes the external interlock circuit

allowing the boiler to re. The diagram below shows the wiring necessary

to install the normally-closed motorized damper.

3.5.1.1 Gas Vent Categories

Several codes and standards have categorized appliances in accordance with the ue gas temperature and pressure produced by the appliance. The applicable categories are dened as follows:

• Category II: An appliance that operates with a non-positive vent

static pressure and with a vent 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 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 ue gases are discharged to the outdoors.

3.5.1.2 Venting materials for Flue/exhaust systems

The P-K SONIC™ boilers are dual certied as a Category II and Category IV appliances, which vents with a temperature that is likely to cause condensation in the vent. Therefore, any venting system used with the

P-K SONIC™ boiler

must comply with the requirements for either Category II or Category IV venting systems as specied 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.

Acceptable materials for Venting systems

Manufactured Venting Systems

us and Canada:

AL29-4C Stainless Steel Vent Systems listed and labeled to UL1738 Venting Systems for Gas-Burning Appliances, Categories II, III, and IV

316L Stainless Steel where certied and warranted by the vent manufacturer for venting of Category II, III, or IV appliances

As per ANsI Z21.13b-2012 * CsA 4.9b-2012:

• The use of cellular core PVC, CPVC and Radel as venting materials is

prohibited.

• The use of external insulation on plastic vent pipe is prohibited.

model Country Al29-4C 316l ss PVC CPVC POlyPROPyleNe

SC-3000 US Yes Yes No Yes Note 2 SC-4000 US Yes Yes No Yes Note 2 SC-3000 Canada Yes Yes No Note 1 Note 1 SC-4000 Canada Yes Yes No Note 1 Note 1

Acceptable Venting materials

Note 1: When this material is used for venting, it must be listed to ULC-S636.

Note 2: When this material is used for venting, it must be listed to UL-1738.

CPVC Venting

us:

CPVC pipe conforming to ASTM F441. Sch 80 ttings conforming to ASTM

F439. Joints are to be sealed with solvent conforming ASTM 493.

Canada: CPVC Pipe, Fitting and Sealant listed and labeled to ULC S-636 Standard for Type BH Venting Systems.

Polypropylene Venting

us and Canada:

Polypropylene such as InnoFlue from Centrotherm or PolyPro from DuraVent or other listed manufacturers. When used, the same manufacturer's material must be used throughout the system. It is not permissible to use material from different manufacturers within the same system.

3.5.2 Combustion Air materials and sizes

The air intake duct can be fabricated from PVC, CPVC, single wall galvanized steel, or other suitable materials. The duct must be rigid enough to maintain the full required cross sectional area under all operating conditions. Proper sealing of the intake ductwork is necessary to prevent inltration of air from conditioned space. Joints in PVC or CPVC must be cemented. For galvanized duct, wrap each joint and seam with adhesive aluminum tape or other sealant. The installation of a bird screen on the intake termination is recommended. Ensure that the screen does not become blocked with snow, ice, insects etc. Combustion air duct should be designed with maximum 0.22” wc friction loss.

Combustion air must be free from dust, lint, etc. The presence of such materials in the air supplied to the burner could cause nuisance "Low Air" shutdowns or premature burner failure. The boiler should not be operated during construction while the possibility of drywall dust, demolition dust, etc. exists.

The combustion air supply must be completely free of chemical fumes which may be corrosive when burned in the boiler. Common chemicals which must be avoided are uorocarbons and other halogenated compounds, most commonly present as refrigerants or solvents, such as Freon, trichloroethylene, perchloroethylene, chlorine, etc. These chemicals, when burned, form acids which quickly attack the boiler and the boiler stack. The result is improper combustion and premature boiler failure.

P-K sONIC™ Boiler model Required sCFm

SC-3000 629

SC-4000 839

Table 3.5.1

Table 3.5.1.2

Table 3.5.3

Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351

INSTallaTION

Gas Fired Boiler

Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351

INSTallaTION

Gas Fired Boiler

under no circumstances shall

the boiler room ever be under a negative pressure. Particular

care should be taken when exhaust fans, compressors, airhandling units or other equipment may rob air from the boiler. Note that this equipment might be in rooms other than the boiler room. This applies to both sealed combustion and atmospheric room combustion air applications.

WARNING

3.5.2.1 Air Inlet Requirements — united states (NFPA 54/ANsI Z223.1 & NFPA/ANsI 211)

When air is supplied from inside the building, the total required volume shall be the sum of the required volume for all the appliances located in the mechanical room. Adjacent rooms furnished with xed openings communicating directly with the mechanical room are considered part of the required volume. The minimum volume is 50 ft

per 1000 Btu/hr (4.8 m3/kW) of

installed appliance input capacity.

Openings used to connect indoor spaces to obtain the required minimum volume shall be sized as follows:

• When rooms are on the same oor, each opening shall have an area equal to

1 square inch for each 1000 Btu/hr (2200 mm2/kW) of installed appliance input capacity, but not less than 100 square inches. One opening should commence less than 12 inches above the oor and the other less than 12 inches below the ceiling. The minimum dimension of air openings shall be 3 inches.

• When rooms are on different oors, each opening shall have an area equal to 2

square inches for each 1000 Btu/hr (4400 mm2/kW) of installed appliance input capacity.

When combustion air is supplied from outside the building, the boiler room shall be provided with one or two openings to ensure adequate combustion air and proper ventilation.

When using one permanent opening, the opening shall commence within 12 inches of the ceiling and shall communicate directly with the outdoors or through a vertical or horizontal duct that communicates to the outdoors.

Minimum free area of the opening is 1 square inch for each 3000 Btu/hr (700

/kW) of installed appliance input capacity, and not less than the sum of

the areas of all vent connectors in the room.

When using two permanent openings, one opening shall commence within 12 inches above the oor and the other within 12 inches below the ceiling, preferably on opposite walls. The openings shall communicate directly, or by way of ducts, with free outdoor air. The minimum net free area of the openings shall be calculated in accordance with the following:

• When air is taken directly from outside the building, each opening (minimum of two, as outlined above), 1 square inch for

each 4,000 Btu per hour (550 mm2/kW) of total boiler input is required.

• When air is taken from the outdoors through a vertical duct into the mechanical room, 1 square inch per 4,000 Btu per hour

(550 mm2/kW) of total boiler input is required.

• When air is taken from the outdoors through a horizontal duct into the mechanical room, 1 square inch per 2,000 Btu per

hour (1100 mm2/kW) of total boiler input is required.

noTe:

1. The required size of openings for combustion and ventilation air shall be based on the net free area of the

opening.

2. Screens shall be not smaller than ¼”

3. Motorized louvers shall be interlocked with the appliance so that they are proven open prior to main burner ignition and operation.

3.5.2.2 Air Inlet Requirements – Canada (CAN/CsA B149.1)

A. Ventilation of the space occupied by fuel burning appliance(s) or equipment shall be supplied by a ventilation opening at the highest practicable point communicating with the outdoors. The total cross sectional area of the ventilation opening must be either 10% of the net free area required for combustion air or 10 sq. in. (6500 mm

whichever is greater.

noTe:

1. The free area of a combustion air supply opening is calculated by deducting the blockage area of any xed louvers, grilles or screens from the total area of the opening.

2. Screens shall be not smaller than ¼”

3. Motorized louvers shall be interlocked with the appliance so that they are proven open prior to main burner ignition and operation.

P-K sONIC™ Boiler model

AIR sOuRCe

INDOOR AIR suPPly OutDOOR AIR suPPly

sAme FlOOR DIFF FlOORs ONe OPeNING

tWO OPeNINGs

DIReCt VeRt DuCt hORIZ DuCt

SC-3000 3000 6000 1000 750 750 1500 SC-4000 4000 8000 1334 1000 1000 2000

US Minimum area of ventilation openings per boiler (sq inches)

B. Use the following opening calculation for P-K SONIC™, MACH® or

MODU-FIRE® FD boilers: When combustion air is supplied for a forced draft burner by natural airow from

the outdoors and there is no draft regulator or draft hood in the same space, there shall be a permanent opening with a cross sectional area not less than 1 sq. in/ 30,000 Btu/Hr (70 mm2/kW) of the total rated input to the burner(s). This opening must not interfere with the ventilation air opening dened in paragraph A.

C. Use the following opening calculation for P-K THERMIFIC® boilers or other natural draft or fan-assist appliances:

When combustion air is supplied for natural or fan-assisted burners by natural airow from the outdoors, there shall be a permanent opening with a cross sectional area not less than 1 sq. in/7000 Btu/Hr (321 mm2/kW) up to and including 1,000,000 Btu/Hr plus 1 sq. in./14,000 Btu/Hr (155 mm2/kW) in excess 1,000,000 Btu/Hr. This opening must be either located at or ducted to a point not more than 18 in. (450 mm) or less than 6 in. (150 mm) above oor level. This opening is in addition to the ventilation air opening dened in paragraph A.

D. When combustion air is supplied by natural airow into a space containing both types of appliance described in paragraphs B and C, the cross sectional area of the opening shall be not less than the sum of the cross sectional areas for all appliances in the space as calculated by the applicable method. This opening is in addition to the ventilation air opening dened in paragraph A.

E. When a duct is used to meet the requirement for combustion air supply, as described in paragraphs A through D, above, the opening of the duct shall be located so there is no possibility of cold air affecting steam or water piping, electrical equipment or mechanical equipment.

F. When combustion air is supplied by mechanical means, an airow-sensing device must be installed. It must be wired into the pre-ignition limit string to prevent the burner from starting or to stop an operating burner in case of air supply failure.

G. When all combustion air is supplied through a make-up air heater, and the appliance is interlocked to the heater, the requirements of paragraphs A through F do not apply.

P-K sONIC™ Boiler Required Combustion Air Opening Ventilation Air Opening

model Input (Btu/hr) in

SC-3000 3,000,000 100 64,516 10 6,452 SC-4000 4,000,000 134 86,451 13.4 8,645

3.5.3 Flue Venting

This boiler is not certied for use with Type "B" vent nor with

PVC venting.

P-K SONIC™ boilers are dual certied as a Category II and Category IV appliances, as dened in ANSI Z21.13/CSA

4.9, latest edition. The vent material must be as listed in the Table of Acceptable Materials for Venting Systems in

Section 3.5.1.2 above. The exhaust vent can be run horizontally or vertically.

Vent installations shall be in accordance with

NFPA54/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.

Canadian minimum Area of Combustion and Ventilation Air Openings

3.5.3.1 Vent sizing

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.

P-K sONIC™ Boiler model Frictional Resistance stack temperature CO2 Natural Gas CO2 lP Gas

SC-3000/SC-4000 0.22” wc 220 °F 9.2% 10.4%

Vent Design Parameters

Table 3.5.2.1

Table 3.5.2.2

Table 3.5.3.1

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INSTallaTION

Gas Fired Boiler

noTICe!

Make sure that the weight of the vent is not supported by the boiler vent collar. the collar is

not designed to support the

weight of the vent. Horizontal vent sections shall be supported in a manner to prevent sags or low spots where condensate can collect. Structural supports must be connected to building elements of sufcient strength to withstand the weight of the vent system and any bending forces imposed by the venting system.

Do not locate intake or exhaust terminations directly above a walkway; dripping of condensation can cause icing of the walking surface. Maintain a minimum clearance of 6 ft (1.83 m) horizontally from any electric or gas meter, regulator or relief equipment.

WARNING

Conventional Vent Systems Clearances

The following termination clearance requirements are for conventional,

non-direct vent installations:

• The vent system shall terminate at least 3 ft above a forced air inlet within 10

feet horizontally.

• The vent system shall terminate at least 4 ft below, 4 ft horizontally from or 1 ft above any door, operable window or gravity inlet into any building. The bottom of the vent terminal shall be at least 12 in. above grade or highest expected snow line (if applicable).

• Through the wall terminations shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators, relief valves or other equipment.

Combustible Non-Combustibles

Unlisted single wall metal pipe Do NOT Use Do NOT Use

Single wall PVC pipe Do NOT Use Do NOT Use

UL 1738 listed Category IV vent Per manufacturer ’s listing Per manufacturer’s listing

Direct Vent (sealed Combustion) systems Clearances

• The vent terminal shall be located at least 12 in. from any air opening into a building. The bottom of the vent terminal shall be at least 12 in. above grade. Both the vent and air intake terminals must be at least 12 in. above the highest expected snow line.

• Through the wall terminations shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators, relief valves or other equipment.

• When multiple direct vent appliances are adjacent, the exhaust must terminate at least 10 feet horizontally or three feet vertically from the air intake of another appliance.

3.5.3.2 Required Clearances

Forced air inlet

Less than 10 ft.

12 in.

min.

12 in.

min.

Mechanical draft

vent terminal

Direct vent

terminal clearanc

e Minimum clearance

12 in.

4 ft.

min.

12 in.

min.

4 ft. min.

Mechanical draft

vent terminal

3 ft. min.

Grade

Mechanical

draft vent

terminal

Reference: NFPA 54/ANSI Z223.1 National Fuel Gas Code

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INSTallaTION

Gas Fired Boiler

The boiler vent should not be connected into any portion of another mechanical draft system without consulting the vent manufacturer. The boiler shall not be connected to any part of a vent system serving a Category I appliance, nor shall a Category I appliance be connected to any part of the vent system serving this appliance. For CAT II common venting refer to local venting codes. Improper interconnection of venting systems may result in leakage of ue gases into occupied spaces.

WARNING

The condensate formed from combustion ue gases is acidic. The condensate shall be drained in accordance with local code requirements. A condensate neutralizer may be required by local code.

noTe!

3.5.3.3 Flue Connection

The complete exhaust with drain system is shown in the gure. The boiler connector (provided) is designed to accept a 10”

OD nominal pipe.

This connector incorporates provisions to drain condensate formed in the vent system using a 3/4”

OD drain stub. This

drain stub should be connected with the condensate drain on the boiler. The condensate drains shall have a 4” tall trap to prevent the passage of ue gases through the condensate system.

4” Tall Condensate Trap

The connection from the boiler to the vent should be as direct as possible and the upward slope of any horizontal breaching should be at least 1/4 inch per linear foot.

←

The vent shall extend at least three (3) feet above the roof, or at least two (2) feet above the highest part of any structure within ten (10) feet of the vent. This is illustrated in the following diagram.

Additionally the boiler vent shall terminate at least 3 ft above a forced air inlet located within 10 ft.

To prevent the possible re-circulation of ue gases, the vent designer must take into consideration such things as prevailing winds, eddy zones, building congurations, etc.

harsco Industrial, Patterson-Kelley cannot

be responsible for the effects such adverse conditions may have on the operation of the

boilers. Dimensions listed above are minimums and may not be sufcient for conditions at a specic job site.

Vertical vents are allowed to be terminated with a variety of ends, including plain straight pipe, elbow or vent tee. Horizontal vents must be terminated as illustrated in section 3.5.5. A birdscreen with 1” x 1” openings is recommended for the termination. Harsco Industrial, PattersonKelley does not recommend using a vent rain cap of any type.

3.5.3.4 Vent

termination

While the vent design parameters outlined in Section 3.5.3 still apply, achieving those same parameters in a combined vent system, adds a signicant degree of complexity. Therefore, venting systems for multiple boilers shall be designed by experienced and knowledgeable venting professionals. The venting system shall be

3.5.4 Venting for multiple Boilers

Table 3.5.3.2

Interior Component Clearances

All vent system components shall be installed so as to maintain the following required minimum clearances:

Figure 3.5.3.2

Figure 3.5.3.3

Figure 3.5.3.4

+ 21 hidden pages

Harsco Industrial P-K SONIC SC-3000, P-K SONIC SC-4000 Installation & Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual