Harsco Industrial SC-1500, SC-2000, SC-3000, SC-4000 Owner's Manual

INSTALLATION

O W N E R’S

P-K SONIC® / NURO® GAS FIRED BOILER

INSTALLATION

SC-1500/SC-2000 SC-3000/SC-4000 Natural Gas/Propane/Dual Fuel

Part # 1004905978

C.S.A Design-Certified Complies with ANSI Z21.13/CSA 4.9 Gas-Fired Low Pressure Steam and Hot Water Boilers

ASME Code, Section IV Certified by Patterson-Kelley

C.S.A Design-Certified Complies with ANSI Z21.13/CSA 4.9 Gas-Fired Low Pressure Steam and Hot Water Boilers

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

The information in this manual is the property of Harsco Industrial Patterson-Kelley. The descriptions and specifications contained in this manual were in

effect at the time this manual was approved for publication. While Harsco Industrial Patterson-Kelley will continue to support earlier model boilers to

within a reasonable time limit, we reserve the right to discontinue models and replacement parts at any time or change specifications or design without

notice and without incurring any obligation.

Revised August 1, 2015

INSTALLATION

MANUA

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MANUA

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MANUA

O W N E R’S

MANUA

O W N E R’S

MANUA

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MANUA

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MANUA

P-K

SONIC

Gas Fired Boiler

Safety

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General

P-K SONIC TM SC-1500, SC-2000, SC-3000 and SC-4000

All P-K SONIC TM SC-1500, SC-2000, SC-3000 and SC-4000 Gas-Fired Boilers must be:

• Installed, operated, and serviced in accordance with

• Installed by qualified personnel in accordance with designs

• Operated and serviced in accordance with a comprehensive

• Operated and serviced by experienced, qualified, and

Safety Precautions

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

instructions contained in this manual and other supplemental manuals.

prepared by qualified facility engineers including: structural, mechanical, electrical, and other applicable disciplines.

safety program determined and established by the customer. Do not attempt to operate or service until such a program has been established.

properly trained personnel in accordance with all applicable codes, laws, and regulations.

OTICE

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

Section 5 Maintenance.

AFETY FEATURES

It is the responsibility of the customer to ensure external safety provisions, such as but not limited to: guards, safety labels, safety controls, interlocks, lockout devices are in place and operable.

AFETY LABELS

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

hazardous situation which, if not avoided, will result in

death or serious injury. This

signal word is to be limited

Indicates an imminently

to the most extreme

situations.

Indicates a potentially

hazardous situation which, if

not avoided, could result in

death or serious injury.

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

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.

OTICE/NOTE - NOTICE

P-K

SONIC

Gas Fired Boiler

OTICE

Training

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The safety labels shown below are affixed 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.

Proper training is the best protection against accidents. It is essential to read, understand, and follow the recommendations of this manual before installing, operating, or servicing this equipment. Failure to do so could result in fire or explosion and serious injury, death, and/or property damage.

Operating and service personnel must be thoroughly familiar with the basic construction of the SC-1500, SC-2000, 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

570.476.7261 or toll free at 877.728.5351.

Electrical Hazards

Crush Hazards

Boiler Model Boiler Size Weight in Pounds

Gas may lose its odor. Proper gas

sensing equipment and procedures

should be used for leak checks.

Failure to detect gas leaks could

result in injury or death.

Bump Hazard from Overhead Ductwork and Piping

Injury Hazard! Install components with adequate vertical clearance.

Pressure Hazards

SC-1500 1,500,000 BTU 1,450 lbs

SC-2000 2,000,000 BTU 1,450 lbs

SC-3000 3,000,000 BTU 1,850 lbs

SC-4000 4,000,000 BTU 1,900 lbs

Service at

Hazard Warnings

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 any electrical components.

Electrical Hazard! Do not alter wiring connections.

Lifting Hazards! Use properly rated lifting

equipment to lift and position the boiler. The load is unbalanced. Test the balance before lifting off the floor. Do not allow personnel beneath the lifted load. Refer to the approximate weights in the table.

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

Pressure Hazard! Hot fluids. Annually test safety relief valve(s) for proper operation. Do not operate boiler with faulty relief valve(s).

P-K

SONIC

Gas Fired Boiler

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Slip, Fall Hazards

Tripping Hazard! Do not install piping on floor surfaces. Maintain a clear path around the boiler.

Slip and Fall Hazard! Use a drip pan to catch water while draining the boiler. Maintain dry floor

surfaces.

Slip and Fall Hazard! Do not locate intake or exhaust terminations above a walkway; dripping of condensate can cause icing of the walking surface. Refer to Section 2.4.6.

Fall Hazard! Do not stand on boiler.

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.

Burn, Fire and Explosion Hazards

Burn, fire, and explosion hazards! Installation must be in strict conformance to all applicable

and standards including NFPA 54, ANSI Z223.1 and CAN/CSA B.149. Install all required vent

codes

lines for gas devices. Refer to Section 3.3 and Section 3.4.

Hazard from Incorrect Fuels! Possible fire, explosion, overheating, and damage. Do not use any

fuels except the design fuels for the unit.

Overfire Hazards! High pressure in gas supply could result in overfiring of this or other devices

supplied from the same source.

Fire and Explosion Hazards! Close the main gas shutoff before servicing boiler.

Fire and Explosion Hazards! Do not store or use gasoline or other flammable vapors or liquids in

the vicinity of this or any other gas fired appliance.

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

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

Burn Hazard! Hot flue! 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 liquefied petroleum gas. Do not use Teflon™ tape on threaded gas piping.

Gas Leak Hazard! Check entire gas train for leaks after installation. If there is a smell of gas, shut down the boiler and obtain immediate assistance from trained service personnel and/or your local fire department.

Overfire Hazard! Possible fire and explosion from excess gas pressure. Make sure that gas inlet pressure does not exceed 14 inches W.C.

Overfire Hazard! Possible fire and explosion. Possible malfunction of regulators and/or gas safety shut off/control valves. Maintain all gas train components in good condition. Do not alter wiring connections. Annual inspection by factory-trained personnel for proper set-up and operation is recommended.

Overfire and Underfire Hazards! Possible fire, explosion, overheating, and component failure. Do not attempt to adjust firing rate of the boiler. The firing rate must be adjusted only by factory trained personnel.

P-K

SONIC

Gas Fired Boiler

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Table of Contents

OCUMENT REVIEW AND ACCEPTANCE

EVISION HISTORY

................................................................ E

1 INTRODUCTION ..................................................... ERROR! BOOKMARK NOT DEFINED.

................................... E

RROR! BOOKMARK NOT DEFINED RROR! BOOKMARK NOT DEFINED

. .

1.1 P

1.2 U

1.3 HARSCO I

URPOSE OF THIS DOCUMENT

SING THIS MANUAL

NDUSTRIAL, PATTERSON-KELLEY PRODUCT ABBREVIATIONS

..................................................................................................... 5

....................................................................................... 5

.......................... 5

2 SITE PREPARATION......................................................................................................... 6

2.1 R

ECEIVING AND STORAGE

............................................................................................. 6

2.1.1 Initial Inspection ...................................................................................................... 6

2.1.2 Storage Prior to Installation ..................................................................................... 6

2.2 C

2.3 L

OMPLIANCE WITH CODES

OCATION SETUP

......................................................................................................... 7

............................................................................................ 6

2.3.1 Placement ............................................................................................................... 7

2.3.2 Clearances .............................................................................................................. 7

2.4

NLET AIR AND EXHAUST VENTING CONSIDERATIONS

....................................................... 8

2.4.1 Applicable Codes and Standards ............................................................................ 8

2.4.2 Gas Vent Category Planning ................................................................................... 9

2.4.3 Air Inlet Planning (United States and Canada Considerations) ................................ 9

2.4.4 Flue Venting Considerations ................................................................................... 9

2.4.5 Venting Materials for Flue/Exhaust Systems............................................................ 9

2.4.6 Required Clearances ............................................................................................ 10

2.4.6.1 Conventional Vent Systems Clearances ........................................................ 10

2.4.6.2 Direct Vent (Sealed Combustion) Systems Clearances ................................. 10

2.4.6.3 Interior Component Clearances ..................................................................... 11

2.4.6.4 Flue Connection ............................................................................................ 11

2.5 G

2.6 W

AS PIPING CONSIDERATIONS

ATER QUALITY STANDARD

........................................................................................ 11

.................................................................................... 11

3 INSTALLATION ............................................................................................................... 12

3.1 O

3.2 E

VERVIEW

LECTRICAL CONNECTIONS

................................................................................................................. 12

........................................................................................ 12

3.2.1 Power Requirements (CM300-CM399-CM500) ..................................................... 12

3.2.2 Single Phase Power Supply Connection (SC-1500 and SC-2000 Only) ................ 13

3.2.3 Three Phase Power Supply Connection (SC-3000 & SC-4000 Only) .................... 14

3.2.4 High Voltage (TB2) Terminal Block ........................................................................ 15

3.2.5 Low Voltage (TB1) Terminal Block ......................................................................... 16

3.3 C

OMBUSTION AIR

........................................................................................................ 17

3.3.1 Air Inlet Requirements ........................................................................................... 18

3.3.1.1 United States Considerations ........................................................................ 18

3.3.1.2 US Requirements .......................................................................................... 18

3.3.1.3 Canadian Considerations .............................................................................. 19

3.3.2 Flue Venting Installation ........................................................................................ 20

3.3.2.1 Vent Sizing .................................................................................................... 20

3.4 V

ENT TERMINATION

..................................................................................................... 21

3.4.1 Venting for Multiple Boilers .................................................................................... 22

3.4.2 Sealed Combustion/Direct Vent Systems .............................................................. 22

3.4.3 Inlet Duct Connection to Boiler .............................................................................. 23

3.4.4 Intake Duct Materials and Sizes ............................................................................ 23

P-K

SONIC

Gas Fired Boiler

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3.4.5 Category II Installations ......................................................................................... 23

3.4.6 Category IV Installations ....................................................................................... 25

3.4.7 Stainless Steel Venting ......................................................................................... 25

3.4.8 CPVC Vent System Installation ............................................................................. 25

3.5 R

3.6 P

EMOVING AN EXISTING BOILER

IPING

....................................................................................................................... 27

.................................................................................. 26

3.6.1 Gas Piping Overview............................................................................................. 27

3.6.2 Gas Supply Piping for Installer ............................................................................... 27

3.7 B

OILER WATER PIPING

............................................................................................... 28

3.7.1 Boiler Inlet and Outlet Connections ....................................................................... 28

3.7.2 Boiler Water Piping (for Installer) .......................................................................... 28

3.7.2.1 Strainer ......................................................................................................... 28

3.7.2.2 Relief Valve Piping ........................................................................................ 29

3.7.2.3 Low Water Cut-Off ......................................................................................... 29

3.7.2.4 Drain Valve and Piping .................................................................................. 29

3.7.2.5 Condensate Drain ......................................................................................... 29

3.8 W

3.9 PRE-S

3.10 S

ATER QUALITY

TART CHECKLIST

AFETY CHECKS

......................................................................................................... 29

.............................................................................................. 30

........................................................................................................ 30

3.10.1 Ignition Safety System Test ............................................................................... 31

3.10.2 Low Water Cut-out Test ..................................................................................... 31

3.10.3 Manual Reset High Temperature Limit Test ......................................................... 32

3.10.4 Gas Pressure Switch Tests ............................................................................... 32

3.10.4.1 Low Gas Pressure Switch .......................................................................... 32

3.10.4.2 High Gas Pressure Switch ......................................................................... 32

3.11 I

NITIAL

NURO C

ONTROL SETUP AND ADJUSTMENT

...................................................... 33

3.11.1 Introduction ....................................................................................................... 33

3.11.2 Startup .............................................................................................................. 33

3.11.3 Home Screen .................................................................................................... 33

3.11.4 Information Screen ............................................................................................ 34

3.11.5 Comfort Heat Setup Wizard............................................................................... 34

3.11.5.1 Comfort Heat Operation ............................................................................ 35

3.12 F

UEL/AIR ADJUSTMENTS

............................................................................................. 35

3.12.1 Gas Pressure Adjustment ................................................................................. 35

3.12.2 Combustion Setup and Adjustment .................................................................... 36

3.12.3 Adjusting High Fire ............................................................................................ 36

3.12.4 Adjusting Low Fire ............................................................................................. 37

3.12.5 Checking Flame Signal ..................................................................................... 37

4 OPERATIONS .................................................................................................................. 38

4.1 NURO T

OUCHSCREEN CONTROL SYSTEM

4.1.1 NURO Control Panel ............................................................................................. 38

4.1.2 NURO Touch Screen Interface ............................................................................. 38

4.1.3 Factory Tests ........................................................................................................ 38

4.2 N

ORMAL LIGHTING AND SHUT-DOWN PROCEDURES

4.2.1 Normal Lighting Procedures .................................................................................. 39

4.2.2 Normal Shut Down Procedures ............................................................................. 39

4.3 E

4.4

MERGENCY SHUT-OFF

YPICAL BOILER OPERATING CONDITIONS

5 MAINTENANCE ............................................................................................................... 40

................................................................... 38

...................................................... 39

.............................................................................................. 39

................................................................... 39

P-K

SONIC

Gas Fired Boiler

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5.1 M

AINTENANCE AND INSPECTION SCHEDULE

................................................................. 40

5.1.1 Semi-Annually ....................................................................................................... 40

5.1.2 Annually ................................................................................................................ 40

5.2 P

REVENTIVE MAINTENANCE

........................................................................................ 41

5.2.1 Daily Preventive Maintenance ............................................................................... 41

5.2.2 Weekly Preventive Maintenance ........................................................................... 41

5.2.3 Monthly Preventive Maintenance .......................................................................... 42

5.3 C

5.4 A

5.5 S

5.6 T

LEANING THE BURNER & COMBUSTION CHAMBER FTER REPAIRS OR MAINTENANCE EQUENCE OF OPERATIONS ROUBLESHOOTING

.................................................................................................... 45

........................................................................................ 44

.............................................................................. 43

...................................................... 42

5.6.1 Loss of Power ....................................................................................................... 45

5.6.2 Loss of Water Level .............................................................................................. 45

5.6.3 Low Gas Pressure................................................................................................. 45

5.6.4 High Gas Pressure ................................................................................................ 45

5.6.5 High Water Temperature ....................................................................................... 45

5.6.6 Low Air .................................................................................................................. 45

5.6.7 Flame Failure ........................................................................................................ 46

5.6.8 Flame Error ........................................................................................................... 46

5.6.9 Flue Problem ........................................................................................................ 46

6 PARTS/TECHNICAL SUPPORT ...................................................................................... 46

6.1 T

ERMINAL BLOCK ASSIGNMENTS AND WIRING DIAGRAMS

............................................. 47

6.1.1 Wiring Diagram – Power Box (SC-3000 and SC-4000 Only .................................. 47

6.1.2 Terminal Block Assignments — High Voltage (TB2) Terminal Block ...................... 48

6.1.3 Terminal Block Assignments — Low Voltage (TB1) Terminal Block ....................... 49

6.1.4 SC-3000 & SC-4000 Control Transformer Diagrams ............................................. 50

6.1.4.1 SC-3000 & SC-4000: 208 VAC, Three Phase, 60 Hertz ................................ 50

6.1.4.2 SC-3000 & SC-4000: 220-240 VAC, Three Phase, 60 Hertz ......................... 50

6.1.4.3 SC-3000 & SC-4000: 440-480 VAC, Three Phase, 60 Hertz ......................... 51

6.1.5 SC-1500 & SC-2000 Wiring Diagram .................................................................... 52

6.1.6 SC-3000 & SC-4000 480V Wiring Diagram ........................................................... 56

6.1.7 Main Boiler Assembly (SC-1500 & SC-2000) ........................................................ 58

6.1.8 NURO Control Panel (SC-1500 & SC-2000) ......................................................... 59

6.1.9 Heat Exchanger Assembly (SC-1500 & SC-2000) ................................................ 60

6.1.10 Natural Gas Train, Burner & Blower Assembly (SC-1500 & SC-2000) .............. 61

6.2 B

OILER PARTS IDENTIFICATION

(SC-3000 & SC-4000) ................................................. 62

6.2.1 Main Boiler Assembly (SC-3000 & SC-4000) ........................................................ 62

6.2.2 NURO Control Panel (SC-3000 & SC-4000) ......................................................... 63

6.2.3 Main Power Box (SC-3000 & SC-4000) ................................................................ 64

6.2.4 Heat Exchanger Assembly (SC-3000 & SC-4000) ................................................ 65

6.2.5 Natural Gas Train, Burner & Blower Assembly (SC-3000 & SC-4000) .................. 66

6.2.6 Propane Gas Train (SC-3000 & SC-4000) ............................................................ 67

7 LIMITED WARRANTY ..................................................................................................... 68

8 BOILER FIRE-TEST REPORT ......................................................................................... 69

APPENDIX A – MAINTENANCE LOG..................................................................................... 70

APPENDIX B – BOILER ALTITUDE DERATE SCHEDULE .................................................... 71

APPENDIX C – WATER QUALITY STANDARDS QUALITY STANDARDS FOR HYDRONIC BOILERS IN

MULTI-METAL SYSTEMS ....................................................................................................... 72

P-K

SONIC

Gas Fired Boiler

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APPENDIX D – INSTALLATION AND QUICK REFERENCE .................................................. 73

UEL/GAS SUPPLY

LECTRICAL/POWER SUPPLY

XHAUST VENTING

YDRONICS/WATER FLOW

................................................................................................................. 73

.................................................................................................. 73

................................................................................................................. 73

(SC-1500 / SC-2000) .................................................................... 74

(SC-3000 / SC-4000) .................................................................... 75

P-K

SONIC

Gas Fired Boiler

1.1 Purpose of this Document

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It is the purpose of this Installation and Owner’s Manual is to provide complete documentation support for P-K

SONIC

boilers featuring NURO controls. HARSCO Industrial, Patterson-Kelley is constantly seeking ways

to produce high quality HVAC products. Our operation is based on the premium quality control program and insures that HARSCO Industrial manufactures quality products.

1.2 Using This Manual

The primary concern of all HARSCO Industrial, Patterson-Kelley equipment installation procedures is Safety. Following a title page Safety instructions and considerations are presented and repeated throughout the document as needed. 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.

1.3 HARSCO Industrial, Patterson-Kelley Product Abbreviations

Abbreviation Description

AMP Ampere or Amperage

ANSI American National Standards Institute

ASME American Society of Mechanical Engineers

AWG American Wire Gauge

BTU British Thermal Unit

CH Comfort Heat

CO2 Carbon Dioxide

CSA Canadian Standards Association

CSD-1 Controls and Safety Devices

CPVC Chlorinated Polyvinyl Chloride

DHW Domestic Hot Water

ID Inside Diameter

MODBUS A serial communication protocol (not an abbreviation)

NFPA National Fire and Protection Agency

NTC Negative Temperature Coefficient

O2 Oxygen

OD Outside Diameter

OEM Original Equipment Manufacturer

SCFM Standard Cubic Feet per Minute

SMACNA Sheet Metal and Thermoplastic Duct Construction Manual Air Conditioning

Contractors National Association

TB<#> Terminal Block (1, 2, 3 etc. depending on how many)

VAC Volts Alternating Current

VDC Volts Direct Current

P-K

SONIC

Gas Fired Boiler

Installation and service must be

performed by a qualified

installer, service agency, or gas

supplier. Failure to install the

equipment in accordance with

this manual could result in an

unsafe operating condition.

OTICE

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

requires additional technicians

to support and move the unit(s)

during installation. Use extreme

caution to avoid dropping the

injury while lifting or handling.

maintain positive control of it at

heed this warning could result

OTICE

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

Bumping hazard from overhead

service access, increasing the

The boiler is heavy and

boiler or cause any bodily

When positioning this boiler,

all times. Do not attempt to

move the boiler on surfaces

that are not level. Failure to

in personal injury or death.

ducts! Install all components

with adequate vertical

clearances. Insufficient

clearance can restrict the

possibility of injury.

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2 Site Preparation

2.1 Receiving and Storage

2.1.1 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.

2.1.2 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.

2.2 Compliance with Codes

The boiler with standard components 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 P-K SONIC TM SC-1500, SC-2000, SC-3000 and SC-4000 heat exchangers are constructed and stamped in accordance with ASME Boiler and Pressure Vessel Code, Section IV.

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 making any installation.

Where required by local codes, the installation must conform to American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers (ASME CSD-1).

In the Commonwealth of Massachusetts (a) this unit must be installed by 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.

a licensed pipe fitter/plumber, (b) field installed gas

P-K

SONIC

Gas Fired Boiler

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2.3 Location Setup

2.3.1 Placement

The boiler must be level to function properly.

Six 9/16” holes in the base may be used for 3/8” anchor bolts.

1. Ensure the boiler is securely connected to the floor.

2. The boiler may be installed on a combustible floor (except carpeting) or a non-combustible surface

such as a concrete housekeeping pad.

NOTE

Never install boiler on carpeting.

3. Once the boiler is situated, use a bubble level to make sure the boiler is completely level.

2.3.2 Clearances

If the boiler is to be installed near combustible surfaces, the inches minimum clearances are shown in the illustration below. Failure to provide adequate service clearances, even with non-combustible surfaces, may present problems during routine maintenance of the boiler. Maintain a clearance from the vent to combustible

surfaces of 24” or as specified 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, NFPA 54/ANSI Z223.1, Latest Edition.

Type of Surface

CSA Minimum Clearances to Combustibles

Recommended Service Clearances

* “B” Clearance depends upon exhaust vent configuration. † “C” Space required for pipes, ducts, etc. in this area above the boiler.

** Do not put pipes, ducts, vents, etc in this space. Electrical conduit must be installed vertically so that the side doors can be opened.

Dimensions (inches)

A B C† D

30 12* 24† 12**

P-K

SONIC

Gas Fired Boiler

Boiler

Size Nom. vent

Stainless

ent

Boiler

Combustion

air

Size

Design and installation of

venting systems should be

done only be qualified 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 fire or

asphyxiation.

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

configuration. In the US,

provisions for combustion air

must be in accordance with

NFPA 54/ANSI Z223.1, National

Fuel Gas Code, latest edition,

or applicable provisions of

local building codes. In

Canada, combustion and

ventilation air openings shall

comply with CAN/CSA B-149.1

Natural Gas and Propane

Installation Code.

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2.4

Inlet Air and Exhaust Venting Considerations

2.4.1 Applicable Codes and Standards

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 System

Sheet Metal and Thermoplastic Duct Construction Manual Air Conditioning Contractors National Association (SMACNA)

These codes and standards contain information for the venting of gas fired appliances, including, but not limited to vent sizing, location, clearance to combustibles, and safe installation practices. The installation must comply with both the above Federal Codes and with state, provincial and local codes.

This table is for information only. Combustion air dampers and vent adapters are listed for use of design and may or may not be specific to your application.

Required Stainless Steel Vent Adapters and Category II Motorized Dampers

NOTE

Boiler Vent and Adapter Sizes

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,

injury or death.

Size

SC-1500 10” 2640000133

SC-2000 10” 2640000133

SC-3000 10” 2640000133

SC-4000 10” 2640000133

Vent Adapter

adapter

size

10” 12” 1004906946 12”

10” 12” 1004906989 14”

Combustion

Air inlet

N.C. Motorized

Damper

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2.4.2 Gas Vent Category Planning

Several codes and standards have categorized appliances in accordance with the flue gas temperature and pressure produced by the appliance. The applicable categories are defined 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 flue gases are discharged to the outdoors.

2.4.3 Air Inlet Planning (United States and Canada Considerations)

• Air inlet considerations for the United States are established by NFPA 54/ANSI Z223.1 & NFPA/ANSI

211.

• Air inlet requirements for the Canada States are established by CAN/CSA B149.1.

For details on the US air inlet requirements see Section 3.3.1 Air Inlet Requirements for more details.

2.4.4 Flue Venting Considerations

P-K SONIC TM boilers are dual certified as a Category II and Category IV appliances, as defined in ANSI

Z21.13/CSA 4.9, latest edition. The vent material to be used for US and Canada is listed in the Table of Acceptable Materials for Venting Systems located in Section 2.4.5 Venting Materials for Flue/Exhaust

Systems. 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.

2.4.5 Venting Materials for Flue/Exhaust Systems

The P-K SONIC 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 must comply with the requirements for either Category II or Category IV venting systems as specified in the latest edition of the latest edition of

CPVC Venting

US: CPVC pipe conforming to ASTM F441. Sch 80 fittings

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.

boilers are dual certified as a Category II and Category IV

CAN/CSA B-149.1

NFPA 54/ANSI Z223.1

in Canada.

in the US or

boiler

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 certified for use with PVC venting. Use of

PVC venting may result in vent

failure and possible serious

injury or death.

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NOTE 1:

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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-1500 US Yes Yes No Yes Note 2

SC-2000 US Yes Yes No Yes Note 2

SC-3000 US Yes Yes No Yes Note 2

SC-4000 US Yes Yes No Yes Note 2

SC-1500 Canada Yes Yes No Note 1 Note 1

SC-2000 Canada Yes Yes No Note 1 Note 1

SC-3000 Canada Yes Yes No Note 1 Note 1

SC-4000 Canada Yes Yes No Note 1 Note 1

NOTE 2: When this material is

When this material is

used for venting, it must be listed to ULC-S636.

used for venting, it must be listed to UL-1738.

2.4.6 Required Clearances

2.4.6.1 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 located within 10 ft. 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.

Acceptable Venting Materials

2.4.6.2 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.

• When multiple direct vent appliances are adjacent, the exhaust must terminate at least 10 ft. horizontally or 3 ft. vertically from the air intake of another appliance.

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2.4.6.3 Interior Component Clearances

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

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

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

NOTE

The condensate formed from combustion flue gases are acidic. The condensate shall be drained in accordance with local code. A condensate neutralizer may be required by local code.

2.4.6.4 Flue Connection

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 complete exhaust with drain system is Section 3.4 Vent Termination. The appliance connector should incorporate provisions to drain condensate formed in the vent system. The connector should include an appropriate drain section (not provided).

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 Category II

common venting, refer to local

venting codes. Improper

interconnection of venting systems may result in leakage of flue gases into occupied spaces.

2.5 Gas Piping Considerations

Before making the gas hook-up, make sure boiler is being supplied with the type of fuel shown on the boiler nameplate. The boiler shall be installed such that gas ignition system components are protected from water (dripping, spraying, rain, etc.) during appliance operation and service (circulator replacement, control adjustment, etc.).

2.6 Water Quality Standard

The boiler’s heat exchanger is made of stainless steel. The heat exchanger requires proper water conditions

to remain efficient and function properly. For information refer to Harsco Industrial, Patterson-Kelley MultiMetal Systems Water Quality Standards in Appendix C, this applies to the warranty of your heat exchanger.

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3 Installation

3.1 Overview

For site preparation follow the guidelines established in Section 2 Site Preparation. The information in this section will partially copy some of the information in that section as a reminder of how important site preparation is in the installation of the P-K SONIC

3.2 Electrical Connections

3.2.1 Power Requirements (CM300-CM399-CM500)

The SC-1500 and operating amperage is indicated on the rating nameplate and the SC-1500 and SC-2000 requires less than 15 Amps at full load. Before starting the boiler, check to ensure that the proper electrical service is connected to the boiler.

The

SC-3000

service OR

440-480VAC

the rating nameplate and the the boiler, check to ensure that the proper electrical service is connected to the boiler.

and

SC-2000

SC-4000

boiler requires

208-240 VAC

boilers can be manufactured for

, three phase, 60 hertz electrical service. The total operating amperage is indicated on

SC-3000 & SC-4000

boilers with NURO controls.

, single phase, 60 hertz electrical service. The total

208-240 VAC

, three phase, 60 hertz electrical

boilers require less than 20 Amps at full load. Before starting

NOTE

The SC-3000 & SC-4000 MUST be ordered to the correct voltage! IT IS NOT

POSSIBLE to convert an SC-3000 or SC-4000 between the 240V and 480V

configurations in the field.

An external electrical disconnect and overload protection (not supplied with the boiler) are required. Refer to

Section 6.1 for proper wiring and configuration of the electrical connections. 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 current Canadian Electrical Code, Part I, CSA C22.1 latest edition. Installed conduit must not block any of the boiler’s openings and must allow the front door to be opened.

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3.2.2 Single Phase Power Supply Connection (SC-1500 and SC-2000 Only)

The SC-1500 and SC-2000 must be supplied with 208-240VAC, single phase, 60 hertz electrical service. The SC-1500 and SC-2000 feature four dedicated power terminals on the High Voltage (TB2) terminal block. The illustration below shows the Low Voltage (TB1) and High Voltage (TB2) terminal blocks on the SC- 1500 and SC-2000 with the front door hidden for clarity:

• TB2 Terminal 1 = HOT L1

• TB2 Terminal 2 = HOT L2

• TB2 Terminal 3 = NEUTRAL

• TB2 Terminal 4 = GROUND

Do not over-tighten the terminal screws. Maximum tightening torque = 6 in-lbs!

NOTE

These terminals can accommodate maximum 10AWG wire.

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3.2.3 Three Phase Power Supply Connection (SC-3000 & SC-4000 Only)

Main Power Connection Box

Check the rating nameplate of the SC-3000 or SC-4000 boiler to determine the required electrical service:

• 208-240VAC, three phase, 60 hertz

• 440-480VAC, three phase, 60 hertz

The incoming three phase power for the SC-3000 & SC-4000 boilers is connected to the over-current safety device (rated for 20 Amps) and the Ground terminal located in the main power connection box. The illustration below shows the Low Voltage (TB1) and High Voltage (TB2) terminal blocks, plus the Main Power Connection Box on the SC-3000 & SC-4000 with the front door hidden for clarity:

• Terminal 1 = HOT L1

• Terminal 3 = HOT L2

• Terminal 5 = HOT L3

• Terminal G = GROUND

The Main Power Connection Box features a Control Transformer which steps down two hot leads from the incoming three-phase power in order to supply 110-120VAC single phase power to the boiler’s control system. Be aware that SC-3000 & SC-4000 boilers ordered in the 240V configuration, are pre-wired from the factory for operation with 240 VAC three phase incoming power.

If 208 VAC three phase power is supplied to the boiler, the internal control transformer must be re-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 Section 6.1 for proper wiring and configuration of the internal control transformer.

Do not over-tighten the hot lead

terminal screws. Maximum tightening

torque = 13 in-lbs!

NOTE

The hot lead terminals can

accommodate maximum 12AWG wire.

The ground terminal can

accommodate maximum 8 AWG wire.

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3.2.4

High

Voltage

(TB2)

erminal

Block

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Be sure to check the

nameplate on the boiler

before connecting the

electrical supply.

OTICE!

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

The high voltage (TB2)

terminal block on the SONIC

SC-1500 and SC-2000 with

NURO controls contains two

hot leads (HOT L1 & HOT L2),

a neutral lead (NEUTRAL) and

a ground lead (GROUND) for

208- 240 VAC, single phase

60Hz electrical supply. This

terminal block (TB2) also

contains dry-contact relays

with a maximum voltage

rating of 240VAC and 1/2 Amp

maximum current capacity. Incorrect wiring can result in equipment damage, injury or

death.

The high voltage (TB2)

terminal block on the SONIC

SC-3000 & SC-4000 with

NURO controls contains dry-

contact relays with a

maximum voltage rating of

240VAC and 1/2 Amp

maximum current capacity. Incorrect wiring can result in equipment damage, injury or

death.

Start Interlock #2 –

The Start Interlock #1 terminals can be used for auxiliary safety devices such as damper end limit switches, control valve end limit switches, emergency stop buttons, and low water cutoff devices. This circuit is energized with safety devices must be rated for a minimum of

Start Interlock #1 –

The Start Interlock #2 terminals are in series with

120VAC

, so the contacts on any auxiliary

120VAC

Start Interlock #1 and provide additional connection points for auxiliary safety devices. This circuit is energized with any auxiliary safety devices must be rated for minimum

120VAC

, so the contacts on

120VAC

The boiler ships with a factory-installed jumper across Start Interlock #1 and Start Interlock #2 terminals. Remove the jumper(s) if using any auxiliary safety devices

NOTE

Both the Start Interlock #1 and Start Interlock #2 circuits must close within 5 minutes of a call for heat. Failure to close the Start Interlock circuit will cause the boiler to lockout on alarm

Auxiliary Input #2 –

circuit is energized with

Auxiliary Input #1 –

circuit is energized with

These terminals are reserved for future use. This

120VAC

These terminals are reserved for future use. This

120VAC

Air Damper Interlock – The Air Damper Interlock provides dedicated terminals for proof of open end limit switch on a motorized air damper. This circuit is energized with 120VAC, so the contacts on the end limit switch must be rated for minimum 120VAC.

The boiler ships with a factory-installed jumper across the Air Damper Interlock terminals. Remove the jumper if connecting a motorized air damper with end limit switch.

Relay A – User-configurable relay output #1. The normally-open contacts on this relay have a maximum voltage rating of 240VAC and maximum current capacity of 1/2 Amp.

Relay B – User-configurable relay output #2. The normally-open contacts on this relay have a maximum voltage rating of 240VAC and maximum current capacity of 1/2 Amp.

Relay C –

User-configurable relay output #3. The normally-open contacts on this relay have a maximum voltage rating of 240VAC and maximum current capacity of 1/2 Amp.

Relay D –

User-configurable relay output #4. The normally-open contacts on this relay have a maximum

voltage rating of 240VAC and maximum current capacity of 1/2 Amp.

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NOTE

Refer to Section 6 Parts and Tech Support for proper wiring and configuration of the electrical connections.

Relays A thru D can be user-configured through the NURO touch screen interface to control devices such the Comfort Heat (CH) Pump, Domestic Hot Water (DHW) Pump, Air Damper, System Pump, etc.

Master Alarm Relay – The Master Alarm Relay terminals are normally-open dry contacts that close in the event of an alarm output from the boiler control.

3.2.5 Low Voltage (TB1) Terminal Block

Enable/Disable –

TB1-1

and

TB1-2

can be used to remotely enable or disable the boiler. The functionality of these terminals is user-configurable through the NURO controls, but generally closure of the Enable/Disable circuit provides a call for heat to the boiler. Opening this circuit prevents the boiler from running.

The boiler ships with a factory-installed jumper across the Enable/Disable terminals. This circuit is energized with a

4-20mA Analog Input –

24VAC

potential, so the contacts on any remote enable devices must be rated for minimum

TB1-3

and

TB1-4

can be used to provide a remote analog 4-20mA control signal to

24VAC

the boiler. This analog signal can be used to change the boiler’s operating setpoint or firing rate.

Spare Analog Input –

HDR Temp Sensor –

TB1-5

TB1-7

and

TB1-6

TB1-8

are reserved for future use.

can be used to connect a remote header temperature sensor, installed in the primary hydronic system piping, downstream of all the boilers. This temperature sensor must be a 2-wire 12kΩ NTC thermistor. This circuit is energized by the boiler with a

DHW Stat/Sensor –

TB1-9

and

TB1-10

can be used to connect either an aquastat or remote DHW

5VDC

potential.

temperature sensor installed in a domestic hot water storage tank. If using an aquastat, use a SPST normally-closed, break on rise type with either a fixed or adjustable deadband above and below the setpoint.

Alternatively, if using a temperature sensor, it must be a 2-wire 12kΩ NTC thermistor and be of sufficient length to measure an accurate storage tank temperature. This circuit is energized by the boiler with a

5VDC

potential.

Outdoor Temp Sensor –

TB1-11

and

TB1-12

can be used to connect an outdoor air temperature sensor which allows the NURO control to be programmed to run an outdoor air schedule. The outdoor air temperature sensor must be a 2-wire 12kΩ NTC thermistor and should be installed on the North face of the building and shielded from direct sunlight exposure. This circuit is energized by the boiler with a

5VDC

potential.

Night Setback –

TB1-13

and

TB1-14

Night Setback circuit enables the Night Setback mode which reduces the boiler’s operating setpoint. Opening this circuit resumes normal operation. This circuit is energized by the boiler with a contacts on the day/night timer must be rated for minimum

4-20mA Analog Output –

TB1-15

firing rate. When operating at full power (maximum firing rate), the boiler will provide a 20mA output. When operating at minimum power (minimum firing rate), the boiler will provide a 4mA output.

Ground –

TB1-17

provides an equipment (frame) ground connection for input, output, or communication

connections. For independently powered control devices, it may be necessary to create a common ground.

can be used to connect a day/night or occupancy timer. Closure of the

5VDC

potential, so the

5VDC

and

TB1-16

provide a 4-20mA analog output signal which tracks the boiler’s

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Cascade Shield & Cascade – multiple SONIC boilers with NURO controls. Terminals

TB1-18, TB1-19

and

TB1-20

TB1-19

can be used to setup a cascade system with

and

communication between the master and member boilers. Terminal

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TB1-20 TB1-18

are reserved for the cascade should be used to connect the

cascade communication wiring shield between all boilers. The cascade and shielding must be wired from the master boiler to each individual member boiler in a daisy-chain fashion. NOTE: Only ground the shield at the master boiler.

MODBUS COM & MODBUS Shield –

TB1-22, TB1-23

and

TB1-24

can be used to integrate the boiler with a Building Management System (BMS), Protocol Converter, or other device capable of RS-485 2-wire MODBUS communication. Terminals

TB1-22

and

TB1-23

are reserved for MODBUS and terminal

TB1-18

provides a connection for the MODDBUS communication wire shield. NOTE: Only ground the shield at the master boiler.

ECOM 1, 2 & 3 –

TB1-25, TB1-26

and

TB1-27

can be used to connect a wireless outdoor air temperature sensor. The wireless receiver should be installed at or near the boiler, and the wireless temperature sensor should be installed on the North face of the building and shielded from direct sunlight exposure.

3.3 Combustion Air

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 infiltration 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” w.c. 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 fluorocarbons 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.

Refer to the table below which summarizes the combustion air requirements for the SONIC boilers. Ensure the combustion air piping is of sufficient size (and acceptable equivalent length) in order to carry the required SCFM with a maximum friction loss of 0.22”

P-K SONIC™ Boiler Model

SC-1500 SC-2000 SC-3000 SC-4000

W.C.

Required SCFM

350 467 629 839

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 GasBurning Appliances, Categories II, III, and IV

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

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3.3.1.2

US Requirements

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3.3.1 Air Inlet Requirements

3.3.1.1 United States Considerations

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 fixed openings communicating directly with the mechanical room are considered part of the required volume. The minimum volume is 50 ft

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

• When rooms are on the same floor, 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 floor 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 floors, 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 mm2/kW) of installed appliance input capacity, and not less than the sum of the areas of all vent connectors in the room.

per 1000 Btu/hr (4.8 m3/kW) of installed appliance input capacity.

Under no circumstances

shall the boiler room ever

be under a negative

pressure.

Particular care should be

taken when exhaust fans,

compressors, air-handling

units or other equipment

may rob air from the boiler.

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.

Air inlet requirements for the United States are established by NFPA 54/ANSI Z223.1 & NFPA/ANSI 211.

openings, one opening shall commence within

When using two permanent

12 inches above the floor 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.

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TWO OPENINGS

DIRECT

VERT

HORIZ

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US Minimum Area of Ventilation Openings per Boiler (Sq In)

AIR SOURCE

SONIC TM Boiler

MODEL

SC-1500 1500 3000 500 375 375 750 SC-2000 2000 4000 667 500 500 1000 SC-3000 3000 6000 1000 750 750 1500 SC-4000 4000 8000 1334 1000 1000 2000

INDOOR AIR SUPPLY OUTDOOR AIR SUPPLY

SAME

FLOOR

DIFF

FLOORS

ONE

OPENING

3.3.1.3 Canadian Considerations

Air inlet requirements for the Canada States are established by CAN/CSA B149.1.

NOTE

1. The free area of a combustion air supply opening is calculated by deducting the

blockage area of any fixed louvers, grilles or screens from the total area of the opening.

2. Screens shall be not smaller than ¼ inch.

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

DUCT

A. 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 mm2), whichever is greater.

B. Use the following opening calculation for P-K SONIC TM boilers:

When combustion air is supplied for a forced draft burner by natural airflow 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 defined 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 airflow 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 of 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 floor level. This opening is in addition to the ventilation air opening defined in paragraph A.

D. When combustion air is supplied by natural airflow into a space containing both types of appliance

described in paragraphs B and C, the cross sectional area of the opening shall not be 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 defined 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.

P-K

SONIC

Gas Fired Boiler

TTTTechnical Service 1.877.728.5351

SONIC

Required Combustion Air

CO2 Natural Gas

echnical Service 1.877.728.5351

echnical Service 1.877.728.5351echnical Service 1.877.728.5351

F. When combustion air is supplied by mechanical means, an airflow-sensing device must be installed. It

must be wired into the pre-ignition limit c 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.

Canadian Minimum Area of Combustion and Ventilation Air Openings

Boiler

Model # Input in2 mm2 in2 mm2

SC-1500 1,500,000 SC-2000 2,000,000 SC-3000 3,000,000 SC-4000 4,000,000

BTU/Hr

Opening

50 32,258 10 6,452

67 43,226 10 6,452 100 64,516 10 6,452 134 86,451 13.4 6,452

Ventilation Air Opening

3.3.2 Flue Venting Installation

This boiler is not certified for use with Type "B" vent nor with certified as a Category II and Category IV appliances, as defined in

PVC

venting. All P-K SONIC

ANSI Z21.13/CSA 4.9

vent material to be used for US and Canada is listed in the Table of Acceptable Materials for Venting Systems located in Section 2.4.5 Venting Materials for Flue/Exhaust Systems. 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.

3.3.2.1 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. See the below table for vent design parameters

boilers are dual

, latest edition. The

P-K SONIC™ Boiler Model Frictional Resistance Stack Temperature

SC-1500, SC-2000, SC3000, SC-4000

0.22” wc 220 °F 9.2% 10.4%

CO2 LP Gas

+ 55 hidden pages

Harsco Industrial SC-1500, SC-2000, SC-3000, SC-4000 Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual