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

Download

Revised Januar y 13, 2015



INSTALLATION

OWNER ’ S



P-K SONIC™ GAS FIRE D BOILER

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



Part # 1004 90 59 78

   



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 Patter son-Kelley

M A N



A L

INSTALLATION

OWNER ’ S

M A N



A L

INSTALLATION

OWNER ’ S

M A N



INSTALLATION

OWNER ’ S

M A N



INSTALLATION

OWNER ’ S

A L

   



CERTIFIE D

     

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



 

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

M A N



A L

INSTALLATION

OWNER ’ S

M A N



A L

INSTALLATION

OWNER ’ S

M A N



A L

INSTALLATION

OWNER ’ S

M A N



A L

INSTALLATION

OWNER ’ S

M A N

A L

Gaass FFiirreedd BBooiilleerr

Installation and Operation Quick Reference

Fuel/Gas Supply

• Refer to Section 3.6 for information on proper sizing of the gas supply piping. Undersized gas piping with too much pressure drop will negatively impact the boiler’s performance.

• Install a lock-up type gas regulator to supply an appropriate gas pressure as described below:

Natural Gas Propane Gas

Minimum In let Pressure = 4.0” w.c. Maximum Inlet P ress ur e = 14.0” w.c.

Minimum In let Pressure = 7.0” w.c. Maximum Inlet P ress ur e = 14.0” w.c.

• NOTE: Harsco Industrial, Patterson-Kelley recommends installing an individual lock-up type gas regulator in the gas supply piping to each boiler. For installations where one master lock-up type gas pressure regulator will service multiple boilers, Patterson-Kelley recommends contacting the local regulator representative for application assistance specifying the appropriate lock-up type regulator and gas pipe sizing.

Electrical/Power Supply

• Carefully inspect the boiler’s nameplate labels which describe the power supply requirements.

• Provide an appropriate power feed to the boiler with overcurrent protection:

Boiler Model Power Supply Requirements

SC-2000 (240V) SC-3000 / SC-4000 (240V) SC-3000 / SC-4000 (480V)

208-240VAC, single phase, 60Hz sized for 15 Amps.

208-240VAC, three phase, 60Hz sized for 20 Amps. 460-480VAC, three phase, 60Hz sized for 20 Amps.

• 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.

• Prior to startup, carefully check all electrical connections for tightness as connections can come lose during shipping.



Exhaust Venting

• The P-K SONIC boilers are dual-certified as Category II & Category IV appliances, capable of oper atin g with slightly negative to slightly positive exhaust pressure. It is critical to ensure the flue venting material is suitable for use with the boiler.

• For Category II installations, ensure the flue venting system is designed to maintain a slightly negative exhaust pressure which does not exceed -0.04” w.c.

• For Category IV installations, ensure the flue venting system is designed to maintain a slightly positive exhaust pressure which does not exceed +0.22” w.c.

  



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351

Gaass FFiirreedd BBooiilleerr

Hydronics/Water Flow (SC-2000)

• The chart below represents the pressure drop (Ft of Head) versus the water flow rate (GPM) for the SONIC SC-20 00. This information is useful to help size an appropriate circulatio n pump. Keep in mind this pressure drop represents the boiler only, additional consideration is needed for any connected piping, valves, strainers, couplings, flanges, etc.

• The table below summarizes the minimum and maximum flow restrictions for the SC-2000:

Flow Condition Boiler Operation Flow Rate Approximate ∆T

Maximum Flow High Fire 192 GPM 20°F

Minimum Flow Ignition 48 GPM 20°F Minimum Flow Low Fire 38 GPM 20°F



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



Gaass FFiirreedd BBooiilleerr

Hydronics/Water Flow (SC-3000 & SC-4000)

• The chart below represents the pressure drop (Ft of Head) versus the water flow rate (GPM) for the SONIC SC-3000 & SC-4000. This information is useful to help size an appropriate circulation pump. Keep in mind this pressure drop repres ents the boiler only, additional consideration is needed for any connected piping, valves, strainers, couplings, flanges, etc.



• The table below summarizes the minimum and maximum flow restrictions for the SC-3000:

Flow Condition Boiler Operation Flow Rate Approximate ∆T

Maximum Flow High Fire 285 GPM 20°F

Minimum Flow Ignition 72 GPM 20°F Minimum Flow Low Fire 57 GPM 20°F

• The table below summarizes the minimum and maximum flow restrictions for the SC-4000:

Flow Condition Boiler Operation Flow Rate Approximate ∆T

Maximum Flow High Fire 384 GPM 20°F

Minimum Flow Ignition 98 GPM 20°F Minimum Flow Low Fire 76 GPM 20°F



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



Gaass FFiirreedd BBooiilleerr

Table of Contents

1 Introduction 6

2 Safety 8

2.1 General 8

2.2 Safety Prec autions 8

2.3 Training 9

2.4 Hazard Warnings 9

3 Installation 11

3.1 Receiving and Storage 11

3.2 Compliance with Codes 11

3.3 Setup 12

3.4 Electric al Connec tions 13

3.5 Inlet Air and Exhaust V enting 17

3.6 Gas Piping 27

3.7 Boiler Wat er Piping 28

3.8 Pre-St art Chec kli st 30

3.9 Safety Checks 30

3.10 Initial NURO Control Setup & Adjustment 32

3.11 Fuel/Air A djusment 34

4 Operations 36

4.1 General 36

4.2 Normal Lighting and Shut-down Procedures 37

4.3 Emergency S hut-Of f 37

4.4 Typical Boiler Operating Conditions 37

5 Maintenance 38

5.1 Maintenance and I nspect ions Schedule 38

5.2 Cleaning the Burner & Combustion Chamber 39

5.3 After Repai r s or Maintenance 40

5.4 Sequence of Operat ion 41

5.5 Troubl eshooting 42

6 Parts/Tech Support 44

6.1 Wiring Diagrams 44

6.2 Boiler Part s Identif ication (SC-2000) 55

6.3 Boiler Part s Identif ication (SC-3000 & SC-4000) 59

7 Warranty 65

Boiler Fire-Test Report

Appendix 1: Maintenance Log 67

Appendix 2: Boiler Altitude Derate Sch. 68 Appendix 3: Water Quality Standards

       



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



WARNING: If the information in this manual is not followed, a fire or explosion may result causing property damage, personal injury or loss of life.

Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance.

Installation and service must be performed by a qualified installer, service agency, or the gas supplier.

WHAT TO DO IF YOU SMELL GAS:

 Do not try to light any appliance.  Do not touch any electrical switch;

do not use any phone in your

building.

 Immediately call your gas supplier

from a neighbor’s phone. Follow

the gas supplier’s instructions.

 If you cannot reach your gas

supplier, call the fire department.



It is essential to read, understand, and follow the recommendations of this manual before installing, operating or servicing this equipment. Failure to do so could result in personal injury or death.



Installation and service must be perform ed by a qu al ified and knowledgeable individual who has been certified on the P-K Sonic™ Boiler. The feature s which permit this boiler to achieve highefficiency performance can be misused which could result in personal injury or death.

Gaass FFiirreedd BBooiilleerr

1 INTRODUCTION

This manual describes the installation and operation of the following

SC-2000:

 Natural Gas, 208-240V (single phase)  Propane Gas, 208-240V (single phase)

SC-3000:

 Natural Gas, 240V (three phase)  Natural Gas, 480V (three phase)  Propane Gas, 240V (three phase)  Propane Gas, 480V (three phase)

SC-4000:

 Natural Gas, 240V (three phase)  Natural Gas, 480V (three phase)  Propane Gas, 240V (three phase)  Propane Gas, 480V (three phase)

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 .7 26 1 or tol l free at 877. 72 8. 5351. The

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 efficiency in a minimum amount of space.



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

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 may not deliver heat to the desired location. Additional equipment such as temperature sensors, pumps, flow switches, balancing valves, and check valves will be required for satisfactory operation of any system. Harsco Industrial, Patterson-Kelley cannot be responsible for the design or operation of such systems and a qualified engineer or contractor must be consulted.

P-K SONIC™ boilers featuring NURO controls:

P-K SONIC™ gas fired boilers are fully modulating using



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



 REVISION NOTES:

 1/13/2015 – Revised flame signal information.  12/10/14 – Revised to include SC-2000 & NURO controls.  07/8/14 – Edited text, made grammar corrections.

Gaass FFiirreedd BBooiilleerr



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



2 S

AFETY

2.1 General

The SC-2 0 00, SC-3000 and SC-4 00 0 gas-fired boilers must be:

• Instal led, operated, and serviced in ac c or danc e with instructions

contained i n this manual and other supplemental manuals.

• Instal led by qualified personnel in accordanc e with designs prepared by qualified facility engineers includi ng: str uc tural, mechanical, electrical, and other applicable disciplines.

• Operat ed and serviced in accordance with a comprehensive safety program det ermined and established by the customer. Do not attempt to operate or servic e until such a pr ogr am has been established.

• Operat ed and serviced by experienced, qualif ied, and properly trained personnel in accor danc e with all applicable codes, laws, and regulations.



2.2 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.

Gas Fired Boile

OTICE

Each safety device must be maintai ne d an d chec ked per the recommended schedule. Refer to Section 5. 1 of this manual.

Safet y Feat ur es

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.

Safet y Labe ls

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



Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations.



Indicates a potentially hazardous situation which, if not avoided, coul d 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.



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351

OTICE/NOTE - NOTICE

Is the preferred signal word to address pr acti ces not rela ted to personal injury. The safety alert symbol is not used with this signal word.



Gas Fired Boile

NOTICE!

The safety labels shown below are affixed to your boi ler. Although the labels are of high quality, they may become dis l o dg ed or unr e adable over time. Contact Harsco Industrial, Patterson-Kelley at

570. 476.7261 or toll-f r ee at

877.728. 5 35 1 for repl ac ements.



Gas may lose its odor. Proper gas sensing eq ui pment and pr ocedures should be used for leak checks. Failure to detect gas leaks could result in injury or death.

2.4.4 Press u re Haz a rd s

Pressure Hazard! Hot fl uids. Install isolation valves on boi ler water inlet and outlet. Make sure

isolati on valves are closed before servicing boiler . Pressure Hazard! Hot fl uids. Annually test safety relief v alve(s) for proper operation. Do not operate

boiler with faulty relief valve(s).

2.3 Traini ng

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 equi pm en t. Fa il ur e to do s o coul d res ult in fir e or ex pl osi on a nd serious injury , death, and/or property damage.

Operating and service personnel must be thoroughly familiar with the basic construction of the SC-2000, 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, Patt er s on- K ell ey Tec hni c al Ser v i ce at

877.728.5351.



2.4 Hazard Warnings

2.4.1 Elect rical Hazard s

Shock Hazard! Properly lockout/tagout the electrical

service and all other energy sources before working on



2.4.2 Crush Hazards



or near the boiler . Shock Hazard! Do not spray water directly on this

boiler or any electrical components.

Electrical Haz ard! Do not alter wiring connections.

Lifting Hazards! Use properly rated lifting equipm ent

to lift and position the boiler. The load is unbalanced. Test the balanc e before lifting off the floor. Do not allow personnel beneath the lifted load. Refer to the approxim ate weights in the table.

Boiler Model Weight in Pounds

SC-2000 1,450 lbs SC-3000 1,850 lbs SC-4000 1,900 lbs

2.4.3 Bump Hazard from Overhead Ductwork and Piping

Injury Hazard ! Install c om ponents with adequate

vertical clearance.

SC-3000 and SC-4000

570.476.7261 or toll free at



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



2.4.5 Slip, Fall Hazards

Tripping Hazard! Do not install piping on floor surfaces. Maintai n a clear pat h ar ound the boiler. Slip and Fall Hazard ! Use a drip pan to catch water while draining the boil er. Maintain dry floor surfaces. Slip and Fall Hazard ! Do not locate intake or exhaust terminati ons di r ectly above a walkway; dripping of

condensate can cause ic ing of the walking surface. Refer to Section 3.5.

Fall Hazard! Do not stand on boiler.

2.4.6 Chemical Hazards

Chemical Hazard s from Clean in g Product s. Use

caution when cleaning the system. The use of professional assistanc e is recommended. Use safe procedures for t he disposal of all cleaning soluti ons.

Combustion Condensate – An acidic pH of approxim ately 3. 0 to 5.0 can be ex pec t ed. Use PVC, CPVC, or other c or r osi on r esi stant piping for drainage. Coll ection and disposal must be in accordance with all applicable regulations. A condensate neutralizati on ki t is available. Please contact your loc al Har sco I ndustr ial, Patterson-Kelley representative for more i nfor matio n.

2.4.7 Burn, Fire and Explosion H azards

Burn, fire, and ex pl osi on hazar ds! Installation must be in s tric t con fo r mance to a ll applicable codes

standards including NFPA 54, AN SI Z223.1 and CAN/CSA B.1 49. Install all required vent lines for gas devices. Refer to Section 3.5 .

Hazard from Incorrect Fuels! Possible fire, e xplosion, overheating, and d amage. Do not use any fu e ls except the design fuels for the unit.

Overfire Hazar ds! H igh pressure in gas s upply could result in o ver firing o f th is or o ther devices supplied from the same source.

Fire a n d E x plo s i on Ha z ar ds! Clos e the ma in gas s hut o f f before ser vicing boiler. Fire and Explosion Hazards! Do not store or use gaso line or o ther fla m mab le vapors or liquids in the

vicinity of this or any other gas fired appliance. Burn hazard! Possible hot sur faces . Do not touch gas vent during firing op era tion. Us e only factory

recommended vent componen ts. Burn Hazard! Pipes, vents, a nd bo iler co mpon ents could be hot. Do not touch p iping or stack surfa ces

during operation or im med iat e ly afte r shutdown of the boiler.

Burn Hazard! Hot flue! Use caution when ser vicing or d r aining boiler. Fire and Explosion Hazards! Use caution when ser vicing bur ner. P rop ane ( LP G) 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/trans ition is securely fastened

following any maintenance perfor med on them. These conne ctions may leak gas if assembled incorrectly. Gas Leak Hazard! A ll threaded gas connections must be made using a pipe compound that is resistant to

liquefied petro leum gas . Do not use Teflon™ tape on thr eaded g as piping. Gas Leak Hazard! Check entire gas tra in for leaks after insta llation. If there is a s me ll of gas, sh ut d ow n the

boiler and obtain immediate assistance from trained ser vice personnel and/or your local fire department . Overfire Hazard! Poss ible 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 inspec tion by facto r y-t ra ined pe rs onne l for pr oper set-up and opera t ion is recommended.

Overfire and Underfire Hazards! Poss ible fire, explosio n, overheating, and compon ent failure. Do not attempt to adjust firing ra te o f the bo iler. The firing rate mus t be adjus ted on ly by fac to ry trained personnel.

Gas Fired Boile

and



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



NSTALLATION

Gas Fired Boile



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.

NOTICE!

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



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.



NOTICE!

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



Bumping hazard from overhead ducts! Install all components with adequate vertical clearances. Insufficient clearance can restrict the service access, increasing the possibility of injury.

3.1 Receiving and Storage

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.

3.1.2 Storage Prior t o In s t all at ion

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.

3.2 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 SC-2000 heat exchanger is constructed and stamped in accordance with ASME Boiler and Pressure Vessel Code, Section IV (160 psig maximum operating pressure).

The SC-3000 and SC-4000 contain two separate heat exchangers constructed and stamped in accordance with ASME Boiler and Pressure Vessel Code, Section IV, and Section VIII – Division 1 (160 psig maximum operation pressure).

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



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



Gas Fired Boile

3.3 S

etup

3.3.1 Foundation

Provide a firm, 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 flat on the provided foundation. If the boiler is to be pulled out for maintenance, the wheels may be left attached.

3.3.2 Plac ement

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



3.3.3 Clearances

If the boiler is to be installed near combustible surfaces, the minimum clearances shown in Table 3.3.3 and Figure 3.3.3. 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 surfaces of 24” or as specified in the vent manufacturer’s listed installation instructions. The boiler must be installed in a space large enough in comparison to the boiler as described in the National Fuel Gas Code, ANSI Z223.1, latest edition.

Table 3.3.3



Type of Surface Dimensions (inches)

  

Combustible Surfaces Minimum Clearances 30 12* 24† 12**

 

Recommended Clearances for Service Access



Figure 3.3.3

A B C D

30 12* 24† 12**

                 

* “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.

NOTE: Annual maintenance items can be accessed from the front of the boiler.



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



Gas Fired Boile

3.4 Electrical Connections

The SC-2000 boiler requires 208-240 VAC, single phase, 60 hertz electrical service. The total operating amperage is indicated on the rating nameplate and the 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.

SC-3000 and SC-4000 boilers can be manufactured for 208-240 VAC, three phase, 60 hertz electrical service

The

440-480VAC, three phase, 60 hertz electrical service. The total operating amperage is indicated on the rating

nameplate and the SC-3000 & SC-4000 boilers require less than 20 Amps at full load. Before starting the boiler, check to ensure that the proper electrical service is connected to the boiler.

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 (not supplied with the boiler) i s 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 Canadian Electrical Code, Part I, Installed conduit must not block any of the boiler’s openings and must allow the side doors to be opened.

3.4.1 Single Phase Power Supply Connection (SC-2000 Only) High Voltage (TB2) Terminal Block

The SC-2000 must be supplied with 208-240VAC, single phase, 60 hertz electrical service. The SC-2000

features four dedicated power terminals on the High Voltage (TB2) terminal block. Figure 3.4.1 shows the Low Voltage (TB1) and High Voltage (TB2) terminal blocks on the SC-2000 with the front door hidden for

clarity:

CSA C22.1, latest edition.

 TB2 Terminal 1 = HOT L1  TB2 Terminal 2 = HOT L2  TB2 Terminal 3 = NEUTRAL  TB2 Terminal 4 = GROUND

NOTE:Theseterminalscan accommodatemaximum10AWG wire.

CAUTION:Donotover‐tighten theterminalscrews.Maximum tighteningtorque=6in‐lbs!

LowVoltage(TB1)TerminalBlock

HighVoltage(TB2)TerminalBlock

Figure3.4.1



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



3.4.2 Three Phase Power Supply Connection (SC-3000 & SC-4000 Only) Main Power Connecti on 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. Figure 3.4.2 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 6.1.4 for proper wiring and configuration of the internal control transformer.

Gas Fired Boile

NOTE:Thehotleadterminalscan accommodatemaximum12AWG wire.Thegroundterminalcan accommodatemaximum8AWG wire.

CAUTION:Donotover‐tightenthe hotleadterminalscrews.Maximum tighteningtorque=13in‐lbs!

LowVoltage(TB1)TerminalBlock

HighVoltage(TB2)TerminalBlock

MainPowerConnectionBox

ControlTransformer



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351

Figure3.4.2



Gas Fired Boile

3.4.2 Hi gh Voltage (TB 2) Terminal Blo ck



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-2000 with NURO controls contains two hot leads ( lead ( (

GROUND

HOT L1 & HOT L2

NEUTRAL

) and a ground lead

) for 208- 240 VAC,

), a neutral

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 and

1/2 Amp

maximum current

240VAC

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

Start Inter lock #1 – 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

120VAC

contacts on any auxiliary safety devices must be rated for a minimum of

120VAC

Start Inter lock #2 – The Start Interlock #2 terminals are in series

with Start Interlock #1 and provide additional connection points for auxiliary safety devices. This circuit is energized with

120VAC

the contacts on any auxiliary safety devices must be rated for minimum

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 #1 – These terminals are reserved for future use.

This circuit is energized with

120VAC

Auxiliary Input #2 – These terminals are reserved for future use.

This circuit is energized with

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

contacts on the end limit switch must be rated for minimum

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 and maximum current capacity of

Relay B – User-configurable relay output #2. The normally-open

1/2 Amp

contacts on this relay have a maximum voltage rating of and maximum current capacity of

Relay C –

User-configurable relay output #3. The normally-open

1/2 Amp

contacts on this relay have a maximum voltage rating of and maximum current capacity of

1/2 Amp

, so the

, so

, so the

120VAC

240VAC

Relay D –

rating of

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

240VAC

and maximum current capacity of

NOTE: 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.

Mast er A l arm Rel ay – The Master Alarm Relay terminals are normally-open dry contacts that close in the event

of an alarm output from the boiler control.

Refer to Section 6.1 for proper wiring and configuration of the electrical connections.



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351

1/2 Amp



3.4.3 Low V o lt age (TB 1) Term in al Blo ck

Gas Fired Boile

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 24VAC.

TB1-3 and TB1-4 can be used to provide a remote analog 4-20mA control signal to the

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

Spare Analog Input –

TB1-5 and TB1-6 are reserved for future use.

HDR Temp Sensor – TB1-7 and TB1-8 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 temperature

5VDC potential.

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

Outdoor Temp Sensor –

TB1-11 and TB1-12 can be used to connect an outdoor air temperature sensor which

5VDC potential.

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

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 on the day/night timer must be rated for minimum

4-20mA Analog Output –

TB1-15 and TB1-16 provide a 4-20mA analog output signal which tracks the boiler’s

5VDC.

5VDC potential, so the contacts

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

Cascade Shield & Cascade –

TB1-18, TB1-19 and TB1-20 can be used to setup a cascade system with multiple

SONIC boilers with NURO controls. Terminals TB1-19 and TB1-20 are reserved for the cascade communication between the master and member boilers. Terminal TB1-18 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.

Refer to Section 6.1 for proper wiring and configuration of the electrical connections.



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



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 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.



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.



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351

Gas Fired Boile

3.5

Inlet Air and Exhaust Venting

3.5.1 A ppli cabl e Cod es and Stand ards Codes

Unit ed St at es :

Canada:

Standards

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.

Table 3.5.1

Required Stainless Steel Vent Adapters and Category II Motorized Dampers



Boiler Size Nom.

SC-2000 10” 2640000133 10” 12” 1004906946 12”

SC-3000 10” 2640000133 10” 12” 1004906946 12”

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

NOTE: 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.

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

Fuel Burning Appliances

CAN/CSA B149.1 Installation Codes for Gas Burning

Equipment

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)

vent Size

Stainless Vent Adapter

Vent adapter size



Boiler Combustion Air inlet

Combustion air N.C. Motorized Damper

Size



Gas Fired Boile

A normally-closed motorized combustion air damper with end limit switch is required for Category II vent installations, and is optional for Category IV vent installations.

120VAC motorized dampers with end limit switches

are available for purchase from Harsco Industrial, Patterson-Kelley. Other damper motor voltages are acceptable, provided they do not exceed always

120VAC which is sourced from the boiler itself. All end limit switches must be rated for a minimum 120VAC.

240VAC. The Air Damper Interlock circuit for the end limit switch is

Motorized dampers must be powered from an external power supply

other than the boiler. Figure 3.5.1 shows a sample installation in

which Relay C is user-selected to operate a

120VAC motorized air

damper. Relay C is normally-open, so when the boiler is in standby, the combustion air damper remains closed. Once a call for heat is received, Relay C closes the

120VAC circuit (external power supply)

which provides power to the damper motor, opening the damper.

OTICE

Relay A, Relay B and Relay C are rated for a maximum voltage of

240VAC and a maximum current

capacity of

1/2 Amp. Connecting a

motorized damper which exceeds

Once the motorized damper is fully-open, its end limit switch completes the Air Damper Interlock circuit (

120VAC) which allows the

boiler to proceed to ignition.

the voltage or current capacity of the relay could cause permanent damage to the relay.

NOTE: The NURO control allows the user to allocate Relay A, B or C for use with a motorized combustion air damper. Figure 3.5.1 shows Relay C in use for the motorized combustion air damper. Depending on the

user-configuration, Relay A, Relay B, or Relay C can be selected to operate the combustion air damper.

Figure 3.5.1



External power supplies are required for Relay A, Relay B and Relay C. Because power is provided from an external source, the power is still present when the boiler is turned off. Check all voltage sources have been

disconnected prior to servicing. Failure to do so could result in electrocution, injury, or death.



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



Gas Fired Boile

3.5.1.1 Gas Vent Categories

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.



3.5.1.2 Venting Materials for Flue/Exhaust Systems

The P-K SONIC™ boilers are dual certified 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

K SONIC™

boiler must comply with the requirements for either Category II

or Category IV venting systems as specified in the latest edition of

54/ANSI Z223.1

in the US or the latest edition of CAN/CSA B-149.1 in

P-

NFPA

Canada.

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.

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

• The u se of cellu lar core PVC, CPVC and Radel as venting materials is

prohibited.

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



Acceptable Venting Materials

Table 3.5 .1.2



Model Country AL29-4C 316L SS PVC CPVC POLYPROPYLENE

SC-2000 US Yes Yes No Yes Note 2

SC-3000 US Ye s Yes No Yes Note 2

SC-4000 US Ye s Yes No Yes Note 2

SC-2000 Canada Yes Yes No Note 1 Note 1

SC-3000 Canada Ye s Yes No Note 1 Note 1

SC-4000 Canada Ye s Yes No Note 1 Note 1

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.



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.





Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



Gas Fired Boile

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 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 Table 3.5.2 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” w.c.

Table 3.5.2

P-K SONIC™ Boiler Model Required SCFM

SC-2000 420

SC-3000 629

SC-4000 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 Gas-Burning 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



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



Gas Fired Boile

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



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.

OTE

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.

When using two permanent openings, one opening shall commence within

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

(4.8 m

/kW) of installed appliance input capacity.

per 1000 Btu/hr

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 mm 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.

/kW) of installed

• When rooms are on different floors, each opening shall have an area

equal to 2 square inches for each 1000 Btu/hr (4400 mm 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 mm

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

than the sum of the areas of all vent connectors in the room.

12 inches above the floor and the other

/kW) of installed

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 mm

• 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 mm

/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 mm

/kW) of total boiler input is required.



Table 3.5.2.1 US Minimum area of ventilation openings per boiler (sq inches)



P-K SONIC™

Boiler Model

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 A IR SUPPLY



SAME FLOOR DIFF FLOORS ONE OPEN ING

Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351

/kW) of total boiler input is required.

AIR SOURCE

DIRECT VERT DUCT HORIZ DUCT

TWO OPENIN GS



Gas Fired Boile

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.

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

boilers:

When combustion air is supplied for a forced draft burner by natural airflow

OTE

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 mm

/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 mm to and including 1,000,000 Btu/Hr plus 1 sq. in./14,000 Btu/Hr (155 mm

/kW) up

/kW)

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”.

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

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.

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.

Table 3.5.2.2 Canadian Minimum Area of Combustion and Ventilation Air Openings

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

Model Input (Btu/Hr) in

SC-2000 2,000,000 667 43,032 67 4,303 SC-3000 3,000,000 100 64,516 10 6,452 SC-4000 4,000,000 134 86,451 13.4 8,645



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



Gas Fired Boile

3.5.3 Flue Venting

This boiler is not certified for use with Type "B" vent nor with



P-K SONIC™ boilers are dual certified as a Category II and Category IV appliances, as defined in ANSI Z21.13/CSA 4.9

Venting Systems in



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

Sectio n 3.5 .1.2 above. The exhaust vent can be run horizontally or vertically.

PVC venting.

Vent installations shall be in accordance with NFPA54/ANSI Z223.1, the National Fuel Gas Code, or CAN/

CSA-B149.1

codes.



, the Natural Gas and Propane Installation Code, or applicable provisions of the local building

3.5.3.1 V en t 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.Table 3.5.3.1 Vent Design

Parameters

P-K SONIC™ Boiler Model Frictional Resistance Stack Temperature CO2 Natural Gas CO2 LP Gas

SC-2000/SC-3000/SC-4000 0.22” wc 220 °F 9.2% 10.4%



3.5.3.2 Required Clearances 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.

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.



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.

OTICE

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 sufficient strength to withstand the weight of the vent system and any bending forces imposed by the venting system.



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



Gas Fired Boile

Interior Component Clearances

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

Table 3.5 .3.2



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

Combustible Non-Combustibles



Figure 3.5.3.2

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

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

3.5.3.3 Flue Connection

Figure 3.5.3.3



        

into occupied spaces.

OTE

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

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

OD nominal

flue 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 flue gases through the condensate system.



4” Tall Condensate Trap



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



Gas Fired Boile

3.5.3.4 Vent Termination

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

Figure 3.5.3.4

at least 3 ft above a forced air inlet located within 10 ft.

To prevent the possible re-circulation of flue gases, the vent designer must take into consideration such things as prevailing winds, eddy zones, building configurations,

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 sufficient for conditions at a specific 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 bird screen with 1” x 1”

openings is recommended for the termination. Harsco Industrial, PattersonKelley does not recommend using a vent rain cap of any type.



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

3.5.4 Venting for Multiple Boilers

While the vent design parameters outlined in S ect ion 3.5.3 still apply, achieving those same parameters in a

combined vent system, adds a significant degree of complexity. Therefore, venting systems for multiple boilers shall be designed by experienced and knowledgeable venting professionals. The venting system shall be designed to prevent backflow of exhaust gas through idle boilers. For combined breeching installations, please follow recommendations of a qualified venting engineer/manufacturer.

Harsco Industrial, Patterson-Kelley recommends that common venting systems be designed for a maximum continuous exhaust pressure of -0.04” w.c. when measured in the common vent. Locking inline dampers are recommended on the discharge of each boiler in order to maintain a slightly positive exhaust pressure within the boiler and upstream of the damper. The -0.04” w.c. in the common flue will help make sure the exhaust gases from an online boiler does not backflow through offline boiler(s). In addition, Harsco Industrial, Patterson-Kelley also recommends the use of motorized dampers in the combu s ti o n air int ake d uct to h elp prev en t the backflo w o f f l u e g as es f r om onli n e bo i lers t hr ough offline boilers.



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



Gas Fired Boile

3.5.5 Sealed Combustion/Direct Vent Systems

These boilers are also certified for operation with a sealed

Figure 3.5.5

combustion air and pressurized venting system. Such a system employs a sealed combustion air intake duct leading from outdoors and a sealed exhaust vent terminating outdoors. Air flow through the

36” Minimum

system is maintained by the combustion air fan. Allowable configurations of vent and air intake terminations are illustrated to the right.

NOTE: Drains have been omitted for clarity.

12” Minimum

The combined pressure drop of the air supply duct and exhaust vent must not exceed 0.44” wc. This pressure drop includes both the inlet and exhaust duct friction loss.

NOTE: The inlet air duct loss should not exceed 0.22” w.c.

If the air inlet and the exhaust vent terminate on the same wall of the building they must utilize the same type of termination fitting. Allowable termination fittings are either 90° elbows or tees.

This boiler may be installed with sidewall vent using room air. (Refer to air inlet requirements Section 3.5.2.1)



Figure 3.5 .5 shows the sidewall penetration requirements. The exhaust vent must be at least 3 feet above the air

intake. The air intake and exhaust vent must extend 6" to 12" from the exterior wall and be offset.



3.5.5.1 Inlet Duct Connection to Boiler

Connect the air supply duct to the inlet air collar on the boiler. The air inlet collar is 11.875” inlet duct to the collar with sheet metal screws at 90° angles and seal with aluminum tape or sealant.



3.5.5.2 Intake Duct Materials and Sizes

The air intake duct can be fabricated from

PVC, CPVC, single wall galvanized steel, or other suitable materials.

OD. Fasten the air

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 birdscreen on the intake termination is recommended. Ensure that the screen does not become blocked with snow, ice, insects, etc.



3.5.6 Removing an Existing Boiler

When an existing boiler is removed from a common venting system, the common venting system is likely to be too large for proper venting of the appliances remaining connected to it.

At the time of removal of an existing boiler, while the other appliances remaining connected to the common venting system are not in operation, the following steps should be followed with each appliance remaining connected to the common venting system placed in operation:

1. Seal any unused openings in the common venting system.

2. Visually inspect the venting system for proper size and horizontal pitch and determine that there is no blockage or restriction, leakage, corrosion or other deficiency which could cause an unsafe condition.

3. Insofar as is practical, close all building doors and windows and all doors between the space in which the appliance remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliances not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



4. Place the appliance being inspected in operation. Follow the lighting instructions. Adjust the thermostat so that the appliance will operate continuously.

5. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle or smoke from a cigarette, cigar or pipe.

6. After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas-burning appliance to their previous conditions of use.

Any improper operation of the common venting system should be corrected so the installation conforms to the National Fuel Gas Code,

ANSI Z223.1 and CSA B149 Installation Code. When resizing

any portion of the common venting system, the common vent system should be resized to approach the minimum size as determined using the appropriate tables in part 11 of the National Fuel Gas Code,

ANSI Z223.1/NFPA 54 and/or CAN/CSA B149.1

Natural Gas and Propane Installation Code.

3.6 Gas Piping

Before making the gas hook-up, make sure the boiler is being supplied with the type of fuel shown on the boiler nameplate.

The boiler shall be installed such that the gas ignition system components are protected from water (dripping, spraying, rain, etc.) during appliance operation and service (circulator replacement, control adjustment, etc.)

Figure 3.6: Simplified Gas Piping

Gas Fired Boile



All threaded connections must be made using a pipe compound that is resistant to the action of liquefied petroleum gases. Do not use Teflon tape on gas line threads!

OTICE

See Pipe Capacity for Natural Gas chart on the following page for required pipe size, based on overall length of pipe from the meter plus equivalent length of all fittings. Approximate sizing may be based on 1 cubic foot of natural gas per 1,000 Btu per hour input, i.e., 3,000,000 Btu/hr requires about 3,000 cubic feet per hour. (See “Typical Boiler Operating

Conditions,” Sec ti o n 4.4 for more

information.)

The boiler is factory fire-tested and adjusted for proper combustion. The gas train components are certified to handle a maximum inlet pressure of 14" w.c. (1/2 psig). Typical gas pressure supply for natural gas is 7" w.c. (11" w.c. for propane). If the available gas pressure exceeds 14" w.c., a suitable additional intermediate gas pressure regulator of the "lock up" type must be provided to reduce the pressure to less than 14" w.c. Refer to boiler label for minimum inlet gas pressure.

Install a sediment trap (drip leg) and a union connection ahead of the primary manual shutoff valve on the boiler. A gas piping schematic is shown above. Gas piping should be installed in accordance with National Fuel Gas Code,

ANSI Z223.1, latest edition, and any other local codes which may apply; in Canada see CAN/CSA-B.149.1,

latest edition. In the Commonwealth of Massachusetts, the gas cock must be a “T-handle type.”

Table 3.6: Pipe Capacity for Natural Gas

Nominal Iron Pipe Size (Inches)

2 2.067 5.17 10.3 2750 - - - - - -

2.5 2.469 6.16 12.3 4350 3000 2400 - - - -

3 3.068 7.67 15.3 7700 5300 4300 3700 - - -

Internal Diameter (Inches)

Equivalen t Pipe Length

90o Ell (Feet)

Tee (Feet)

Maximum Capacity in Cubi c Feet of Natural Gas Per Hour Pressure Drop of 0.5 inch Water Column/Equivalent Length of Pipe (in feet)

20 40 60 80 100 150 200

4 4.026 10.1 20.2 15800 10900 8800 7500 6700 5500 4600



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



OTICE

The SC-2000 boiler is furnished with 3” grooved connections and Victaulic Style 75 couplings. The SC-3000 and SC-4000 boilers are furnished with 4” grooved connections and Victaulic Style 75 couplings. These couplings must be used with the EPDM Victaulic seals. Isolating valves must be installed in both the inlet and outlet water connections.

OTICE

The Condensate Trap must be piped to a drain in accordance with all national, state and local codes. If installed outdoors and the local requires freeze protection, it must be field heat traced.

Gas Fired Boile

3.6.1 Gas Supply Pipi ng by Ins taller

The boiler and all gas piping connections should be pressure-tested and must be checked for leaks before being placed into service. Test with compressed air or inert gas if possible.

The boiler must be disconnected at the boiler’s manual shut-off valve

(located at the end of the supplied gas train) from the gas supply piping system during any pressure testing of the system at pressures in excess of 1/2 psig (14" w.c.).

During any pressure testing of the gas supply piping system at pressures equal to or less than 1/2 psig (14" w.c.), the boiler must be isolated from the gas supply piping system by closing the manual shutoff.

Some leak test solutions, including soap and water, may cause corrosion of the carbon steel gas pipe fittings. These leak test solutions should be cleaned off after testing is complete.



3.7 Boiler Water Piping

3.7.1.1 Pi p ing wit h Ref r i g erat ion Lines

When installed in a two-pipe system that provides both chilled and hot water, the control system should be configured so as to limit the time rate of change of temperature at the boiler. Consult your authorized Harsco Industrial, Patterson-Kelley boiler representative for application guidance.

3.7.1.2 Piping with A ir Handling Units

The boiler piping system of a hot water heating boiler connected to heating coils located in air handling units, where they may be exposed to refrigerated air circulation, must be equipped with flow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle.



3.7.2 Boiler Inlet and Outlet Connections

All water connections should be in compliance with national, state and local code requirements. Adapters from Victaulic to NPT are available from Harsco Industrial, Patterson-Kelley. The bottom rear connection to the boiler is the INLET and must be used for the return from the system. The top rear connection to the boiler is the OUTLET and must be connected as the supply to the system. All water piping must be installed such that no stresses are

transmitted to the boiler. The boiler shall not be used as a pipe anchor.

Figure 3.7.2

Install Section IV Relief Valve Here

OUTLET ( Supply) 

Possible installation location of Section VIII Relief Valve (SC-3000 & SC-4000 Only)

INLET (Return) 



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



Gas Fired Boile

3.7.3 Boiler Water Piping by Installer Strainer

To avoid possible contamination of the boiler with dirt, rust or sediment from the system, a strainer near the boiler inlet is strongly recommended. Even new systems may contain sufficient foreign material to eventually reduce the performance of the heat exchanger. Adequate circulation of good clean water is essential for maximum efficiency and long life of the boiler.

Relie f Valve Pipin g

Each boiler must be supplied with pressure-relief valves sized in accordance with ASME requirements. The relief valves must be piped to an acceptable drain. Reducing couplings or other restrictions are not permitted in the discharge line.

The SC-2000, SC-3000 and SC-4000 boilers require an ASME Section IV relief valve to be installed on the top of the OUTLET (Supply) connection. The spindle of the relief valve must be vertical. The ASME Section IV relief valves are available for purchase from Harsco Industrial, Patterson-Kelley.

The SC-3000 and SC-4000 boilers also require an ASME Section VIII relief valve to be installed somewhere on the boiler or connecting piping before any isolation valve(s). A side port on the OUTLET (Supply) connection is available for this purpose. The ASME Section VIII relief valve is provided with the SC-3000 and SC-4000 boilers for convenience.



Low Water Cut-off

The boiler is furnished with a probe-type low water cut-off; no field piping is required. If the water level in the boiler drops below the probe, the boiler will shut down and will be displayed on the control panel. The low water cutoff circuit will automatically reset when the low water condition clears; however the boiler controls will retain the lockout condition until the reset button on the display is depressed. Installation of external limit controls may be required by certain codes or in certain installations. Review applicable local codes for details.



Drain Valve and Piping

A drain valve is factory installed in the boiler inlet (system return) piping. Prior to draining the boiler, electrical power and gas supply must be turned off to the boiler, and the boiler must be isolated from the system at the supply and return connections.



Condensate Drain

The condensate is acidic (pH between 3.0 and 5.0) and may be corrosive to some building drain systems. A condensate neutralization system may be required and is available from Harsco Industrial, Patterson-Kelley. If the condensate drainage system is exposed to freezing temperatures, it must be field heat traced. The boiler could generate up to one gallon of condensate per 100,000 BTU input. As an example, an 40 gallons per hour of condensate!

SC-4000 boiler at full fire can produce

LOCKOUT LOW WATER LEVEL

OTICE

The low water cutoff probe only allows boiler operation when the water level in the boiler is sufficient. It does not detect low water conditions in other parts of the system. Installation of additional low water safety devices to protect the system should be considered.

OTICE

This drain valve is factory installed for draining the boiler water only, not the entire system. Draining of the system through the boiler will result in depositing sediment from the system in the boiler which will result in poor heat transfer characteristics of the boiler and early boiler failure.

OTICE

Condensate Trap must be piped to drain in accordance with all national, state and local codes.

OTICE

Glycol or other treatment chemicals added to the system must be certified by the chemical manufacturer for use in multi-metal systems that include Stainless Steel boilers.

OTICE

Under no circumstances should petroleum based cleaning or sealing compounds be used in the boiler system.

OTICE

Under no circumstances should the hydronic system be flushed while the boiler is attached to the system since the debris or corrosion products could accumulate in the boiler and plug the boiler’s heat exchanger.



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



3.7.4 Flushing and Filling Water Quality

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, please refer to Harsco Industrial Patterson Kelley

Multi- Metal Systems Water Quality Standards as it appears in Appendix 3 as this applies to the warranty of

your heat exchanger.



Never attempt to operate a boiler that has failed to pass all the safety checks described below. Operating a boiler that has failed a safety checks could result in injury. Bypassing safety mechanisms will result in unsafe boiler operation which could result in injury or death.



After checking controls by manual adjustment, make sure they are always reset to their proper settings.

OTICE

If the expected error code(s) do not



appear, call for qualified service.

3.8 Pre-Start Checklist

Before attempting to start the boiler, make sure the following items have been completed.

1. Inspect the gas train, blower, ignition electrode and boiler in general to be sure there was no damage during shipment or installation.

2. Flue gas from the boiler is properly vented.

3. Gas connection has been made, pressure tested for leakage and the line purged of air. Make sure all required vents have been installed.

4. Water connections are complete and the boiler and system have been filled and purged of air.

5. The boiler is connected to the correct electrical power source listed on the nameplate, a disconnect having adequate overload protection is required.

6. Combustion air openings are not obstructed in any way and have adequate capacity.

7. The boiler is placed the proper distance from any combustible walls.

8. Relief valves have been piped to an acceptable drain at a safe point of discharge.

9. Condensate piping is properly connected.

10. Verify system water quality is within specifications.

Gas Fired Boile

3.9 Safety Checks

The following checks of safety systems must be made before putting the boiler into normal operation.

Before firing the boiler refer to Section 4 for information on the use of

the controls, lighting, and shut-down procedures.



3.9.1 Ignition Safety System Test

Test the ignition system safety shutdown as follows:

1. Cycle the boiler on by generating a heat request. (The method for this will depend on your boiler configuration.)

2. During the pre-purge cycle (before ignition), smoothly close the downstream manual isolation valve (inside the boiler cabinet) to reduce the gas flow.

3. Closing the manual isolation valve will prevent a successful ignition, and the NURO will display either:

 109: “Ignition Failed”  110: “Ignition Failure Occurred”

The user should become thoroughly familiar with the operation of the boiler and controls before attempting to make any adjustments.

Changing parameters requires an understanding of the parameters and the functionality of the boiler. The boiler may not function properly if parameters are changed from the factory values.



These alarms indicate an ignition failure and the lockout will remain until the control is reset. After completing this test, turn the boiler off, open the downstream manual isolation valve, then turn the boiler back on.



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



Gas Fired Boile

3.9.2 Low Water Cut-out Test

The boiler is furnished with a probe-type low water cut-out. The probe is installed near the boiler’s outlet in order to detect the presence of water at the highest possible location in the boiler and is connected to the low water cutout circuit board by a single wire. The low water cut-out circuit board is located inside the boiler’s front door, toward the top of the control panel and is identified with a yellow label.

In order to test the low water cut-out, press and hold the red “Push to Test” button for at least 5 seconds. A manual

lockout reset error displaying 10010: “Low Water Limit” on the NURO touchscreen should occur. The red LED

indicator on the Low Water cut-off will no longer be illuminated.



Optional Test Me thod: First turn the boiler off, and then turn off the boiler’s circulating pump. Isolate the

boiler from the system. Drain the water level below the low water cut-off probe. Turn the boiler back on. It

should not operate, and a manual lockout reset error displaying 10010: “Low Water Limit”

touchscreen should occur. The red



LED indicator on the Low Water cut-off will no longer be illuminated.

on the NURO

Return the system to normal operation by refilling with water, restarting the boiler’s circulating pump, and then turning the boiler back on.

3.9.3 Manual Reset High Temperature Limit Test

The boiler is furnished with a manual reset high temperature limit which features a probe installed near the boiler’s outlet in order to measure the outgoing supply water temperature. This probe is connected to the manual reset high temperature limit by a thin, metal capillary tube. The manual reset high temperature limit is located inside the boiler’s front door, toward the top of the control panel and is identified with a yellow label.

Test the manual reset high temperature limit control as follows:

1. Cycle the boiler on by generating a heat request.

2. Allow the boiler to proceed through ignition until main flame is established.

3. Using a flathead screwdriver, turn down the setting on the manual reset high temperature limit to its

lowest value. Turning the screwdriver counter-clockwise decreases the temperature setting.

4. When the outgoing supply water temperature exceeds the setting on the manual reset high temperature

limit, the main burner will shut off.

The NURO touchscreen will display 10009: “High Temperature Limit”. Return the system to normal operation

by readjusting the setting on the manual reset high temperature limit to its default setting, press the reset button on the manual reset high temperature limit, and finally touch any prompts from the NURO control.



3.9.4 Gas Pressure Switch Tests Low Gas Pressure Switch

The boiler is furnished with a low gas pressure switch, installed near the boiler’s main gas shutoff/control valve. The operation of this switch must be checked as follows:

1. Cycle the boiler on by generating a heat request.

2. Allow the boiler to proceed through ignition until main flame is established.

3. Slowly close the main gas cock while the burner is operating.

4. When the available gas pressure drops below the setting of the low gas pressure switch, the main

burner will shut off.

When the low gas pressure switch opens, the NURO touchscreen will display 10012: “Low Gas Limit”. Even after re-opening the main gas cock, 10012: “Low Gas Limit” will remain on until the NURO display until the

boiler is manually reset.



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



High Gas Pressure Switch

The boiler is furnished with a high gas pressure switch, installed near the boiler’s main gas shutoff/control valve. The operation of this switch must be checked as follows:

1. Before starting the boiler, close the downstream gas cock located inside the boiler’s enclosure.

2. Cycle the boiler on by generating a heat request.

3. Allow the boiler to proceed to ignition.

4. When the gas pressure exceeds the setting of the high gas pressure switch, the main burner will shut

off.

When the high gas pressure switch opens, the NURO touchscreen will display 10011: “High Gas Limit”. Even after re-opening the downstream gas cock inside the boiler, 10011: “High Gas Limit” will remain on the NURO

display until the boiler is manually reset.



Gas Fired Boile

3.10 Initial NURO Control Setup & Adjustment

This manual covers basic NURO control setup and adjustment. For a basic walkthrough of the control setup, please refer to the NURO Getting Started Guide which is helpful for basic boiler installations. For more complex boiler applications and more information on the parameters, please refer to the NURO Advanced User’s Guide.

Startup

When the boiler is powered on, the NURO touchscreen will display an initial Startup Screen and Rep Information

Screen (Fi gu re 3.10a & F ig ur e 3.1 0b ). After a brief time, the Rep Information Screen will timeout automatically which will load the Home Screen (Figure 3.10c). The Home Screen shows a snapshot of the boiler’s current

operating conditions:

 Outlet (Supply) Temperature

 Inlet (Return) Temperature

 Exhaust Temperature

 Firing Rate, etc.

Figure3.10a:StartupScreen Figure3.10b:RepInformationScreen Figure3.10c:HomeScreen



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



Figure3.10d:InformationScreen

Information Screen

Pressing the “Info” button in the lower left corner will load the Information Screen (Figure 3.10d). The Information

Screen contains real-time read-only boiler values such as temperatures, relay states, etc. Scroll through the Information Screen by sliding your finger up or down.

Figure3.10e:MainMenuScreen

Figure3.10f:SetupWizard

Gas Fired Boile

This screen is helpful to determine the operating characteristics of the boiler. For more information on any value, please refer to the NURO Getting Started Guide or the NURO Advanced User’s Guide.

Comfort Heat Setup Wizard

From the Home Screen, touch the “Settings” button in the lower right corner which will load the Main Menu

Screen (Figure 3.10e). Next, touch the “Comfort Heat Wizard” to launch the Setup Wizard (Figure 3.10f).

The first step of the Setup Wizard is to assign functionality to the user-configurable Relays A thru D. Touching one of the Relay buttons will bring up the Relay Assignment Screen. This screen allows the user to assign

functions like “Boiler Pump”, “System Pump”, “Flame Detected” and “Air Damper” to the relays. NOTE: The relay assignments must agree with the wiring to/from the boiler. For example, if Relay A is user-configured to

enable/disable the Boiler Pump, the control wires to operate the boiler pump must be properly wired to the Relay A terminals in the High Voltage (TB2) terminal block. Press the “Next” button to continue.

The next step of the Setup Wizard is to define how the boiler is enabled. This will prompt the user to “Check All That Apply”. Most installations may include a dry contact “Remote Enable” signal to the boiler. Other installations may also use an “Outdoor Air Sensor”. Select the methods by which the boiler will be enabled or disabled for operation. Press the “Next” button to continue.

Once the control strategy has been defined, the Setup Wizard steps through the temperature setpoints, differentials, outdoor air reset curve (if applicable), etc. You can change these values in one of three ways:

1. Use the slider bar for quick, large temperature adjustments.

2. Use the UP or DOWN arrows for fine-tuning the temperature.

3. Touch the numeric value directly which will load a 10-digit keypad for precise control settings.



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



Gas Fired Boile

Comfort Heat Operation

Once the desired temperature adjustments are complete, touch the “Home” button to return to the Home Screen. The Home Screen will now show the temperature setpoint, and will announce the operating condition “Standby”, “Prepurge”, “Ignition” at the top of the screen. Ensure that all external control equipment (Remote Enable, Outdoor Air Temperature Sensor, etc.) selected during the Setup Wizard is installed and properly wired to the boiler. The boiler is now programmed for Comfort Heat operation. For applications including Domestic Hot Water (DHW), Cascade, etc., please refer to the NURO Getting Started Guide or NURO Advanced User’s Guide.

3.11 Fuel/Air Adjustment



The SC-2000, SC-3000 and SC-4000 boilers are equipped with a gas/air ratio control valve and a gas safety shut off control valve, combined into one valve assembly. The valve functions in series with the variable speed combustion blower to supply the correct gas/air mixture for optimum firing performance and efficiency. The combustion blower speed is controlled automatically by the boiler controller. The blower speed determines the amount of air flow and the amount of suction/negative pressure at the gas valves. The gas valve adjusts gas flow to maintain the proper delivery pressure at the outlet of the valve.



3.11.1 Gas Pressure Adjustment

See rating plate for the minimum and maximum gas pressure of the boiler. The supply pressure during main burner operation must be greater than the minimum indicated on the rating plate. Nominal gas supply pressure is 7” w.c. for natural gas. The gas pressure must not exceed 14” w.c. which is the maximum allowable pressure on the gas train components. Each boiler is furnished with a manual shut-off valve which has an integrated test port. This port is located on the upstream side of the valve body for

measuring supply pressure. (Refer to Figure 3.11)

Figure 3.11

GasValvew/TestPort

The air flow is pre-set at the factory prior to shipment. Gas flow is dependent primarily on fan speed not upstream gas pressure. The automatic gas valve may have to be adjusted to obtain proper combustion readings for specific

local conditions. A combustion analyzer must be used. Combustion must be set in accordance with Table 3.11.2.



3.11.2 Combustion Setup and Adjustment

To adjust/tune combustion, use the NURO’s “Manual Control Firing Rate” mode. To access, touch the “Info” button in the lower left corner of the screen, and then touch “Service” in the lower left. Next, touch “Press to Activate Manual Control” which will open the “Manual Control Firing Rate” mode. This test mode should be used when adjusting or tuning the gas safety shut off/control valve on the

In this mode a heat request is required. Once the boiler cycles on and is running in “Manual Control Firing Rate”, use the UP and DOWN arrow keys or the slider to force the boiler to operate at low fire or high fire (or anywhere in-between). To prevent the boiler from cycling off prematurely during adjustment, ensure that any load devices (air handlers, control valves, radiators, etc.) are in operation and able to shed/dump the heat load created by the boiler.



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351

SC-2000, SC-3000 or SC-4000 boilers.



Table 3.11.2: Recommended Combustion Settings for SONIC Boilers

Fuel Nominal Gas PressureHigh Fire Setting Low Fire Sett ing

% O2 % CO2 % O2 % CO2

Natural Gas

Propane Gas

7" w.c.

11" w.c.

4.8

± 0.2

4.8

± 0.2 10.4 ± 0.3 5.0 ± 0.2 10.3 ± 0.3

9.2 ± 0.1

5.0 ± 0.2 9.1 ± 0.1

Gas Fired Boile

Adjusting High Fire Required Tools: Flat head screwdriver and combustion analyzer

Start the boiler and observe proper operating parameters for the system. Set boiler to the

“Manual Control Firing Rate”, as

described above, and increase the firing rate to 100%.

Check combustion readings using the combustion analyzer. If

combustion readings do not agree with Table 3.11.2, adjust as

follows:

Open the front panel of the boiler. Locate the automatic gas valve. Turn the orifice adjusting screw, located on the downstream side of the valve, in the direction indicated on the sticker to increase or decrease the gas flow. Increasing the gas flow decreases the combustion exhaust the gas flow increases the combustion exhaust

, while decreasing

There will be a slight time delay between the adjustment and the response of the settings in small increments and allow

CO2 /O2 measuring instrument. Adjust the

the combustion readings

to stabilize before readjusting. When desired adjustments are complete, check and adjust low fire if necessary.

Adjusting Low Fire Required Tools: 2.5 mm hex wrench and combustion analyzer

Figure3.11.2

Start the boiler and observe proper operating parameters for the system. Set boiler to the

“Manual Control Firing Rate”, as

described above, and decrease the firing rate to 1%. Once the boiler has reached low fire operation, check combustion readings using the combustion analyzer. If combustion

readings are not in accordance with Ta b l e 3 .11. 2, adjust as

follows:

Open the front panel of the boiler. Locate the automatic gas valve. Turn the offset screw, located in the bottom center of the side of the valve, in the direction indicated on the label to increase or decrease the gas. Increasing the gas concentration decreases the

There will be a slight time delay between the adjustment and the response of the

, while decreasing the gas concentration increases the O2.

CO2/O

measuring instrument.

Adjust the settings in small increments and allow the combustion readings to stabilize before readjusting. When desired adjustments are complete, check and adjust High Fire if necessary.

3.11.3 Checking Flame Signal

Touch the “Info” button in the lower left corner of the NURO display to load the “Information” menu which shows real-time read-only boiler values such as temperatures, relay states, etc. Scroll down the “Information” menu to find the “Flame Signal” value. This value displays the strength of the combustion flame (units = V) as measured by the ignition electrode/ionization probe. When the boiler is in standby, prepurge, or postpurge the flame signal should read 0V. During main flame, a strong flame signal should read between 20-50V.



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



Gas Fired Boile

4 Operations

4.1 General

4.1.2 NURO Control Panel

Once the boile r has been in stalled in comp liance with t his manual, it is necessary to open the front door of the boile r in order to access the power (on/off) switch located in the upper right hand corner of the NURO control panel, as sho wn in Figure 4.1. 1a and Figure 4.1.1b:

Figure4.1.1a(SC‐2000) Figure4.1.2b(SC‐3000&SC‐4000)



Do not use this boiler if any part has been under water. Immediately call a qualified service technician to inspect the boil er and to replace any part of the control system and any gas control which has been under water. Failure to do so could result in electrocution, injury, or death.



If overheating occurs or the gas supply fails to shut off, do not turn off or disconnect the electrical supply to the pump. Instead, shut off the gas supply at a location external to the boiler.

4.1.2 NURO Touch Screen Interface

Once the boiler is switched to the “ON” position, the SONIC boiler can be programmed and operated with the NURO touch screen interface located on the front door as shown in Figure 4.1.2. A clear plastic cover protects the touch screen which can be opened by pinchi ng th e clasp and swin gi n g op en to th e le ft.



4.1.3 Factory Tests

Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on this boiler when the boiler underwent factory tests specified in latest edition. (See "Fa c to ry

Firetest" label.)

ANSI Z21.13/CSA 4.9,

NOTICE!

The heat exc ha ng er is cons tructed and stamp ed for 16 0 ps i g maximum operating pressure and 210°F maximum temperature.

Figure4.1.2



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



Gas Fired Boile

4.2 Normal Lighting and Shut-down Procedures

Normal Lighting Procedures

1. Make sure the system is filled with water and water is circulating in the system. Turn on electrical supply and open the gas s upply valves to th e boiler.

2. Turn the on/off switch to the “On” posit ion. If an error is ind icated, refe r to the NURO Advanced User’s Guide to troubleshoot the problem and take necessary corrective action before proceeding.

3. Set the desired high temperature limit and operating temperature. The NURO controller will now begin

the au tomatic firing sequence.



Normal Shut Down Procedures

1. Allow the boiler to turn off on its own once the

temperature satisfies, or remove the call for heat to the bo i ler.

2. Once the boiler completes a successful “Post-

Purge” and “Post-Pump”, it will return to “St an dby”.

3. Once in standby, turn the on/off switch to the “Off”

position.

4. Close all manual gas valves (See Figure 4.3).

5. Turn off the el ectr i cal di sc o nn ec t to the boi ler .

Figure4.3

PropaneGas

4.3 Emergency Shut-Off

In cas e of emerg ency, shut off the gas supp ly at a va lve external to the boiler. See Figure 4.3 for valve locations. The upper shut off valve is for Propane Gas and the lower valve for Natural Gas.



4.4 Typical Boi ler Oper ating Condition s

Table 4.4

Model

Number

SC-2000 2,000,000 208- 240 Single Less than 15



SC-3000 3,000,000



SC-4000 4,000,000

Input

(BTU/Hr)

Rating

Voltage

208-240 Three Less than 20 440-480 Three Less than 20

Phase Total

Amperage

Gas Flow Rate (CFH)

Natural

Gas

(1030 Btu/ft^3)

1942 800 1,920,000

2913 1200 2,880,000

3883 1600 3,840,000

Gas

(2500 Btu/ft^3)



Output

Capacity

(Btu/hr)

NaturalGas

Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



Gas Fired Boile



5 Maintenance

Lockout/tagout procedure must be employed when servicing this unit. Failure to do so could result in electrocution, injury, or death.



Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper an d da ng er ous operati o n.



Use care when reassembling main gas line and ensure all co nn ec tions are tight. Use a leak detector to check for leaks before and after servicing any compone nt of the gas piping. Failure to do so could result in injury or death.



Use care when servicing boiler to prevent the ac cumulation of gas in or around the combustion chamber. Pockets of accumulated gas are subj ect to combustion and/or explosion which could result in injury or death.



Determin e the c a us e o f any lockout or errors before resetting the boiler. If ab le to determine cause of lockout, th en ap pr o pr i at e corr e c ti ve action should be taken. If unable to determine cause of the problem, call a qualified service technician. Verify prop er operation after servicing.



Check daily to be sur e that the boiler area is free and cle ar of any combustible m ateria ls, including flammable va



ors and liquids.

Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351

5.1 Maintenance and Inspections Schedule

This schedule applies when the boiler is in use. Verify proper operation after se rvicing. NOTE: The blower motor is permanently lubricat ed and does no t re quir e per iodic lubr i c a ti o n.

5.1.1 Daily

Observe operating temperature and general conditions. Make sure that the flow of combustion and ventilating air to the boiler is not obstructed. Determine the cause of any service codes or lockouts on the display panel. Observe any unusual noises or operating conditions and make the necessary corrections. Notify responsible individuals for required corrective action or repair.

5.1.2 Weekly

Observe the conditions of the main flame. A normal high fire flame is mostly oran ge with a blue halo , while at low f ire the burner will glow yellowish-orange.

Correct air adjustment is essential to the efficient operation of this boiler. Ensure that the flow of combustion and ventilation air is not obstructed.

If an adjustment in the combustion appears necessary, the flue gas composition should be checked with a carbon dioxide ( oxygen (

3.1 1.2 of Section 3.11.2. If an adjustment to the combustion is

necessary, call a qualified and knowledgeable installer or service agency that has been trained on the Harsco Industrial, PattersonKelley boilers.

5.1.3 Monthly

Install ation and serv i ce mu st be performe d by a qual ified and knowledgeable installer or service agency that has been trained on the Harsco Industrial, Patterson-Kelley boilers.

) analyzer and compared to the values stated in Table

1. Press the “Info” button on the NURO touch screen to load the Information Screen and scroll down to view the flame signal measured in Volts. Typical flame signals should read between 20-50V. If the flame signal is below 20V, the ignition electrode may need to be replaced.

2. Test the low water level cut-off. Refer to Secti o n 3.9 . 2.

3. Test the manual r eset high-temp limit. Refer to Sectio n 3. 9. 3.

4. Test low gas pressure s wi tc h. Refer to Secti on 3 .9. 4.

5. Test operating temperature controls by reducing or increasing temperature setting as necessary to check burner operation.

6. Check the condensate drain system. Clean and flush as necessary.

) or



Gas Fired Boile

5.1.4 Semi-Annually (Required for Boilers Operated Year Round)

In addition to the recommended monthly service:

1. Clean burner of any acc um ulated dus t or li nt. Refer to Sec tion 5. 2 on "Cleaning the Burner."

Inspect burner for any signs of deterioration or corrosion. Replace immediately if det eri or ation or corrosion is

evident.

3. Check the pH level of the system fluid. Verify the pH is in accordance wit h A ppendix 3.

4. Inspect and cl ean the condensate system and check for leaks. If a condensate neutrali zation kit is present, open

the lid and inspect the limestone rocks. If they are absent or have been significantl y worn away, replace them with new limestone rocks. Use hi gh- c alcium (or pure)

limestone.

5.1.5 Annually

In addition to the recommended monthly and semi-annual service:

1. Inspect and clean the inlet screen of any accum ulated dust or lint.

2. Check burner and clean off any soot or foreign m aterial that may have accum ulated.

"Cleaning the Burner." Check for c or r osi on of the burner and its parts. If there is ev idence of deterioration or corrosion, replace immediately. Inspect combustion chamber when the burner is removed for inspection. Note any signs of deterioration. Clean as necessary.

3. Inspect and clean heat exchanger. Remove the vari ous cov ers to inspect the flue gas passageways. Clean t he

combustion side casting pins by flushing with clean water and blowing dry with compressed air. Do not use any cleaning agent s or solvents. Do not use soap. A soft nylon brush may be used i n acces sibl e areas. Be sure t o i nspect the condensate collection pan that is the lowest part of the heat ex c hanger.

4. Replace the ignition electrode and gasket .

5. Drain and flush the water side of t he heat exchanger as required ( separate f rom system fl ush) using clean water

only.

6. Inspect and clean the condensate system and check for leaks. If a condensate neutr aliz ation kit is present, open

the lid and inspect the limestone r oc k s. If they are absent or have been signif icantly worn away, replace them with new limestone rocks. Use hi gh- c alcium (or pure) limestone.

7. Examine the venting system. Refer to the vent manufacturer's instr uctions for requir ements in addition to those

listed below.

a. Check all joints and pipe connections for tightness. b. Check pipe for corrosi on or deterioration. If any piping needs replacing, do so immediately. c. Inspect and clean any screens i n the vent terminal.

8. Qualified service personnel should thoroughly i nspect the heating system and correct any problem s prior to re-

starting t he boiler.

9. Qualified service personnel should thoroughly i nspect the heating system and correct any problem s prior to re-

starting t he boiler.

10. Perform combustion analysis and readjust as necessary according to Table 3.11.2 and Section 3.11.2. It is

recommended that a c opy of this report is filed for future reference.

11. P erform a leak test of the gas valves in accordance with the manufacturer' s instruc tions.

Refer to Se ction 5. 2 on

5.2 Cleaning the Burner & Combustion Chamber

Harsco Industrial, Patterson-Kelley r ec ommends cleaning the burner and combustion c ham ber at least once annually:

1. Lockout/tagout gas supply to the boiler .

2. Lockout/tagout electric al power to the boiler.

3. Disconnect the condensate neutralization tank piping in order to install a temporary drain hose into the

condensate drai n. Run the open end of this hose to a nearby floor drain.

4. Open the front and side doors of the boiler.

5. Protect the electrical and contr ol c om ponents from exposure to water with towels, a nylon t ar p, or plastic wrap.

6. Remove the wires/cables from the igniti on elec trode and flame/ionizati on r od.

7. Locate the blower and burner transition pieces located directly in the front of t he boiler. Refer to Section 6.2 for

an illustration of these components.

8. Remove the nuts and bolts connecting the blower trans ition piece to the burner transition piece. The blower

transition piece will remains supported in plac e.

9. Remove the nuts holding the burner transition piece to the studs on the front of the boil er.

10. Pull out the burner transiti on piec e with the 2 gaskets and set aside.



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



11. Carefully remove the burner from the boiler and clean with pressurized water. NOTE: Do not attempt to wash the

burner while i nstalled in the boiler. When cleaning the burner, use a mild detergent such as Simple Green t o help loosen built-up debris trapped in the burner mesh.

12. Now that t he bur ner is removed, the burner hole is open which provides access to the combustion chamber.

13. Use a pressuriz ed water hose with control noz zl e. Begin by spraying just a few seconds of water into the

combusti on chamber and then close off the nozzle.

14. Walk around to the rear of the boiler and ensure the wash water is draining into the temporar y dr ain hose off the

condensate drai n. Adjust the temporary drain hose if needed to hel p dr ain the wash water from the boiler.

15. Af ter inspecting the temporar y drain hose, continue washing the inter nal c om bustion chamber with pressurized

water for sev er al mi nutes. Spr ay as much of the internal surface area as possible. BE VERY CAREFUL when cleaning to avoid spraying any of the electrical or cont rol c om ponents.

16. Some SONIC boiler models feature two small washout ports between the upper combusti on chamber and lower

economizer. T he plugs i n these ports can be r emoved for additional acc ess to t he fireside surfaces. If necessary, continue washing the f ireside surfaces through these two washout por ts.

17. Af ter several minutes of washing, turn off the hose and allow all the wash water to drain f r om the boiler .

18. Rei nstall the plugs into the two washout ports (if applicable).

19. Reconnect the condensate tubing to the condensate neutralization tank.

20. Rei nstall the gasket over the boiler ’s thr eaded studs, and CAREFULLY insert the burner into the burner hole.

Support the burner so it r em ains horizontal while inserting.

21. Onc e the burner is installed, rei nstall the gasket over the burner’s flange.

22. Rei nstall the burner transition piece (and lower gasket) and bolt to t he bur ner flange.

23. Onc e secured to the burner flange, bolt t he bur ner transit ion piece to the blower transition piece. Ensure the

gasket between the burner transition piece and blower tr ansi tion piece is in place.

24.

Reinstall the i gnition electrode assembly (if previously removed).

25. Rei nstall the flame/ioniz ation rod assembly (if previously remov ed) .

26.

Reinstall t he wir es/c ables to the ignition electr ode and flame/ionization rod.

27.

Double check the tightness of all bolted joints.

Gas Fired Boile

5.3 After Repairs or Maintenance

Following any major repairs or preventative maintenance, follow the steps below before returning the boiler to service.

1. Follow “Pre-Start Check List” (Refer to Sectio n 3.8) and all “Safety Checks” (Refer to Section 3.9).

2. Check the gas pressur e (Re f er to Section 3.11.2) and ensure proper operation of the boiler.

3. Perform combustion check (Refer to Sectio n 3.1 1. 2) and adjust air/gas mixtur e at hi gh fir e & low fir e i f

the O

NOTE: Installation and service must be performed by a qualified installer or service agency that has been trained on the Harsco Industrial, Patterson-Kelley boiler.

% or CO2% are out of rang e.



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



Gas Fired Boile

NOTICE!

Once the boiler begins the ignition sequence, the firing sequence will continu e until m ai n fl am e is reac hed regardless of heat request. The sequence can be interrupted by turning the power switch off.



If any “Manual Reset” limit device trips, DO NOT reset without dete r m ining and correcti ng the cause. Manual Reset Limits include: Flame safeguard, high or low gas pressure, high temperature limit, stack temperature, low water level. Attemptin g to op er at e a boi l er without diagnosing the cause of failure can result in unsafe operation, increasing the risk of injury. Neve r at te mpt to bypass a safety limit device.

         

 



Figure5.4

5.4 Sequenc e of Op eration

1. When the Boiler On/Off switch i s turned on, power is provi ded thr ough over-cur rent protection (fuse and/ or circuit br eaker) to the boil er control and the combustion blower.

2. When the outlet water temperature drops below “CH SETPOINT” minus “CH DIFFERE NTIAL O N”, a heat request is generated.

3. Provi ded all lim its are m ade and the r em ote enabl e signal ( if install ed) is active, the boiler will attempt to start.

4. The NURO control c hecks to make sure air pressure switch i s open indicati ng there is no airflow through t he boiler. The combustion blower is then driv en towards the pre-start f an speed. When the air pr essure switch closes, t he “PRE PURGE TIME” timer is started. Once the “PRE PURGE TIME” timer expir es, the blower is driven to the ignition speed.

5. A trial for ignition begins and the sequence of events is illustrated graphically below in Figure 5.4. A valid flame signal must be det ected within 4 seconds after the gas valves open (elapsed tim e 7 seconds).

6. After a successful ignition, the fan is driven to low fire and the “CH LOW FIRE HOLD TIME ” timer is started. Once t he “LOW FIRE HOLD TIME” timer expires, the boiler is released to modulati on.

7. The NURO control modul ates the fi ring r ate bet ween l ow and high f i re to maintain the desired outlet water temperature.

8. The burner will continue firing until the outlet water temperature exceeds “CH SETPOINT” plus “CH DIFFERENTIAL OFF”. At this temperature, the gas valves are closed com bustion air fan continues to run until the “POST PURGE TI ME” timer has expired.

9. When the outlet water temperature is reduced by the load on the system, a heat request is generated. The operating sequence will recycle to

Step 3 .



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



Gas Fired Boile

5.5 Troubleshooting

The NURO cont rol will d isplay graphical and/or text based erro r descriptions to announce any p roblems with the boiler. There are two types of lockouts: manual reset lockouts which require the operator to physically press the on-screen or device’s reset bu tton, and automatic reset lockouts which will self reset when the error condition clears. For a comprehensive list of errors and potential resolutions, please refer to the NURO Advanced User’s Guide.

Should the unit fail to operate, call a qualified service technician to troubleshoot the problem and implement corrective actions.

5.5.1 Loss of Power

In the event of a power failu re, the NURO touch screen will go dark an d the entire boiler will de-energize. The signal relays used to command auxiliary devices connected to the boiler (a ir dampers, pumps, etc.) will also lose power, so these devices will deactivate. When power is restored, the sequence of operation will resume a t Step 3 (Section 5.4). If any error/lock out errors were pre sent at the time of the powe r failure, the NURO control will retain that error/lockout when power is resto red .

5.5.2 Loss of Water Level

The low water switch opens when there is an insufficient water level in the boiler. The NURO control will display 10010: “Low Water Limit”, close the gas valve, and lock the boiler out. When the water level is corrected and the on-screen reset button is pressed, the boiler will reset and resume the sequence of operatio n at Step 3 (Section 5.4)

5.5. 3 Low Gas Pressure

The low gas pressure switch opens when there is (or has been) insufficient gas pressure available for proper operation of the boiler. If an external gas-supply shut-off valve is closed for any reason, a low gas condition will result. The NURO control will d isplay 10012: “Low Gas Limit”, close the gas valve, and lock the boiler out. When proper gas pressure is restored, and the on-screen re set button is pressed, the boiler will reset and resume the sequen ce o f oper ation at Step 3 (Section 5.4).

5.5.4 High Gas Pressu re

The high gas pressure switch opens when there is (or has been) excessive gas pressure for the proper operation of the boile r. The NURO control will display 10011: “High Gas Limit”, close the gas valve, and lock the boiler out. When proper gas pressure is restored, and the on-screen reset button is pressed, the boiler will reset and resume the sequence of operation at Step 3 (Section 5.4).

5.5.5 Hi gh Water Temperature

When the boiler water has exceeded both the operating temperature limit and the manual reset hightemperature limit , the NURO cont rol will d isplay 10009: “High Temperature Limit”, close the gas valve, and lock the boile r out. W hen the water te mperature falls b elow the high-limit te mperature set ting, the bo iler will remain locked out until the water high-temperature limit switch is manually reset and the on-screen reset button is pressed. Once reset, the control will resume the sequence of operat ion at Step 3 (Section 5.4)

5.5.6 Low Air If the NURO control displays either 65: “Interrupted Airflow Switch OFF” or 66: “Interrupted Airflow

Switch ON”

when the boiler is in “Standby”, the blower should also be in standby.

, this indicates improper airflow through the boiler. First, verify proper standby blower operation –

Next, check for obstructions of the combustion air intake and/or exhaust (flue) piping. Next, check the hoses leading to the air switches are not kinked or obstructed. An error related to the air switch does not necessarily mean that the air switch is defective.

When 6 6: “ Inte rru pte d Airf lo w Sw itch ON” is displayed, check that the air switch is open when the blower is offline. Ensure there is no air flow through the boiler when the blower is offline. An excessive negative draft in the flue piping can cause air flow through the offline boiler which may be strong enough to maintain closure of the air switch.



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



When 65: “Interrupted Airflow Switch OFF” is displayed, check that the air switch is closed when the blower is running. If the air switch does not close within 5 minutes during purge, the boiler locks out. Check that the burner is clean ("Cleaning the Burner," S ecti o n 5. 2) and that there are no obstructions to airflow in the intake or exhaust ducts.

5.5.7 Flame Failure

In the event of a flame failure, the NURO control may display one of the following error messages:

 106: “Flame Lost in Main Flame Establish Period”  107: “Flame Lost Early in Run”  108: “Flame Lost in Run”  109: “Ignition Failed”  110: “Ignition Failure Occurred”

When 10 9: “Ignition Failed” or 110: “Ignition Failure Occurred” is displayed, the boiler did not light during the trial for ignition. Check that the ignition electrode, ignition wire, and gas valve are functioning properly. Check that the direct spark ignition is visible through the flame observation port during the trial for ignition.

When 106: “Flame Lost in Main Flame Establish Period”, 107: “Flame Lost Early in Run”, or 108: “Flame

Lost in Run”

properly, the gas pressure is correct, and the ignition electrode, ignition wire, and gas valve are functioning properly.

5.5.8 Flame Error

is displayed, the boiler lost the flame signal during operation. Check that combustion is adjusted

Gas Fired Boile

In the event of a flame error (premature or late flame signal), the NURO control will display 105: “Flame Detected Out of Sequence”. This may be caused by a failed/leaky gas valve or a flame rod or ionization rod malfunction. If gas valve leakage is suspected, the unit must be isolated by turning off the main gas supply line. Lockout/tagout the boiler until qualified and knowledgeable service personnel are available to evaluate and repair or replace the failed parts. Check that the incoming gas pressures have not exceeded 14” w.c. (1/2 psig).

5.5.9 Flue Problem

When the no rmally-closed high e xhaust bac k pressure switch opens , the NURO cont rol will display 10013: “High Back Pressure Limit”. This may be caused by an obstruction in the flue piping, an obstruction in the combustion air intake, or a blocked condensate system. When the blockage is removed, the boiler will automatically restart. If no blockage is found, it may be necessary to replace the high exhaust back pressure switch.



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



Gas Fired Boile

6 Parts/Tech Support



Use of Non-Factory Authorized replacement parts are not recommended for this equipment. All control components are engineered for safety and are designed to work in unison with each of the other components. Use of non-factory authorized replacement parts jeopardizes the functionality of the safety features as well as the performance of the boiler.

Spare parts and replacement parts can be ordered from Harsco Industrial, Patterson-Kelley by calling toll free (877) 728-5351. Reach us by fax at (570) 476-7247.



Refer to the parts list shown on the assembly drawings provided in this manual.



Technical information is also available by calling or visit the Harsco Industrial, Patterson-Kelly website, www.harscopk.com.



When ordering replacement parts please have the model number and serial number of your boiler available.



Typical schematic drawings are shown on the following pages. Drawings specific to your particular boiler can also be supplied by your local Harsco Industrial, Patterson-Kelley representative.

6.1 Wiring Diagrams

6.1.1 Terminal Block Assignments – Power Box (SC-3000 & SC-4000 Only)

The power box is located in the front of the boiler, at the lower left corner. This power box houses the control transformer, fuses, the power box terminal strip circuit breakers, and the blower motor relay.

The three phase circuit breaker is mounted on The terminals on the circuit breaker can accommodate maximum 10AWG wire. There is an additional terminal on the

DIN rail for a ground connection. Refer to the Ratings Nameplate on the back surface of the boiler to verify

the required electrical supply prior to connection.

DIN rail and allows for direct connection of the three power leads.

Figure 6. 1.1 Power Box Wiring Diagram (240V Configuration Shown)





Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



6.1.2 Term i n al Bl o ck Assi gn ments — High Vol t ag e (TB2) Terminal Block

Gas Fired Boile

SC-2000 Terminal Number

25 22

24 21

23 20

22 19

21 18

20 17

19 16

18 15

17 14

16 13

N/A 12

15 11

14 10

13 9

12 8

11 7

10 6

9 5

8 4

7 3

6 2

5 1

4 N/A 3 N/A 2 N/A 1 N/A



SC-3000 SC-4000 Terminal Number

Label Description

MASTER ALARM RELAY

RELAY A

RELAY B

RELAY C

RELAY D

GROUND

[120V+] AIR DAMPER

AIR DAMPER INTERLOCK

[120V+] AUXILIARY #1

AUXILIARY INPUT #1

[120V+] AUXILIARY #2

AUXILIARY INPUT #2

START INTERLOCK #1

START INTERLOCK #2

GROUND G1 for 208-240VAC, Single phase, 60Hz

NEUTRAL N1 for 208-240VAC, Single phase, 60Hz

HOT L2 L2 for 208-240VAC, Single phase, 60Hz

HOT L1 L1 for 208-240VAC, Single phase, 60Hz

Normally-Open Dry Contact, Close on Alarm (240VAC Max Voltage & 1/2Amp Max Current)

User-Configurable Normally-Open Dry Contact A (240VAC Max Voltage & 1/2Amp Max Current)

User-Configurable Normally-Open Dry Contact B (240VAC Max Voltage & 1/2Amp Max Current)

User-Configurable Normally-Open Dry Contact C (240VAC Max Voltage & 1/2Amp Max Current)

User-Configurable Normally-Open Dry Contact D (240VAC Max Voltage & 1/2Amp Max Current)

Ground Terminals for I/O Devices

120VAC Pilot-Duty for Air Damper End Limit Switch Contact Closure When Air Damper Proven Open

Reserved for Future Use

External Interlock Circuit #1

External Interlock Circuit #2 (In Series w/ #1)





Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



6.1.3 Term i n al Bl o ck Assi gn ments — Low Voltage (TB1) T erminal Bl o ck



Terminal Number Label Description

Gas Fired Boile



ECOM 3

ECOM 2

ECOM 1

MODBUS SHIELD

MODBUS COM B

MODBUS COM A

MODBUS/CASCADE REF

CASCADE B TO B

CASCADE A TO A

CASCADE SHIELD

GROUND

ANALOG OUTPUT [-]

4-20mA ANALOG OUTPUT [+]

NIGHT SETBACK

OUTDOOR TEMP SENSOR

DHW STAT / SENSOR

HDR TEMP SENSOR

SPARE ANALOG INPUT

ANALOG INPUT [-]

4-20mA ANALOG INPUT [+]

ENABLE / DISABLE

Wireless Outdoor Air Receiver

2-Wire MODBUS RS485 & Shield Terminal

Reference Terminal (Application Dependent)

2-Wire Cascade & Shield Terminal

Ground Terminal for I/O Devices

4-20mA Analog Output Tracks Boiler Firing Rate 100% Firing Rate = 20mA, 1% Firing Rate = 4mA

Contact Closure Enables Night Setback Operation Open Circuit Disables Night Setback Operation

Outdoor Air Temperature Sensor for ODA Reset Configurable for 10kΩ or 12kΩ Sensor

DHW Enable Circuit Configurable for SPST Break-onrise Aquastat, or 10kΩ or 12kΩ Tank Sensor

Hydronic Supply Header Temperature Sensor Configurable for 10kΩ or 12kΩ Sensor

Reserved for Future Use

4-20mA Analog Input Configurable for Setpoint or Firing Rate Control

Contact Closure Enables Comfort Heat Operation Open Circuit Disables Comfort Heat Operation



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



6.1.4 SC-3000 & SC-4000 Control Transformer Diagrams

Gas Fired Boile

Figure 6. 1.4 a SC-3000 & SC-4000: 208 VAC, three phase, 60 hertz:



Before making any electrical connections to the boiler, verify that the control transformer is properly configured for the applicable incoming power supply to the boiler:

 208V, three phase, 60Hz  220-240V, three phase, 60Hz  440-480V, three phase, 60Hz

Improper configuration of the control transformer could result in serious injury or death.

Figure 6. 1.4b SC-300 0 & SC- 40 00 : 22 0- 2 40 VAC, three phas e, 60 hertz:



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



Figure 6. 1.4 c SC-3000 & SC-4000: 440-480 VAC, three phase, 60 hertz:

Gas Fired Boile





Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



6.1.4 SC-2000 Wiring Diagram

Gas Fired Boile



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



Gas Fired Boile



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



6.1.5 SC-3000 & SC-4000 240V Wiring Diagram

Gas Fired Boile



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



Gas Fired Boile



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



6.1.6 SC-3000 & SC-4000 480V Wiring Diagram

Gas Fired Boile



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



Gas Fired Boile



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



Gas Fired Boile

6.2 Boiler Parts Identification (SC-2000)

6.2.1 Main Boiler Assembly (SC-2000)

6

5



Mark Description

1 HeatExchanger 5 FrontDoor/NUROTouchscreen 2 Burner/BlowerAssembly 6 NUROControlPanel 3 CabinetBase 7 SheetMetalCabinet 4 NaturalGasTrain



Mark Description





Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



6.2.2 NURO Control Panel (SC-2000)



1

2

Gas Fired Boile

12

8

11

10

9

Mark Description

1 PushtoTestLWCOButton 7 NUROTouchscreenAssembly 2 ManualResetHiTempLimit 8 ClearPlasticProtectiveCove 3 CircuitBreake 4 On/OffSwitch 10 LowVoltage(TB1)TerminalBlock 5 SOLAMainboard 11 TransformerXFMR2(40VA) 6 IgnitionCable 12 TransformerXFMR1(20VA)

Mark Description

9 HighVoltage(TB2)TerminalBlock



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



6.2.3 Heat Exchanger Assembly (SC-2000)

Gas Fired Boile

14

13

15

4

5

12

11

10

9

Mark Description

1 OutletCoupling(3”Victaulic) 9 HighExhaustPressureSwitchPort 2 ReliefValvePort 10 HeatExchanger 3 SupplyTemperatureSensor 11 HeatExch.TemperatureSensor 4 InletCoupling(3”Victaulic) 12 BurnerFlange/Hole 5 ManualDrainValve 13 LowWaterCutoffProbe 6 10”FlueAdapter 14 ManualResetHighLimitProbe 7 CondensatePan 15 AutomaticAirVent 8 CondensateTrap



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351

Mark Description



6.2.4 Natural Gas Train, Burner & Blower Assembly (SC-2000)

12

11

10

9

Gas Fired Boile

15

8

7

5

6

Mark Description Mark Description

1 StainlessSteelMeshBurner 9 BlowerTransitionPiece 2 External(Upstream)GasCock 10 CombustionBlower/Fan 3 GasPiping&Supports 11 BurnerTransitionPiece 4 AirIntakeTransitionPiece 12 IgnitionElectrode&Gasket 5 LowGasPressureSwitch 13 Flame/IonizationRod&Gasket 6 HighGasPressureSwitch 14 OuterBurnerGasket 7 MainGasShutoff/ControlValve 15 InnerBurnerGasket 8 Internal(Downstream)GasCock



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



Gas Fired Boile

6.3 Boiler Parts Identification (SC-3000 & SC-4000)

6.3.1 Main Boiler Assembly (SC-3000 & SC-4000)

7

6



Mark Description

1 HeatExchanger 5 MainPowerBox 2 Burner/BlowerAssembly 6 FrontDoor/NUROTouchscreen 3 CabinetBase 7 NUROControlPanel 4 NaturalGasTrain 8 SheetMetalCabinet



Mark Description



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



6.3. 2 NURO Contr ol Panel (SC-3 000 & SC-4000)

1

Gas Fired Boile



12

2



6

11

10

9



Mark Description Mark Description

1 PushtoTestLWCOButton 7 NUROTouchscreenAssembly 2 ManualResetHiTempLimit 8 ClearPlasticProtectiveCove 3 FuseHolder&Fuse 9 HighVoltage(TB2)TerminalBlock 4 On/OffSwitch 10 LowVoltage(TB1)TerminalBlock 5 SOLAMainboard 11 6 IgnitionCable 12



ransformerXFMR2(40VA) ransformerXFMR1(20VA)



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



6.3.3 Main Power Box (S C-3000 & SC-4000)



1

Gas Fired Boile

5

Mark Description Mark Description

1 20AThreePhaseBreaker

(IncomingThreePhasePower) 2 GroundingTerminal 5 PowerLeadtoBlowerMotor 3 ControlTransformer 6 BlowerMotorRelay

4 FuseHolde



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



6.3.4 Heat Exchanger Assembly (SC-3000 & SC-4000)

17

16

15

Gas Fired Boile



14

13

12

11

10

Mark Description

1 OutletCoupling(4”Victaulic) 10 HighExhaustPressureSwitchPort 2 ASMESectionVIIIReliefValve(150#) 11 SectionVIIIEconomizer 3 SupplyTemperatureSensor 12 InterconnectingElbows 4 Nuts/Bolts 13 InternalCouplings(2‐1/2”Victaulic) 5 InletCoupling(4”Victaulic) 14 BurnerFlange/Hole 6 ManualDrainValve 15 LowWaterCutoffProbe 7 10”FlueAdapter 16 SectionIVBoiler 8 CondensatePan 17 ManualResetHighLimitProbe 9 CondensateTrap 18 AutomaticAirVent

Mark Description



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



6.3.5 Natural Gas Train, Burner & Blower Assembly (SC-3000 & SC-4000)

Gas Fired Boile

12

11

10

9

8

14

7

6

Mark Description Mark Description

1 StainlessSteelMeshBurner 8 HighGasPressureSwitch 2 External(Upstream)GasCock 9 BlowerTransitionPiece 3 GasPiping&Supports 10 BurnerTransition Piece 4 BlowerMotorSplashGuard 11 Flame/IonizationRod&Gasket 5 CombustionBlower/Fan 12 IgnitionElectrode&Gasket 6 LowGasPressureSwitch 13 OuterBurnerGasket 7 MainGasShutoff/ControlValve 14 InnerBurnerGasket



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



6.3.6 Propane Gas Train (SC-30 00 & SC- 4 00 0)

Gas Fired Boile



7

6

5

Mark Description

1 External(Upstream)GasCock 5 Internal(Downstream)GasCock 2 GasPiping&Supports 6 HighGasPressureSwitch 3 FlexibleGasHose 7 MainGasShutoff/ControlValve 4 LowGasPressureSwitch



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351

Mark Description



Gas Fired Boile

7 Limited Warranty



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



Gas Fired Boile

Boiler Fire-Test Report



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



Gas Fired Boile

Appendix 1: Maintenance Log

Date

Hi Fire /

Low Fire

O2 CO CO2

Stack Temp

pH Action By



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



Gas Fired Boile

Appendix 2: Boiler Altitude Derate Schedule



For installations over 2000 ft. elevations, a derate schedule is applied. The boiler input rating must be reduced by 4% per 1000 ft. which is illustrated in the graph below.



Derate procedure is as follows:



With the boiler at high fire, adjust the gas valves (as described in Section 3.10.4) to get 5% O2 in the flue gas. If

this cannot be achieved, perform the following steps:



•

If the O2% is too high, then the inlet gas pressure should be adjusted to the minimum pressure allowed, typically 5” wc The gas valve should be adjusted to obtain approximately 5% O2. If the O2% is still too high, the fan speed may be lowered. This procedure should only be performed by factory trained personnel.

•

If the O2% is too low, then the gas valve settings should be reduced. This procedure is also described in

Bulletin 06-08.



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351



Gas Fired Boile

Appendix 3: Water Quality Standards for Hydronic Boilers in Multi-Metal Systems



Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351

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

Specifications and Main Features

Frequently Asked Questions

User Manual