Harsco Industrial P-K SONIC SC-3000 Page 13 Installation & Owner'S Manual Download

Page: 13 / 31

Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351

INST

alla

TION

Gas Fired Boiler

The

SC-3000

and

SC-4000

boilers are

equipped with

ENVI®

control; an intelligent

control system

with advanced

features such as

text-based display,

communication

capabilities, and

boiler sequencing.

Errors are date

and time stamped

providing built-in

history of boiler

status and performance.
This control constantly tracks the load by recording burner high, low and mid run hours. One control to do it

all – temperature control, flame safeguard, firing rate control, blocked flue protection, outdoor air reset, freeze

protection, built-in cascade sequencing, MODBUS communication and more.
The boiler control has a text display panel. The display panel is used to setup and monitor boiler operation by

means of six push buttons

BACK

ENTER

DOWN

, and

RESET

as shown above. The buttons across

the bottom are used to navigate through the various screens. The four line screen shows boiler operating

information on various screens. The display screen is back lit for ease of viewing. Pressing any key will illuminate

the back light.

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

Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351

INST

alla

TION

Gas Fired Boiler

After checking controls by manual

adjustment, make sure they are

always reset to their proper settings.

Never attempt to operate a boiler

that has failed to pass all the safety

checks described below.

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

been completed. Refer to the engineering manual for your model for

additional information.

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, and having a disconnect having adequate overload protection.
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.

3.8 p

-s

TarT

heCklIsT

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 s

afeTy

heCks

WARNING

If the expected error code(s) do not

appear, call for qualified service.

oTICe

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. Place the boiler in operation at the high fire setting BNR TEST MODE HI.
3. Smoothly close the downstream manual isolation valve to reduce the gas flow and cause flame failure.
4 The display will show LOCKING FLAME FAILURE indicating a flame failure. The lockout will remain until the control is reset.

After completing this test, turn off the boiler and open the downstream manual isolation valve and turn the boiler

back on.

3.9.1 test of Ignition safety system

The boiler is furnished with a probe-type low water cut-out in the outlet nozzle. Test as follows:
Push and hold the red “Push to test” button for at least 5 seconds. A manual lockout reset error displaying

LOCKOUT LOW WATER LEVEL

on the display panel should occur. The

LED

indicator on the Low Water cut-off will no

longer be illuminated.

Optional Test Method:

First turn the boiler off, and then turn the pump off. 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

LOCKOUT LOW WATER LEVEL

on the display panel should occur. The

LED

indicator

on the Low Water cut-off will no longer be illuminated.
Return the system to normal operation by refilling and restarting the boiler and pump.

3.9.2 test of low Water Cut-out

3.9.3 test of high-limit Control

Fire the boiler and test the high limit control as follows:
With the main burner operating, turn down the temperature setting on the "high-limit" thermostat until the main

burner shuts off. A manual reset lockout displaying

LOCKING HIGH LIMIT

on the display panel will occur. The

high-limit switch must be manually reset prior to resetting the boiler at the display panel. Readjust the high-limit

thermostat to the desired setpoint.

low Gas Pressure switch

The boiler is furnished with a low gas pressure switch. The operation of this switch must be checked by slowly

closing the main gas cock while the burner is operating. The switch should shut down the main burner. When

the gas pressure switch opens, a manual reset lockout displaying

LOCKING LOW GAS PRESSURE

on the display

panel will occur. Upon re-opening the main gas cock, the