Harsco Industrial P-K THERMIFIC N700 Installation & Owners Manual Download Page 1

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Harsco Industrial, Patterson-Kelley

Printed 11/4/2011

THERM

201_2-19-12

P-K THERMIFIC

GAS-FIRED BOILER

Model#: __________________________

Serial#: __________________________

Start-up Date:

__________________________

Harsco Industrial, Patterson-Kelley
100 Burson Street
East Stroudsburg, PA 18301
Telephone: (570) 476-7261
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

ASME Code, Section IV
Certified by Patterson-Kelley

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

Summary of Contents for P-K THERMIFIC N700

Page 1: ...12 P K THERMIFIC GAS FIRED BOILER Model __________________________ Serial __________________________ Start up Date __________________________ Harsco Industrial Patterson Kelley 100 Burson Street East...

Page 2: ...P K THERMIFIC Gas Fired Boiler 2...

Page 3: ...3 7 Boiler Water Piping 29 3 8 Pre Start Check List 33 3 9 Safety Checks 34 3 10 Initial Adjustments 35 4 OPERATION 43 4 1 General 43 4 2 Lighting and Shut Down Procedures 43 4 3 Typical Boiler Opera...

Page 4: ...plier It is essential to read understand and follow the recommendations of this manual before installing operating or servicing this equipment Installation and service must be performed by a qualified...

Page 5: ...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 enginee...

Page 6: ...4 SAFETY LABELS The following words are used in this manual to denote the degree of seriousness of the individual hazards indicates a potentially hazardous situation which if not avoided may result i...

Page 7: ...damage Do not use any fuels except the design fuel for the unit Over fire hazards High pressure in gas or propane supply could result in over firing of other devices supplied from the same source Fir...

Page 8: ...g and component failure Do not attempt to adjust firing rate of the boiler The firing rate must be adjusted only by factory trained personnel 2 5 3 Crush Hazards Lifting hazards Use properly rated lif...

Page 9: ...ton is equipped with a Tip N Tell If Tip N Tell arrow point is blue that indicates that the package has been on its side or tipped over in transit The exterior cabinet must be reasonably air tight for...

Page 10: ...3 3 1 Foundation Provide a firm level foundation preferably of concrete NOTICE The boiler may be installed on a combustible floor however the boiler must never be installed on carpeting 3 3 2 Placeme...

Page 11: ...ons should be made in the junction box on the rear of the boiler The total operating amperage is indicated on the rating nameplate The 700 and 1000 series require less than 8 amps while the 1500 1700...

Page 12: ...ows Category I An appliance that operates with a non positive vent static pressure and with a vent temperature that avoids excessive condensate production in the vent Category II An appliance that ope...

Page 13: ...uld 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...

Page 14: ...ng shall commence within 12 inches above the floor and the other within 12 inches below the ceiling preferably on opposite walls The openings shall communicate directly or by way of ducts with free ou...

Page 15: ...d 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...

Page 16: ...B149 1 the Natural Gas and Propane Installation Code or applicable provisions of the local building codes If the boiler is installed using sealed combustion direct vent see Section 3 5 5 3 5 3 1 Vent...

Page 17: ...combustibles NOTICE The collar is not designed to support the weight of the vent Assure that the weight of the vent is not supported by the boiler vent collar NOTICE If using manufactured vent assure...

Page 18: ...Vertical Transitions The turn from horizontal to vertical should be made with two 45 ells a long radius 90 ell or a 135 boot tee Do not use short radius ells 3 5 3 5 Vent Termination The vent may be...

Page 19: ...rence NFPA 54 ANSI Z223 1 National Fuel Gas Code 3 5 4 Fresh Air System Ducted Combustion Air In some instances compliance with ANSI Z21 13 may not be required in which case a fresh air system may be...

Page 20: ...llar 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 3 5 5 2 Sealed Combustion System Design Pressur...

Page 21: ...text Sealant Centering Support Plate Outside Plate Cover Plate Fastener Sealant Field Provided Inlet Screen The boiler combustion air inlet duct must be fitted with a termination device meeting the re...

Page 22: ...e Section 6 1 for the logic and wiring diagrams for this auxiliary control panel and the sealed combustion boilers There are five 5 field run wires between the boiler and its associated auxiliary cont...

Page 23: ...between the vacuum breaker and the tee must be between 2 and 3 ft In transitioning from the horizontal to the vertical a boot tee 135 tee must be installed not a standard tee NOTICE A minimum vertica...

Page 24: ...en installing a sidewall exhaust system the termination must be either backed by a metal plate se cured to the wall as shown in the figure or incorporate an approved vent manufacturers wall penetratio...

Page 25: ...let Roof 1 Both the combustion air inlet 2 Both the combustion air inlet and flue gas exhaust through the roof and flue gas exhaust through the sidewall Exhaust Vent Air Inlet Sidewall Roof 3 Combusti...

Page 26: ...y will operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers 4 Place the appliance being inspected in operation Follow the lighting instructions Adjust the thermostat so...

Page 27: ...n accordance with CAN CSA B 149 1 latest edition in Canada NOTICE See chart below for required pipe size based on overall length of pipe from meter plus equivalent length of all fittings Approximate s...

Page 28: ...ng a trap into the vent line Vent limiters are NOT to be installed on the primary gas regulator on this boiler The pilot regulator is equipped with a vent limiting device and does not require external...

Page 29: ...m Return Water Temperature should be greater than 130 F to avoid condensation on the outside of the heat exchanger or in the flue passages NOTICE Return water temperatures below 130 F will cause conde...

Page 30: ...rameters P K THERMIFIC N1500 N2000 Boilers P K THERMIFIC Model Minimum Flow GPM Delta T F Maximum Flow GPM Delta T F N1500 90 28 3 150 17 0 N1700 100 28 9 150 19 3 N2000 120 28 3 150 22 7 Pressure Dro...

Page 31: ...iner 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 m...

Page 32: ...ng system attached to this unit will be chemically cleaned the boiler must be disconnected from the system and a bypass installed so that the chemical cleaning solution does not circulate through the...

Page 33: ...for analysis and recommendations 3 8 PRE START CHECK LIST Before attempting to start the boiler make sure the following items have been completed 1 Inspect the burners to be sure nothing was damaged o...

Page 34: ...e pilot gas cock open the burner should be cycled on When air flow is established and all the safety limits on gas pressure water flow and temperature are satisfied the blower will run and pre purge t...

Page 35: ...ch 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...

Page 36: ...ature drops to 155 F 170 F 15 F It will then modulate to Hi Fire NOTICE The set points and differentials should be adjusted for system requirements Contact your local Harsco Industrial Patterson Kelle...

Page 37: ...TPOINT value for Relay 1 should appear and be blinking 5 Use the buttons to raise or lower the set point temperature Range is 40 F to 248 F 40 C to 120 C 6 Press to accept change and or display the ne...

Page 38: ...and displayed 31 Press HEAT should be highlighted and displayed 32 If HEAT is displayed press 33 If COOL is displayed press and then 34 EXIT should be highlighted and displayed 35 Press MENU to get ba...

Page 39: ...of air inlet temperatures will occur over the heating season A special setup table is shown in Section 3 10 3 6 below and must be followed 3 10 3 3 Cabinet Air Pressure Adjustment The air flow is pre...

Page 40: ...safeguard to TEST Grasp the damper rod with locking pliers as shown in the photo right loosen the two allen screws 5 64 on damper shaft and make very small adjustment to the damper shaft position unt...

Page 41: ...adjusting screw clockwise to increase pressure counter clockwise to decrease pressure The manifold gas pressure indicated on the Factory Firetest label affixed on the back of the cabinet should be us...

Page 42: ...of your boiler Write your 100 F outdoor air temperature range in the chart below Start with the Minimum Outdoor Design Temperature at the top of the chart and fill in the chart using 5 F increments T...

Page 43: ...not use this boiler if any part has been under water Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system and any gas control which has b...

Page 44: ...nal to the boiler 4 3 TYPICAL BOILER OPERATING CONDITIONS Model Number Input Rating Btu hr Natural Gas 1030 Btu cu ft LP Gas 2500 Btu cu ft Total Amperage amps Gas Rate CFH Output Capacity Btu hr Gas...

Page 45: ...ermine the cause of any lockout or errors before resetting the boiler If able to determine cause of lockout then appropriate corrective action should be taken If unable to determine cause of the probl...

Page 46: ...int Installation and service must be performed by a qualified installer or service agency that has been trained on the Harsco Industrial Patterson Kelley P K THERMIFIC boiler 5 1 4 Semi Annually In ad...

Page 47: ...system a Check all joints and pipe connections for tightness b Check vent pipe for corrosion or deterioration If any venting needs replacing do so immediately 12 Perform combustion analysis and adjust...

Page 48: ...as above 2 Remove the front doors by pulling forward and upward 3 Remove the top panel of the inner cabinet 4 Close the isolation valves to the system 5 Drain the boiler 6 Disconnect the supply and re...

Page 49: ...mit control applies power the flame safeguard programmer and the green Heat light 6 The flame safeguard programmer supplies power to the blower motor and the air flow switch The red Low Air indicator...

Page 50: ...tion Once the switch is reset the sequence returns to Step 5 provided that the other limits are satisfied High Water Temperature When the boiler water has exceeded both the operating and high limit te...

Page 51: ...number is 570 476 7247 Refer to the parts list shown on the assembly drawing provided with this manual Technical information is also available at the above number When ordering replacement parts plea...

Page 52: ...P K THERMIFIC Gas Fired Boiler 52 6 1 1 On Off 6 1 1 1 On Off Wiring Diagram 700 1000 1500 1700 2000...

Page 53: ...P K THERMIFIC Gas Fired Boiler 53 6 1 1 2 On Off Sealed Combustion Diagram 700 1000...

Page 54: ...P K THERMIFIC Gas Fired Boiler 54 6 1 1 3 On Off Sealed Combustion Diagram 1500 1700 2000...

Page 55: ...P K THERMIFIC Gas Fired Boiler 55 6 1 2 Lo Hi Lo 6 1 2 1 Lo Hi Lo Wiring Diagram 1500 1700 2000...

Page 56: ...P K THERMIFIC Gas Fired Boiler 56 6 1 2 2 Lo Hi Lo Sealed Combustion Diagram 1500 1700 2000...

Page 57: ...P K THERMIFIC Gas Fired Boiler 57 6 1 3 Low Water Cutoff 6 1 3 1 Field Installed Low Water Cut Off Diagram...

Page 58: ...P K THERMIFIC Gas Fired Boiler 58 6 1 3 2 Factory Installed Low Water Cut Off Diagram...

Page 59: ...12 Water Flow Switch 13 Blower Motor 14 Blower Housing No Part 15 Blower Wheel 16 Press Temp Gauge w 100 PSI relief valve 17 Damper Rod Lo Hi Lo 18 Damper Bracket 19 Junction Box Power Installation O...

Page 60: ...L Two Stage Thermostat Operating Temp 7 Air Flow Switch 8 Operating Lights 2 Green 9 Error Lights 4 Red No Part 10 Ignition Transformer 11 Ignition Cable 12 Pilot Assembly incl Ignition Electrode 13 U...

Page 61: ...Gas Train 9 7 10 10 5 6 2 8 1 4 9 12 13 No Part 1 Main Gas Shut off Valve 2 Main Gas Regulator 3 Main Gas Valve Diaphragm 4 Main Gas Valve Body On Off 5 Main Gas Valve Body LHL 6 Main Gas Valve Actuat...

Page 62: ...art 1 Exterior Cabinet Assy 2 Exterior Cabinet Door 3 Exterior Cabinet Top 4 Sight Glass 5 Sight Glass Bezel 6 Combustion Chamber Assy 7 Combustion Chamber Door 8 Combustion Chamber Top 9 Control Pane...

Page 63: ...oduct for any particular application 6 Any failure resulting from misuse modification not authorized by Seller in writing improper installation or lack of or improper maintenance 7 Equipment furnished...

Page 64: ...P K THERMIFIC Gas Fired Boiler 64...

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