Harsco Industrial SC-1500 Owner'S Manual Download Page 69

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P-K SONIC

Gas Fired Boiler

Technical Service 1.877.728.5351

echnical Service 1.877.728.5351

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

Mark

Description

Mark

Description

Outlet Coupling (4” Victaulic)

High Exhaust Pressure Switch Port

ASME Section VIII Relief Valve (150#)

Section VIII Economizer

Supply Temperature Sensor

Interconnecting Elbows

Nuts/Bolts

Internal Couplings (2-1/2” Victaulic)

Inlet Coupling (4” Victaulic)

Burner Flange / Hole

Manual Drain Valve

Low Water Cutoff Probe

10” Flue Adapter

Section IV Boiler

Condensate Pan

Manual Reset High Limit Probe

Condensate Trap

Automatic Air Vent

Summary of Contents for SC-1500

Page 1: ...015 INSTALLATION O WNER S MANUAL INSTALLATION O WNER S MANUAL INSTALLATION O WNER S MANUAL INSTALLATION O WNER S MANUAL INSTALLATION O WNER S MANUAL INSTALLATION O WNER S MANUAL INSTALLATION O WNER S...

Page 2: ...fic 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 NOTICE...

Page 3: ...le safety precautions If any of the provisions of this manual are not fully and completely understood contact Harsco Industrial Patterson Kelley Technical Service at 570 476 7261 or toll free at 877 7...

Page 4: ...e main gas shutoff before servicing boiler Fire and Explosion Hazards Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other gas fired appliance Burn ha...

Page 5: ...erations 9 2 4 5 Venting Materials for Flue Exhaust Systems 9 2 4 6 Required Clearances 10 2 4 6 1 Conventional Vent Systems Clearances 10 2 4 6 2 Direct Vent Sealed Combustion Systems Clearances 10 2...

Page 6: ...fety System Test 31 3 10 2 Low Water Cut out Test 31 3 10 3 ManualReset High Temperature Limit Test 32 3 10 4 Gas Pressure Switch Tests 32 3 10 4 1 Low Gas Pressure Switch 32 3 10 4 2 High Gas Pressur...

Page 7: ...48 6 1 3 Terminal Block Assignments Low Voltage TB1 Terminal Block 49 6 1 4 SC 3000 SC 4000 Control Transformer Diagrams 50 6 1 4 1 SC 3000 SC 4000 208 VAC Three Phase 60 Hertz 50 6 1 4 2 SC 3000 SC...

Page 8: ...Service 1 877 728 5351 echnical Service 1 877 728 5351 echnical Service 1 877 728 5351 APPENDIX D INSTALLATION AND QUICK REFERENCE 73 FUEL GAS SUPPLY 73 ELECTRICAL POWER SUPPLY 73 EXHAUST VENTING 73 H...

Page 9: ...contained within or do not fully and completely understand the content please contact Harsco Industrial Patterson Kelley Technical Service at 570 476 7261 or toll free at 877 728 5351 1 3 HARSCO Indus...

Page 10: ...Storage Prior to Installation If the boiler is not installed immediately it must be stored in a location adequately protected from the weather preferably indoors If this is not possible then it shoul...

Page 11: ...rfaces the inches minimum clearances are shown in the illustration below Failure to provide adequate service clearances even with non combustible surfaces may present problems during routine maintenan...

Page 12: ...stallation can allow toxic fumes to be released into living areas This may cause property damage injury or death 2 4 Inlet Air and Exhaust Venting Considerations 2 4 1 Applicable Codes and Standards U...

Page 13: ...vertically Vent installations shall be in accordance with NFPA54 ANSI Z223 1 the National Fuel Gas Code or CAN CSA B149 1 the Natural Gas and Propane Installation Code or applicable provisions of the...

Page 14: ...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 t...

Page 15: ...med from combustion flue gases are acidic The condensate shall be drained in accordance with local code A condensate neutralizer may be required by local code 2 4 6 4 Flue Connection The connection fr...

Page 16: ...can be manufactured for 208 240 VAC three phase 60 hertz electrical service OR 440 480VAC three phase 60 hertz electrical service The total operating amperage is indicated on the rating nameplate and...

Page 17: ...60 hertz electrical service The SC 1500 and SC 2000 feature four dedicated power terminals on the High Voltage TB2 terminal block The illustration below shows the Low Voltage TB1 and High Voltage TB2...

Page 18: ...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...

Page 19: ...safety devices This circuit is energized with 120VAC so the contacts on any auxiliary safety devices must be rated for minimum 120VAC The boiler ships with a factory installed jumper across Start Inte...

Page 20: ...rmistor This circuit is energized by the boiler with a 5VDC potential DHW Stat Sensor TB1 9 and TB1 10 can be used to connect either an aquastat or remote DHW temperature sensor installed in a domesti...

Page 21: ...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...

Page 22: ...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 f...

Page 23: ...er by natural airflow from the outdoors and there is no draft regulator or draft hood in the same space there shall be a permanent opening with a cross sectional area not less than 1 sq in 30 000 Btu...

Page 24: ...boiler is not certified for use with Type B vent nor with PVC venting All P K SONIC TM boilers are dual certified as a Category II and Category IV appliances as defined in ANSI Z21 13 CSA 4 9 latest e...

Page 25: ...revent 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 Kelle...

Page 26: ...ckflow through offline boiler s In addition Harsco Industrial Patterson Kelley also recommends the use of motorized dampers in the combustion air intake duct to help prevent the backflow of flue gases...

Page 27: ...boilers under Category II conditions 1 A stainless steel vent adapter is required to mate the boiler exhaust connection and the vent pipe See the table below for the applicable part numbers 2 A normal...

Page 28: ...t is received Relay C closes the 120VAC circuit external power supply which provides power to the damper motor opening the damper Once the motorized damper is fully open its end limit switch completes...

Page 29: ...prefabricated venting systems must be installed according to the manufacturer s installation instructions Special care should be taken to ensure that any and all integral gasketing is properly assembl...

Page 30: ...nspected 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 mai...

Page 31: ...nd 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 Pipe Capacity for Natural Gas Nominal Ir...

Page 32: ...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 p...

Page 33: ...lation of external limit controls may be required by certain codes or in certain installations Review applicable local codes for details NOTICE The low water cut off probe only prevents boiler operati...

Page 34: ...rating 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...

Page 35: ...ler off open the downstream manual isolation valve then turn the boiler back on 3 10 2 Low Water Cut out Test The boiler is furnished with a probe type low water cut out The probe is installed near th...

Page 36: ...al reset high temperature limit and finally touch any prompts from the NURO control 3 10 4 Gas Pressure Switch Tests 3 10 4 1 Low Gas Pressure Switch The boiler is furnished with a low gas pressure sw...

Page 37: ...1 2 Startup When the boiler is powered on the NURO touchscreen will display an initial Startup Screen then the Local Representative screen This shows the name address and phone number of the local HAR...

Page 38: ...p Wizard From the Home Screen press the Settings will load the Main Menu Screen shown at the right Touch the Comfort Heat Wizard to launch the Setup Wizard screen shown at the far right The first step...

Page 39: ...Hot Water DHW Cascade etc please refer to the NURO Boiler Controller Advanced User s Guide Part Number is 1004905979 3 12Fuel Air Adjustments The P K MACH C750 C900 C1050 boilers are equipped with a g...

Page 40: ...mended Combustion Settings for P K MACH Boilers 3 12 3 Adjusting High Fire Required Tools Flat head screwdriver and combustion analyzer Start the boiler and observe proper operating parameters for the...

Page 41: ...label to increase or decrease the gas 3 Increasing the gas concentration decreases the O2 while decreasing the gas concentration increases the O2 There will be a slight time delay between the adjustm...

Page 42: ...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 sup...

Page 43: ...ies or remove the call for heat to the boiler Once the boiler completes a successful Post Purge and Post Pump it will return to Standby Once in standby turn the on off switch to the Off position Close...

Page 44: ...RSCO Industrial Patterson Kelly blower warranty The boiler motor is permanently lubricated and does not require periodic lubrication 5 1 1 Semi Annually In addition to the recommended monthly service...

Page 45: ...ustion settings table Refer to Section 3 12 2 Combustion Setup and Adjustment It is recommended that a copy of this report is filed for future reference 12 Perform a leak test of the gas valves in acc...

Page 46: ...e agency that has been trained on the SONIC TM boiler 5 3 Cleaning the Burner Combustion Chamber Harsco Industrial Patterson Kelley recommends cleaning the burner and combustion chamber once annually...

Page 47: ...and lower economizer The plugs in these ports can be removed for additional access to the fireside surfaces If necessary continue washing the fireside surfaces through these two washout ports 16 After...

Page 48: ...blower 2 When the outlet water temperature drops below CH SETPOINT minus CH DIFFERENTIAL ON a heat request is generated 3 Provided all interlocks are made and the remote enable signal if installed is...

Page 49: ...en 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 displa...

Page 50: ...ayed the boiler lost the flame signal during operation Check that combustion is adjusted properly the gas pressure is correct and the ignition electrode ignition wire and gas valve are functioning pro...

Page 51: ...al 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 followin...

Page 52: ...able Normally Open Dry Contact C 240VAC Max Voltage 1 2Amp Max Current 18 15 RELAY C 17 14 RELAY D User Configurable Normally Open Dry Contact D 240VAC Max Voltage 1 2Amp Max Current 16 13 RELAY D N A...

Page 53: ...ate 100 Firing Rate 20mA 1 Firing Rate 4mA 15 4 20mA ANALOG OUTPUT 14 NIGHT SETBACK Contact Closure Enables Night Setback Operation Open Circuit Disables Night Setback Operation 13 NIGHT SETBACK 12 OU...

Page 54: ...00 SC 4000 208 VAC Three Phase 60 Hertz 6 1 4 2 SC 3000 SC 4000 220 240 VAC Three Phase 60 Hertz Before making any electrical connections to the boiler verify that the control transformer is properly...

Page 55: ...M Gas Fired Boiler T T T Technical Service 1 877 728 5351 echnical Service 1 877 728 5351 echnical Service 1 877 728 5351 echnical Service 1 877 728 5351 6 1 4 3 SC 3000 SC 4000 440 480 VAC Three Phas...

Page 56: ...K SONIC TM Gas Fired Boiler T T T Technical Service 1 877 728 5351 echnical Service 1 877 728 5351 echnical Service 1 877 728 5351 echnical Service 1 877 728 5351 6 1 5 SC 1500 SC 2000 Wiring Diagram...

Page 57: ...P K SONIC TM Gas Fired Boiler T T T Technical Service 1 877 728 5351 echnical Service 1 877 728 5351 echnical Service 1 877 728 5351 echnical Service 1 877 728 5351...

Page 58: ...P K SONIC TM Gas Fired Boiler T T T Technical Service 1 877 728 5351 echnical Service 1 877 728 5351 echnical Service 1 877 728 5351 echnical Service 1 877 728 5351...

Page 59: ...P K SONIC TM Gas Fired Boiler T T T Technical Service 1 877 728 5351 echnical Service 1 877 728 5351 echnical Service 1 877 728 5351 echnical Service 1 877 728 5351...

Page 60: ...SONIC TM Gas Fired Boiler T T T Technical Service 1 877 728 5351 echnical Service 1 877 728 5351 echnical Service 1 877 728 5351 echnical Service 1 877 728 5351 6 1 6 SC 3000 SC 4000 480V Wiring Diag...

Page 61: ...P K SONIC TM Gas Fired Boiler T T T Technical Service 1 877 728 5351 echnical Service 1 877 728 5351 echnical Service 1 877 728 5351 echnical Service 1 877 728 5351...

Page 62: ...5351 echnical Service 1 877 728 5351 echnical Service 1 877 728 5351 6 1 7 Main Boiler Assembly SC 1500 SC 2000 Mark Description Mark Description 1 Heat Exchanger 5 Front Door NURO Touchscreen 2 Burne...

Page 63: ...URO Control Panel SC 1500 SC 2000 Mark Description Mark Description 1 Push to Test LWCO Button 7 NURO Touchscreen Assembly 2 Manual Reset Hi Temp Limit 8 Clear Plastic Protective Cover 3 Circuit Break...

Page 64: ...000 Mark Description 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 Senso...

Page 65: ...cription 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 Tr...

Page 66: ...5351 echnical Service 1 877 728 5351 6 2 Boiler Parts Identification SC 3000 SC 4000 6 2 1 Main Boiler Assembly SC 3000 SC 4000 Mark Description Mark Description 1 Heat Exchanger 5 Main Power Box 2 Bu...

Page 67: ...RO Control Panel SC 3000 SC 4000 Mark Description Mark Description 1 Push to Test LWCO Button 7 NURO Touchscreen Assembly 2 Manual Reset Hi Temp Limit 8 Clear Plastic Protective Cover 3 Fuse Holder Fu...

Page 68: ...51 echnical Service 1 877 728 5351 echnical Service 1 877 728 5351 6 2 3 Main Power Box SC 3000 SC 4000 Mark Description Mark Description 1 20A Three Phase Breaker Incoming Three Phase Power 4 Fuse Ho...

Page 69: ...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...

Page 70: ...SC 4000 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 Pie...

Page 71: ...vice 1 877 728 5351 echnical Service 1 877 728 5351 6 2 6 Propane Gas Train SC 3000 SC 4000 Mark Description Mark Description 1 External Upstream Gas Cock 5 Internal Downstream Gas Cock 2 Gas Piping S...

Page 72: ...P K SONIC TM Gas Fired Boiler T T T Technical Service 1 877 728 5351 echnical Service 1 877 728 5351 echnical Service 1 877 728 5351 echnical Service 1 877 728 5351 7 Limited Warranty...

Page 73: ...P K SONIC TM Gas Fired Boiler T T T Technical Service 1 877 728 5351 echnical Service 1 877 728 5351 echnical Service 1 877 728 5351 echnical Service 1 877 728 5351 8 Boiler Fire Test Report...

Page 74: ...oiler T T T Technical Service 1 877 728 5351 echnical Service 1 877 728 5351 echnical Service 1 877 728 5351 echnical Service 1 877 728 5351 Appendix A Maintenance Log Date Hi Fire Low Fire O2 CO CO2...

Page 75: ...h the boiler at high fire adjust the gas valves to get 5 O2 in the flue gas Refer to Section 3 12 2 Combustion Setup and Adjustment If this cannot be achieved perform the following steps If the O2 is...

Page 76: ...T T Technical Service 1 877 728 5351 echnical Service 1 877 728 5351 echnical Service 1 877 728 5351 echnical Service 1 877 728 5351 Appendix C Water Quality Standards Quality Standards for Hydronic...

Page 77: ...er 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 Su...

Page 78: ...boilers This information is useful to help size an appropriate circulation pump Keep in mind this pressure drop represents the boiler only additional consideration is needed for any connecting piping...

Page 79: ...rop represents the boiler only additional consideration is needed for any connecting piping valves strainers couplings flanges etc The table below summarizes the minimum and maximum flow restrictions...

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