Harsco Industrial MODU-FIRE FORCED DRAFT N1000 Installation & Owner'S Manual Download

Page: 1 / 54

Printed: 1/21/2010

Model #:_______ Serial #______________________

Start-Up Date:

_______________________

Harsco Industrial, Patterson-Kelley

100 Burson Street

East Stroudsburg, PA 18301

Telephone: (570) 476-7261

Facsimile: (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 MODU-FIRE FORCED DRAFT N1000

Page 1: ...y 100 Burson Street East Stroudsburg PA 18301 Telephone 570 476 7261 Facsimile 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 ...

Page 2: ...6 3 9 Pre Start Check List 26 3 10 Safety Checks 27 3 11 Boiler Operating Control 28 3 12 Burner Adjustment 30 4 0 OPERATION 31 4 1 General 31 4 2 Lighting and Shut Down Procedures 31 5 0 MAINTENANCE 32 5 1 Maintenance and Inspection Schedule 32 5 2 Cleaning the Burner 34 5 3 Removing the Heat Exchanger 35 5 4 After All Repairs or Maintenance 35 5 5 Sequence of Operation 36 5 6 Troubleshooting 37 ...

Page 3: ...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 and knowledgeable individual who has been trained on the MODU FIRE Forced Draft boiler The same features which permit this boiler to achieve high efficiency performance make it unlike most other boil...

Page 4: ...r other operating characteristics not deliver heat to the desired location Additional equipment such as temperature sensors pumps flow switches balancing valves and check valves will be re quired 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 2 0 S...

Page 5: ...s The safety labels shown above are affixed to your boiler Although the labels are of high quality they may be come dislodged or unreadable over time Contact Harsco Industrial Patterson Kelley toll free at 877 728 5351 for replacement labels 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 ...

Page 6: ...e codes and standards including NFPA 54 ANSI Z223 1 and CSA B 149 Hazard from incorrect fuels Possible fire explosion overheating and damage Do not use any fuels except the design fuel for the unit Overfire hazards High pressure in gas or propane supply could re sult in overfiring of other devices supplied from the same source Fire and explosion hazards Close the main gas shutoff before ser vicing...

Page 7: ...and component failure Do not attempt to adjust firing rate of the boi ler The firing rate must be adjusted only by factory trained person nel 2 5 3 Crush Hazards Lifting hazards Use properly rated lifting equipment to lift and position the boiler The load is unbalanced Test balance be fore lifting 3 ft above the floor Do not al low personnel beneath the lifted load Refer to approximate weights in ...

Page 8: ...is not installed immediately it must be stored in a location adequately protected from the weather and freezing conditions 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 NOTICE Controls and other equipment that are damaged or fail due to weather exposure are not covered by warranty 3 2 COMPLIANCE...

Page 9: ...ld installed gas 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 3 3 SETUP 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 in stalled on carpeting NOTICE This boiler is certifie...

Page 10: ...d earth ground green wire is re quired to avoid nuisance shutdowns It is also important that proper polarity be maintained The junction box at the rear of the boiler contains terminal strips for power and control connections A detailed schematic of the connections is shown in 6 1 7 These connections are as fol lows 3 4 1 High Voltage HV Terminal Block The boiler power circuit requires 240 volts si...

Page 11: ...e switch is in the remote position This circuit is energized by the boiler It has a 24VAC potential Devices connected to these terminals must be rated for 24VAC The remote local enable switch bypasses the Enable Disable LV1 to LV2 when in the local position Do not connect safety devices into the Enable Disable circuit Auxiliary Low Water Cutoff These terminals are used for connection of a secondar...

Page 12: ...es Canada CAN CSA B149 1 Installation Codes for Gas Burning Equipment STANDARDS UL 1738 Venting Systems for Gas Burning Appliances Categories II III and IV 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 F...

Page 13: ... 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 MODU FIRE Forced Draft boilers are Category IV appliances which vent with a positive exhaust pressure and with a temperature that is likely to cause condensation in the vent Therefore any venting system used with the MODU FIRE Forced Draft boiler mu...

Page 14: ...e input capacity When combustion air is supplied from outside the building the boiler room shall be provided with one or two open ings 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 com municate directly with the outdoors or through a vertical or horizontal duct that communicates to the ...

Page 15: ... Btu Hr 321 mm 2 kW up to and including 1 000 000 Btu Hr plus 1 sq in 14 000 Btu Hr 155 mm 2 kW in excess 1 000 000 Btu Hr This opening must be either located at or ducted to a point not more than 18 in 450 mm nor less than 6 in 150 mm above floor level This opening is in addition to the ventilation air opening de fined in paragraph A D When combustion air is supplied by natural airflow into a spa...

Page 16: ... used with a heat actuated automatic vent damper All boiler venting systems should be designed by a qualified venting profes sional experienced in venting system design The information contained herein should be used as a guide only and is not intended to be used in lieu of qualified technical expertise 3 5 3 1 Vent Sizing The vent must be sized in accordance with the ASHRAE Systems and Equipment ...

Page 17: ...apor could create a nuisance or hazard or could be detrimental to the operation of regulators relief valves or other equipment 3 5 3 2 2 Direct Vent Sealed Combustion Systems 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 th...

Page 18: ... this con nection may be reduced to 4 or 5 diameter The 1 500 000 Btu 2 000 000 Btu boilers have 8 OD connections for the vent If venting design permits this connection may be reduced to 6 diameter The connection from the boiler to the vent should be made using an adapter that is designed to fit the OD of the boiler outlet The vent manufacturer s adapter must be sealed to the boiler outlet with se...

Page 19: ... feet of the vent This is illustrated in the following diagram Reference NFPA 54 ANSI Z223 1 National Fuel Gas Code 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 can not be responsible for the effects such adverse conditions may have on the...

Page 20: ...aled exhaust vent leading from the boiler and terminating outdoors Air flow through the system is maintained by the combustion air fan 3 5 5 1 Intake Duct 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 Prop...

Page 21: ...n Close fireplace dampers 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 ...

Page 22: ...s must be made using a pipe compound that is certified resistant to the action of liquefied petroleum gases Do not use Teflon tape on gas line threads NOTICE Piping must be installed such that no piping stresses are transmitted to the boiler The boi ler shall not be used as a pipe anchor The boiler and all gas piping connections should be pressure tested and must be checked for leaks before being ...

Page 23: ...810 2 2 067 5 17 10 3 2 750 1 900 1 520 1 300 1 150 950 800 2 1 2 2 469 6 16 12 3 4 350 3 000 2 400 2 050 1 850 1 500 1 280 3 3 068 7 67 15 3 7 700 5 300 4 300 3 700 3 250 2 650 2 280 4 4 026 10 1 20 2 15 800 10 900 8 800 7 500 6 700 5 500 4 600 3 7 BOILER WATER PIPING 3 7 1 Piping Design 3 7 1 1 Water Flow in System Ideal operation of the MODU FIRE Forced Draft boiler would consist of a 20º F tem...

Page 24: ...to prevent gravity circulation of the boiler water during the cooling cycle 3 7 2 Boiler Water Connections Boiler Water Connections Make water connections as the application warrants or at a minimum as shown but always in compliance with the local requirements NOTICE Pipe unions and isolating valves must be installed in both water connections for ease of service The bottom connection to the boiler...

Page 25: ...tain codes or in certain installations Consult your local code for details Never install a valve that can isolate the low water cut off from the boiler 3 7 3 4 Drain Valve and Piping The boiler is not provided with external drain connections A drain valve should be installed near the inlet system return connection to the boiler and piped to a suitable floor drain The boiler can be completely drain...

Page 26: ...er use and disposal 3 8 BURNER AND IGNITION SYSTEM 3 8 1 Inspection Inspect the burners to be sure nothing was damaged or knocked loose during shipment Inspect the main gas train and ignition assembly to be sure they were not damaged during shipment or installation Check all gas unions for tightness 3 9 PRE START CHECK LIST Before attempting to start the boiler make sure the following items have b...

Page 27: ...g to light 4 The main gas valve will not open because there is no power to the valve due to the disconnected wires Hence no flame will be established and the flame safeguard will not receive a flame signal from the UV scanner 5 After 4 seconds the flame safeguard programmer will assume a Flame Failure condition and go to a lockout mode Lockout will require manual reset of the flame safeguard After...

Page 28: ... trip the high gas pressure switch The switch should shut down the main burner The control will display HIGH GAS PRESSURE This is a manual reset error and the boiler should not start until the gas valve is opened the low gas pressure switch is reset and the control is reset 3 11 Boiler Operating Control The MODU FIRE Forced Draft boiler is equipped with a combination combustion and temperature con...

Page 29: ...ETERS CONFIGURATION CASCADE and SERVICE menus The UP and DOWN buttons are used to position the arrow next to the desired option and the ENTER button is pushed to access that option 3 11 1 1 Configuring the Control First push the MENU button and then select PROGRAM PARAMETERS from the menu A screen opens that allows the user to view and change various operating parameters Select the CH SETTINGS to ...

Page 30: ...automatic air gas ratio valve This valve is adjusted at the factory to give 5 5 6 O2 at high fire and 7 5 7 9 O2 at low fire in the exhaust gas However the fuel air ratio should be checked using a combustion analyzer at start up to verify that the combustion is proper Remove the vent plug and place the analyzer probe in the vent as shown Be sure to replace the plug after combustion has been set St...

Page 31: ...d personnel to inspect the boiler and replace any part of the control sys tem and any gas control which has been exposed to water 4 2 1 Initial Lighting Procedures 1 Utilities Turn on electrical supply to the boiler Open the gas supply valves Make sure the system is filled with water and turn on the circulation pump 2 Reset Switches Press the reset button on both the high gas and low gas pressure ...

Page 32: ...ULE Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing 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 illuminated red indicators unusual noises or operating...

Page 33: ... shut Please see the manufacturer s recommendations on the relief valve tag 5 1 4 Annually In addition to the recommended monthly service 1 Inspect burner and ignition system Wash the burner do not scrub or use wire brush to remove any soot or foreign material that may have accumulated See Section 5 2 on Cleaning the Burner Check the burner and its parts If there is evidence of deterioration or co...

Page 34: ...isconnect the air gas mixer sensing tubes Note these tubes are color coded and must be correctly reins talled 6 Remove the blower air gas mixer assembly from the top of the burner 7 Clean the blower vanes Do not disassemble the blower motor or aluminum housing 8 Remove the burner using the four hold down screws 9 Clean the burner to remove any soot or foreign material that may have accumulated Blo...

Page 35: ...e wire plug to the blower the two air gas mixer sensing tubes the UV scanner and wires to the back pressure switch Before starting the boiler make sure to reconnect and tighten the gas union 4 Reinstall all covers 5 Fire Test the boiler and use a combustion analyzer to ensure that the fuel air ratio is set correctly If adjust ment is required refer to section 3 12 3 5 3 REMOVING THE HEAT EXCHANGER...

Page 36: ...ower is driven to the ignition speed 7 A trial for ignition begins The sequence of events is illustrated graphically below 8 After ignition the fan may be driven to low fire before the boiler is released to modulation 9 The control modulates the firing rate between low and high fire to maintain the desired outlet water temperature 10 The burner will continue firing until the outlet water temperatu...

Page 37: ...restored LOW GAS PRESSURE will remain on the display panel A manual reset is required to restart the boiler provided that all other limits are satisfied 5 6 4 High Gas Pressure The high gas pressure switch opens when there is excessive manifold gas pressure for the proper operation of the boiler HIGH GAS PRESSURE is displayed and the burner operation is interrupted When proper gas manifold pressur...

Page 38: ...ccurs A manual reset of the programmer located inside the control panel is required 5 6 9 Flame Failure In the event of a flame failure the main fuel valves are de energized and a manual reset lockout occurs IGNITION ERROR or FLAME ERROR is shown on the display The cause of flame failure must be diagnosed and repaired be fore the control is reset When IGNITION ERROR is shown on the display the boi...

Page 39: ...purge A20 EARLY FLAME Early Flame Flame detected before boiler gas valve opened during pre purge A30 HIGH GAS PRESSURE High Gas Pressure Error The gas pressure is too high and has tripped the HGPS A31 LOW GAS PRESSURE Low Gas Pressure Error The gas pressure is too low and has tripped the LGPS A32 INTERAL ERROR 23 Internal Error 23 Call for service A33 FAN WRONG SPEED Wrong Fan Speed Error Fan devi...

Page 40: ...lame detected when no flame should be present E21 LOW FLOW ILK Low Water Flow or Open Inter lock Circuit E21 converts to A07 after 5 minutes E22 NO GROUND 60 HZ ERR No Ground error No ground connected or voltage on ground E23 LINE FREQUENCY ERR Line Frequency Error Line frequency deviates from 60Hz by more than 2 E24 FAULTY GROUND Faulty Ground Ground Earth connection is not functioning correctly ...

Page 41: ...representative 6 1 1 Terminal Block Assignments High Voltage Circuit HV Terminal Number Label Description 1 L1 208 240 V Boiler Supply Power L1 230 VAC 1 ph 60 Hz 2 L2 208 240 V Boiler Supply Power L2 230 VAC 1 ph 60 Hz 3 N 208 240 V Boiler Supply Neutral 0 VAC 4 120 VAC Switched Output Neutral Line for HV 12 Switched Output 5 120 VAC Switched Output Neutral Line for HV 13 Switched Output 6 3 Way ...

Page 42: ...door Temp Sensor Outdoor Temperature Sensor Circuit 8 9 DHW Stat or Sensor Domestic Hot Water Thermostat contact closure or Tem perature Sensor 10 11 Header Temp Sensor Header Temperature Sensor 12 13 DHW Flow Switch Domestic Hot Water flow switch contact closure 14 15 0 10V Analog Input 0 10VDC Remote Control Input 16 0V Analog Input 0VDC Remote Control Common 17 For Future Use Not Used 18 For Fu...

Page 43: ...ENABLE DISABLE COM 1A COM 1B A TO A B TO B 10 G 1 2 3 4 5 6 7 8 12 13 14 15 16 17 18 19 20 21 11 0 10V 0V COM FLAME DETECTED RELAY MASTER ALARM RELAY CIRC PUMP RELAY 120V AC SWITCHED OUTPUT DHW PUMP RELAY DHW PUMP RELAY CIRC PUMP RELAY DAMPER RELAY DAMPER RELAY 9 L1 208 240V G 3 WAY VALVE 120V AC SWITCHED OUTPUT 3 WAY VALVE L2 208 240V N 208 240V GROUND P K MODU FIRE FD 750 2000 ENVI Control 23000...

Page 44: ...splay Panel 8 Neutral Terminal Block 2 ENVI Main Board 9 ENVI Interface Board 3 Inverter Fuses 10 Air Switch 4 Blower Inverter Control 11 Ignition Transformer 5 On Off Switch 12 High Water Temp Limit 6 Circuit Breaker 13 Remote Local Enable 7 Hot 120V Terminal Block Main Control Panel 1 2 3 13 12 11 On Rear 10 9 5 8 6 4 7 ...

Page 45: ...MODU FIRE Forced Draft Gas Fired Boiler 45 6 1 5 Main Control Panel Point to Point Left Side Alarm Flame Enable ...

Page 46: ...MODU FIRE Forced Draft Gas Fired Boiler 46 6 1 6 Main Control Panel Point to Point Right Side ...

Page 47: ...MODU FIRE Forced Draft Gas Fired Boiler 47 6 1 7 Junction Box Point to Point and Customer Connections ...

Page 48: ...MODU FIRE Forced Draft Gas Fired Boiler 48 6 1 8 Customer Connections Details ...

Page 49: ...k Description 1 Main Gas Valve 2 Low Gas Pressure Switch 3 Leak Test Ports 4 Automatic Dual Gas Valve 5 Solenoid Coils 6 Gas Union 7 High Gas Pressure Switch 8 Secondary Gas Shutoff Valve 9 Air Gas Mixer Head 10 Blue Dot attach Blue Hose Here 6 9 8 8 10 1 2 3 4 5 ...

Page 50: ...oiler 50 6 1 10 Blower Burner Ignition Assembly Mark Description 1 Burner Grid 2 Burner Gasket 3 Mounting Plate 4 Blower Gasket 5 Blower w Motor 6 Ignition Gasket 7 Ignition Electrode 8 UV Scanner 9 Backpressure Switch 9 7 8 1 2 3 4 5 6 ...

Page 51: ...MODU FIRE Forced Draft Gas Fired Boiler 51 6 1 11 Heat Exchanger and Combustion Chamber Mark Description 1 Front Wrapper 2 Heat Exchanger 3 Gasket Set 4 Removable Top Head 4 3 2 1 ...

Page 52: ...ft Gas Fired Boiler 52 6 1 12 Cabinet Assembly Mark Description 1 Front Door 2 Side Covers 3 Top Cover 4 Control Panel 5 Relief Valve 6 Flow Switch 7 Low Water Cutoff Switch optional 8 Air Inlet Assembly 1 2 2 3 4 5 6 7 8 ...

Page 53: ...lication F Any failure resulting from misuse modification not authorized by Seller in writing improper installation or lack of or improper maintenance G Equipment furnished by the owner either mounted or unmounted or when contracted for by the owner to be installed or han dled H Leakage or other malfunction caused by 1 Defective installations in general and specifically any installation which is m...

Page 54: ... exits boiler High Low w c High Inlet Gas w c w c w c Low Oxygen O2 10 Electrical Supply Power L1 to L2 Volts Carbon Dioxide CO2 L1 to N Volts Carbon Monoxide CO ppm ppm Less than 1 volt between neutral and ground YES or NO Stack Temperature net F F 11 Total Cycles Main Flame Signal Yes No Yes No 12 Total Hours Inlet Air Temperature F F 13 Any Faults Describe with code time and description 14 Cond...

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Harsco Industrial MODU-FIRE FORCED DRAFT N1000, Installation & Owner'S Manual

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