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P-K THERMIFIC

Gas-Fired Boiler

6.2.3 Gas

Train

N1000 Gas Train

N1500-2000 Gas Train

Pilot Gas Train

N1000 Gas Train

N1500-2000 Gas Train

Pilot Gas Train

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 Actuator (On/Off)
7  Main Gas Valve Actuator (LHL)

8 Low Gas Pressure Switch
9 High Gas Pressure Switch

10 Manifold Gas Test Port
11 Pilot Shut-off Valve

12 Pilot Regulator

13 Pilot Solenoid Valve
14 Pilot Gas Test Port

Содержание P-K THERMIFIC N700

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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