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P-K SOLIS™

Gas Fired Boiler

Technical Service 1.877.728.5351

Revised: March 15, 2021
Released: March 15, 2021



Patterson-Kelley 2021

2701000090 P-K SOLIS NURO Installation and

Owners Manual (Rev A).docx

Page 86

Burner & Blower Assembly (SL-2500 & SL-3000)

Содержание SOLIS SL-1500

Страница 1: ...ley The descriptions and specifications contained in this manual were in effect at the time this manual was approved for publication While Patterson Kelley will continue to support earlier model boile...

Страница 2: ...es proper ventilation and lighting with a structure sufficiently strong and rigid to support the weight of the boiler all piping and accessories NOTICE Each safety device must be maintained and checke...

Страница 3: ...any of the provisions of this manual are not fully and completely understood contact Patterson Kelley Technical Service at 570 476 7261 or toll free at 877 728 5351 Hazard Warnings Electrical Hazards...

Страница 4: ...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 hazard Possible hot surfaces Do not touch gas vent dur...

Страница 5: ...ARD 11 3 INSTALLATION 11 3 1 OVERVIEW 11 3 2 APPLIANCE CONNECTIONS 11 Appliance Connections SL 1500 SL 2000 12 Appliance Connections SL 2500 SL 3000 13 3 3 ELECTRICAL CONNECTIONS 14 Power Requirements...

Страница 6: ...sure Switch Tests 47 3 11 FUEL AIR ADJUSTMENTS 48 Gas Pressure Adjustment 49 Manual Control Mode for High and Low Fire Adjustment 49 Adjusting High Fire 50 Adjusting Low Fire 50 Checking Flame Signal...

Страница 7: ...ER PARTS IDENTIFICATION SL 1500 SL 2000 76 Main Boiler Assembly SL 1500 SL 2000 76 NURO Control Panel SL 1500 SL 2000 77 Heat Exchanger Assembly SL 1500 SL 2000 78 Natural Gas Train SL 1500 SL 2000 79...

Страница 8: ...Service 1 877 728 5351 Revised March 15 2021 Released March 15 2021 Patterson Kelley 2021 All Rights Reserved 2701000090 P K SOLIS NURO Installation and Owners Manual Rev A docx Page viii HYDRONICS WA...

Страница 9: ...balancing valves and check valves will be required for satisfactory operation of any system Patterson Kelley cannot be responsible for the design or operation of such systems and a qualified engineer...

Страница 10: ...from RCFs and avoid contact with Skin or Eyes The National Institute for Occupational Safety and Health NIOSH recommends the use of a respirator meeting current standards to avoid inhalation of dust...

Страница 11: ...ely understand the content please contact Patterson Kelley Technical Service at 570 476 7261 or toll free at 877 728 5351 1 2 Common Abbreviations Abbreviation Description AMP Ampere or Amperage ANSI...

Страница 12: ...positive control of it at all times Do not attempt to move the boiler on surfaces that are not level Failure to heed this warning could result in personal injury or death NOTICE The boiler may be ins...

Страница 13: ...tpoint 200 F Maximum Setpoint 185 F Installation of the boiler must conform to all the requirements of all national state and local codes established by the authorities having jurisdiction or in the a...

Страница 14: ...ade of concrete The P K SOLIS boilers must be level and upright to function properly There are six leveling pads on the bottom of the boiler Once the boiler is installed on the foundation use a bubble...

Страница 15: ...cified in the vent manufacturer s listed installation instructions The boiler must be installed in a space large in comparison to the boiler as described in the National Fuel Gas Code NFPA 54 ANSI Z22...

Страница 16: ...aterials can result in serious injury or death due to fire or asphyxiation Before connecting a boiler to a venting system it must be determined whether the boiler is to be installed in a conventional...

Страница 17: ...erial is certified for Category II or IV operation NOTE For Category II installations ensure the flue venting system is designed to maintain a slightly negative exhaust pressure between 0 01 W C and 0...

Страница 18: ...rom different manufacturers within the same system As per ANSI Z21 13b 2012 CSA 4 9b 2012 The use of cellular core PVC CPVC and Radel as venting materials is prohibited The use of external insulation...

Страница 19: ...t Vent Sealed Combustion Systems Clearances 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 B...

Страница 20: ...ion codes and the requirements of the gas supplier Interior Component Clearances All vent system components shall be installed so as to maintain the following minimum clearances Material Combustible N...

Страница 21: ...ient and function properly For more information refer to Patterson Kelley s Water Quality Standards for Hydronic Boilers in Multi Metal Systems in Appendix C Water Quality Standards Quality Standards...

Страница 22: ...15 2021 Released March 15 2021 Patterson Kelley 2021 All Rights Reserved 2701000090 P K SOLIS NURO Installation and Owners Manual Rev A docx Page 12 Appliance Connections SL 1500 SL 2000 All connecti...

Страница 23: ...15 2021 Released March 15 2021 Patterson Kelley 2021 All Rights Reserved 2701000090 P K SOLIS NURO Installation and Owners Manual Rev A docx Page 13 Appliance Connections SL 2500 SL 3000 All connecti...

Страница 24: ...ration of the electrical connections The electrical service to the boiler must be installed and grounded in accordance with local codes or in the absence of such requirements in the U S with National...

Страница 25: ...3000 boiler to determine the required electrical service 208 240VAC three phase 60 hertz 440 480VAC three phase 60 hertz The incoming three phase power for the SL 2500 SL 3000 boilers is connected to...

Страница 26: ...NURO Installation and Owners Manual Rev A docx Page 16 Do not over tighten the hot lead terminal screws Maximum tightening torque 13 in lbs NOTE The hot lead terminals can accommodate maximum 12AWG w...

Страница 27: ...The Start Interlock 2 TB2 5 and TB2 6 terminals are in series with Start Interlock 1 and provide additional connection points for auxiliary safety devices This circuit is energized with 120VAC so the...

Страница 28: ...the Air Damper Interlock terminals Remove the jumper if connecting a motorized air damper with end limit switch Ground Grounding connection for auxiliary safety limit devices on terminal TB2 15 Relay...

Страница 29: ...ces such as damper limit switches control valve limit switches emergency stop buttons and low water cutoff devices This circuit is energized with 120VAC so the contacts on any auxiliary safety devices...

Страница 30: ...19 TB2 20 B TB2 17 TB2 18 C TB2 15 TB2 16 D TB2 13 TB2 14 The normally open contacts on these relays have a maximum voltage rating of 240VAC and maximum current capacity of 1 2 Amp Master Alarm Relay...

Страница 31: ...but generally closure of the Enable Disable circuit provides a call for heat to the boiler Opening this circuit prevents the boiler from running 4 20mA Analog Input TB1 3 and TB1 4 can be used to pro...

Страница 32: ...s normal operation This circuit is energized by the boiler with a 5VDC potential so the contacts on the day night timer must be rated for minimum 5VDC 4 20mA Analog Output TB1 15 and TB1 16 provide a...

Страница 33: ...nicate 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 for each 3 000 Btu Hr 700 mm2 kW of insta...

Страница 34: ...aph A C When combustion air is supplied by natural airflow into a space containing the type of appliance described in Paragraph B the cross sectional area of the opening shall not be less than the sum...

Страница 35: ...ir supply must be free from dust lint etc The presence of such materials in the air supplied to the burner could cause nuisance Low Air shutdowns or premature burner failure The appliance should not b...

Страница 36: ...es the combustion air supply when the appliance is in standby Once the appliance receives a call for heat the motorized combustion air damper opens and the end limit switch must close before the appli...

Страница 37: ...om the appliance itself All end limit switches must be rated for 120VAC External power supplies are required for Relay A Relay B Relay C and Relay D Because power is provided from an external source t...

Страница 38: ...be responsible for the effects such adverse conditions may have on the operation of the appliances Vertical vents are allowed to be terminated with a variety of ends including plain straight pipe elbo...

Страница 39: ...table for vent design parameters P K SOLIS Boiler Model Draft Stack Temperature CO2 Natural Gas SL 1500 SL 2000 SL 2500 SL 3000 Category II 0 01 to 0 05 W C 220 F gross 9 3 SL 1500 SL 2000 SL 2500 SL...

Страница 40: ...rol the exhaust back pressure within the appliance and upstream of this damper The 0 04 W C in the common flue will also help make sure the exhaust gases from an online appliance does not backflow thr...

Страница 41: ...ns of vent and air intake terminations are illustrated below The combined pressure drop of the air supply duct and exhaust vent must not exceed 0 44 W C This pressure drop includes both the inlet and...

Страница 42: ...e exhaust pressure between 0 01 W C and 0 05 W C NOTE For Category IV installations ensure the flue venting system is designed to maintain a slightly positive exhaust pressure which MUST BE in the fol...

Страница 43: ...een 0 01 W C and 0 05 W C NOTE For Category IV installations ensure the flue venting system is designed to maintain a slightly positive exhaust pressure which MUST BE in the following ranges 0 01 W C...

Страница 44: ...leased March 15 2021 Patterson Kelley 2021 All Rights Reserved 2701000090 P K SOLIS NURO Installation and Owners Manual Rev A docx Page 34 When terminating on the same vertical axis the following opti...

Страница 45: ...ral requirements for reliable operation of the 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 b...

Страница 46: ...re that any and all integral gasketing is properly assembled and creates a gas and water tight seal Systems that require silicone caulking for gasketing should only be installed with silicone caulk th...

Страница 47: ...d make certain the end of the drain line is not submerged or otherwise blocked 3 All condensate plumbing must be protected from freezing Do not locate the condensate piping such that an ice dam of fro...

Страница 48: ...as Fired Boiler Technical Service 1 877 728 5351 Revised March 15 2021 Released March 15 2021 Patterson Kelley 2021 All Rights Reserved 2701000090 P K SOLIS NURO Installation and Owners Manual Rev A d...

Страница 49: ...ampers Dans la mesure du possible fermer toutes les portes et les fen tres du b timent et toutes les portes entre l espace o les appareils toujours raccord s au syst me d vacuation sont install s et l...

Страница 50: ...mon vent system should be resized to approach the minimum size as determined using the appropriate tables in part 11 of the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CAN CSA B149 1 Natural Gas...

Страница 51: ...able additional intermediate gas pressure regulator of the lock up type must be provided to reduce the pressure to less than 14 W C Refer to the table below or the appliance s label for the minimum in...

Страница 52: ...9 6 16 12 3 4350 3000 2400 2050 1850 1500 3 3 068 7 67 15 3 7700 5300 4300 3700 3250 2650 2280 4 4 026 10 1 20 2 15800 10900 8800 7500 6700 5500 4600 Pressure Testing the Gas Piping The appliance and...

Страница 53: ...ling units where they may be exposed to refrigerated air circulation must be equipped with flow control valves or other automatic means to prevent gravity circulation of the boiler water during the co...

Страница 54: ...ertical The ASME Section IV relief valves are available for purchase from Patterson Kelley Low Water Cut Off The boiler is furnished with a probe type low water cut off no field piping is required If...

Страница 55: ...t gravity circulation of the boiler water during the cooling cycle 3 8 Water Quality The P K SOLIS boiler s heat exchanger is made of stainless steel The heat exchanger requires proper water condition...

Страница 56: ...on by generating a heat request The method for this will depend on your boiler configuration 2 During the pre purge cycle before ignition smoothly close the downstream manual isolation valve inside th...

Страница 57: ...and is identified with a yellow label Test the manual reset high temperature limit control as follows 1 Cycle the boiler on by generating a heat request 2 Allow the boiler to proceed through ignition...

Страница 58: ...ay 10011 High Gas Limit Even after re opening the downstream gas cock inside the boiler 10011 High Gas Limit will remain on the NURO display until the boiler is manually reset by pressing Reset Contro...

Страница 59: ...fo button in the lower left corner of the screen and then press Service in the lower left Next touch Press to Activate Manual Control which will open the Manual Control Firing Rate mode This test mode...

Страница 60: ...et boiler to the Manual Control Firing Rate mode as described above and decrease the firing rate to 0 Once the boiler has reached low fire operation check combustion readings using the combustion anal...

Страница 61: ...f the complete control setup please refer to the NURO Boiler Controller Advanced User s Guide Part Number is 1004905979 which is helpful for more complex installations For more complex boiler or water...

Страница 62: ...erature Inlet Return Temperature Exhaust Temperature Firing Rate etc Pressing the Info button in the lower left corner will load the Information screen For the setup wizard press the Settings button i...

Страница 63: ...NEXT at the bottom of the screen The NURO control also allows the user to back track at any time by pressing PREVIOUS in the bottom left corner of the screen The Setup Wizard allows the user to assign...

Страница 64: ...e opened by pinching the clasp and swinging open to the left Factory Tests Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on this boiler when...

Страница 65: ...high temperature limit and operating temperature The NURO controller will now begin the automatic firing sequence Normal Shut Down Procedures 1 Allow the boiler to turn off on its own once the temper...

Страница 66: ...croll down to view the flame signal measured in Volts Typical flame signals should read between 20 50V If the flame signal is below 10V the UV scanner may need to be replaced 2 Test the low water leve...

Страница 67: ...oot or foreign material that may have accumulated Refer to 5 3 Check for corrosion of the burner and its parts If there is evidence of deterioration or corrosion replace immediately Inspect combustion...

Страница 68: ...nance followed by scheduled routine maintenance 5 3 Cleaning the Burner Combustion Chamber Patterson Kelley recommends cleaning the burner and combustion chamber once annually Required Replacement Par...

Страница 69: ...nd then close off the nozzle 17 Walk around to the rear of the boiler and ensure the wash water is draining into the temporary drain hose off the condensate drain Adjust the temporary drain hose if ne...

Страница 70: ...installed one way The inside baffles will be perpendicular and parallel to the boiler sides See figures below b Ensure the graphite burner gasket is in place before installing burner c Gradually tigh...

Страница 71: ...TIONS ASSOCIATED WITH HANDLING REFRACTORY LINING MATERIAL This Patterson Kelley product contains a Combustion Area lined with REFRACTORY CERAMIC FIBERS RCFs similar to many other devices produced in t...

Страница 72: ...ntative maintenance follow the steps below before returning the boiler to service 1 Follow 3 9 and all safety checks in 3 10 2 Check the gas pressure refer to 3 11 1 to ensure proper operation of the...

Страница 73: ...nd the CH LOW FIRE HOLD TIME timer is started Once the LOW FIRE HOLD TIME timer expires the boiler is released to modulation 7 The NURO Control modulates the firing rate between low and high fire to m...

Страница 74: ...the boiler out When proper gas pressure is restored and the on screen reset button is pressed the boiler will reset and resume the sequence of operation at Step 3 5 5 High Gas Pressure The high gas p...

Страница 75: ...e trial for ignition When 106 Flame Lost in Main Flame Establish Period 107 Flame Lost Early in Run or 108 Flame Lost in Run is displayed the boiler lost the flame signal during operation Check that c...

Страница 76: ...lable by calling or visit the Patterson Kelley website ww pattersonkelley com When ordering replacement parts please have the model number and serial number of your boiler available Typical schematic...

Страница 77: ...20mA Analog Output Tracks Boiler Firing Rate 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...

Страница 78: ...AY A 18 RELAY B User Configurable Normally Open Dry Contact B 240VAC Max Voltage 1 2Amp Max Current 17 RELAY B 16 RELAY C User Configurable Normally Open Dry Contact C 240VAC Max Voltage 1 2Amp Max Cu...

Страница 79: ...l Service 1 877 728 5351 Revised March 15 2021 Released March 15 2021 Patterson Kelley 2021 All Rights Reserved 2701000090 P K SOLIS NURO Installation and Owners Manual Rev A docx Page 69 6 2 Wiring D...

Страница 80: ...as Fired Boiler Technical Service 1 877 728 5351 Revised March 15 2021 Released March 15 2021 Patterson Kelley 2021 All Rights Reserved 2701000090 P K SOLIS NURO Installation and Owners Manual Rev A d...

Страница 81: ...er Technical Service 1 877 728 5351 Revised March 15 2021 Released March 15 2021 Patterson Kelley 2021 All Rights Reserved 2701000090 P K SOLIS NURO Installation and Owners Manual Rev A docx Page 71 S...

Страница 82: ...as Fired Boiler Technical Service 1 877 728 5351 Revised March 15 2021 Released March 15 2021 Patterson Kelley 2021 All Rights Reserved 2701000090 P K SOLIS NURO Installation and Owners Manual Rev A d...

Страница 83: ...iler Technical Service 1 877 728 5351 Revised March 15 2021 Released March 15 2021 Patterson Kelley 2021 All Rights Reserved 2701000090 P K SOLIS NURO Installation and Owners Manual Rev A docx Page 73...

Страница 84: ...as Fired Boiler Technical Service 1 877 728 5351 Revised March 15 2021 Released March 15 2021 Patterson Kelley 2021 All Rights Reserved 2701000090 P K SOLIS NURO Installation and Owners Manual Rev A d...

Страница 85: ...vised March 15 2021 Released March 15 2021 Patterson Kelley 2021 All Rights Reserved 2701000090 P K SOLIS NURO Installation and Owners Manual Rev A docx Page 75 Wiring Diagram Power Box 240V SL 2500 S...

Страница 86: ...5351 Revised March 15 2021 Released March 15 2021 Patterson Kelley 2021 All Rights Reserved 2701000090 P K SOLIS NURO Installation and Owners Manual Rev A docx Page 76 6 3 Boiler Parts Identification...

Страница 87: ...chnical Service 1 877 728 5351 Revised March 15 2021 Released March 15 2021 Patterson Kelley 2021 All Rights Reserved 2701000090 P K SOLIS NURO Installation and Owners Manual Rev A docx Page 77 NURO C...

Страница 88: ...nical Service 1 877 728 5351 Revised March 15 2021 Released March 15 2021 Patterson Kelley 2021 All Rights Reserved 2701000090 P K SOLIS NURO Installation and Owners Manual Rev A docx Page 78 Heat Exc...

Страница 89: ...echnical Service 1 877 728 5351 Revised March 15 2021 Released March 15 2021 Patterson Kelley 2021 All Rights Reserved 2701000090 P K SOLIS NURO Installation and Owners Manual Rev A docx Page 79 Natur...

Страница 90: ...nical Service 1 877 728 5351 Revised March 15 2021 Released March 15 2021 Patterson Kelley 2021 All Rights Reserved 2701000090 P K SOLIS NURO Installation and Owners Manual Rev A docx Page 80 Burner B...

Страница 91: ...5351 Revised March 15 2021 Released March 15 2021 Patterson Kelley 2021 All Rights Reserved 2701000090 P K SOLIS NURO Installation and Owners Manual Rev A docx Page 81 6 4 Boiler Parts Identification...

Страница 92: ...chnical Service 1 877 728 5351 Revised March 15 2021 Released March 15 2021 Patterson Kelley 2021 All Rights Reserved 2701000090 P K SOLIS NURO Installation and Owners Manual Rev A docx Page 82 NURO C...

Страница 93: ...Technical Service 1 877 728 5351 Revised March 15 2021 Released March 15 2021 Patterson Kelley 2021 All Rights Reserved 2701000090 P K SOLIS NURO Installation and Owners Manual Rev A docx Page 83 Main...

Страница 94: ...nical Service 1 877 728 5351 Revised March 15 2021 Released March 15 2021 Patterson Kelley 2021 All Rights Reserved 2701000090 P K SOLIS NURO Installation and Owners Manual Rev A docx Page 84 Heat Exc...

Страница 95: ...echnical Service 1 877 728 5351 Revised March 15 2021 Released March 15 2021 Patterson Kelley 2021 All Rights Reserved 2701000090 P K SOLIS NURO Installation and Owners Manual Rev A docx Page 85 Natur...

Страница 96: ...nical Service 1 877 728 5351 Revised March 15 2021 Released March 15 2021 Patterson Kelley 2021 All Rights Reserved 2701000090 P K SOLIS NURO Installation and Owners Manual Rev A docx Page 86 Burner B...

Страница 97: ...cility for repairs of any products or party alleged defective shall in all events be at Buyer s sole risk and cost This warranty applies only if the original installer and Seller Attention Patterson K...

Страница 98: ...ng in whole or in part from any modification or alteration Buyer makes to any product sold hereunder and N Design defects where Seller has complied with Buyer s design specifications III PROOF OF PURC...

Страница 99: ...l Service 1 877 728 5351 Revised March 15 2021 Released March 15 2021 Patterson Kelley 2021 All Rights Reserved 2701000090 P K SOLIS NURO Installation and Owners Manual Rev A docx Page 89 8 Boiler Fir...

Страница 100: ...8 5351 Revised March 15 2021 Released March 15 2021 Patterson Kelley 2021 All Rights Reserved 2701000090 P K SOLIS NURO Installation and Owners Manual Rev A docx Page 90 Appendix A Maintenance Log Dat...

Страница 101: ...B Boiler Altitude Derate Schedule For installations over 2 000 ft elevations a derate schedule is applied The boiler input rating must be reduced by 4 per 1 000 ft which is illustrated in the graph b...

Страница 102: ...e than 10 of the system volume per year and meter readings should be recorded at least monthly to ensure system losses are minimized and corrective actions shall be taken when needed Treatment program...

Страница 103: ...piping It can also be used to establish a rough estimate of the total system volume during the initial fill In general the annual amount of fresh water make up should be less than 10 of the total syst...

Страница 104: ...ds These are typically a result of deteriorating piping fittings or legacy boiler s heat exchangers Patterson Kelley recommends installing a side stream filter maximum 10 micron to remove this existin...

Страница 105: ...r 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 Sup...

Страница 106: ...15 2021 Released March 15 2021 Patterson Kelley 2021 All Rights Reserved 2701000090 P K SOLIS NURO Installation and Owners Manual Rev A docx Page 96 Appliance Connections SL 1500 SL 2000 All connecti...

Страница 107: ...15 2021 Released March 15 2021 Patterson Kelley 2021 All Rights Reserved 2701000090 P K SOLIS NURO Installation and Owners Manual Rev A docx Page 97 Appliance Connections SL 2500 SL 3000 All connecti...

Страница 108: ...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 valves strainers coupling...

Страница 109: ...Model SL 1500 SL 2000 SL 2500 SL 3000 Mixture Flow Pressure Flow Pressure Flow Pressure Flow Pressure 0 144 GPM 2 9 ft 192 GPM 5 2 ft 240 GPM 7 3 ft 288 GPM 10 5 ft 10 146 GPM 3 0 ft 194 GPM 5 3 ft 2...

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