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Harsco Industrial SC-1500 Installation & Owner's Manual

P-k sonic gas fired boiler w/ nuro control system
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P-K SONIC
®
w/ NURO
CONTROL SYSTEM
®
Natural Gas or Propane Gas
SC-1500/SC-2000/SC-3000/SC-4000
Dual Fuel
SC-1500GG/SC-2000GG
SC-3000GG/SC-4000GG
Part # 1004905978
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
Model Number:
Serial Number:
Start-Up Date:
Harsco Industrial, Patterson-Kelley
155 Burson Street
East Stroudsburg, PA 18301
Telephone: 570.476.7261
Toll Free: 877.728.5351
Fax: 570.476.7247 www.harscopk.com
The information in this manual is the property of Harsco Industrial Patterson-Kelley. The descriptions and specifications contained in this
manual were in effect at the time this manual was approved for publication. While Harsco Industrial Patterson-Kelley will continue to
support earlier model boilers to within a reasonable time limit, we reserve the right to discontinue models and replacement parts at any
time or change specifications or design without notice and without incurring any obligation.
GAS FIRED BOILER
Released June 2, 2017
 HARSCO Industrial, Patterson-Kelley 2017: All Rights Reserved.
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Summary of Contents for Harsco Industrial SC-1500

  • Page 1 The information in this manual is the property of Harsco Industrial Patterson-Kelley. The descriptions and specifications contained in this manual were in effect at the time this manual was approved for publication. While Harsco Industrial Patterson-Kelley will continue to support earlier model boilers to within a reasonable time limit, we reserve the right to discontinue models and replacement parts at any &...

  • Page 2: Safety Precautions

    Technical Service 1.877.728.5351 Safety General OTICE Each safety device must be ® P-K SONIC SC-1500, SC-2000, SC-3000 and SC-4000 maintained and checked per the ® All P-K SONIC SC-1500, SC-2000, SC-3000 and SC-4000 recommended schedule. Refer to Gas-Fired Boilers must be: Maintenance.

  • Page 3: Hazard Warnings

    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 877.728.5351. Hazard Warnings...
  • Page 4 CPVC, or other corrosion resistant piping for drainage. Collection and disposal must be in accordance with all applicable regulations. A condensate neutralization kit is available. Please contact your local Harsco Industrial, Patterson-Kelley representative for more information. Burn, Fire and Explosion Hazards Burn, fire, and explosion hazards! Installation must be in strict conformance to all applicable codes and standards including NFPA 54, ANSI Z223.1 and CAN/CSA B.149.

  • Page 5: Table Of Contents

    LECTRICAL ONNECTIONS Power Requirements (SC-1500 & SC-2000) ..............13 Single Phase Power Supply Connection (SC-1500 & SC-2000) ........13 Power Requirements (SC-3000 & SC-4000) ..............14 Three Phase Power Supply Connection (SC-3000 & SC-4000) ........14 High Voltage (TB2) Terminal Block (SC1500 & SC2000) ..........16 High Voltage (TB2) Terminal Block (SC3000 &...
  • Page 6 Normal Shut Down Procedures ..................53 ......................53 MERGENCY MAINTENANCE .......................... 54 ....................54 REVENTATIVE AINTENANCE  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved. Released: June 2, 2017 Owners Manual (Rev F Jun-2017).docx Page vi...
  • Page 7 NURO Control Panel (SC-1500 & SC-2000) ..............84 Heat Exchanger Assembly (SC-1500 & SC-2000) ............85 Natural Gas Train, Burner & Blower Assembly (SC-1500 & SC-2000) ......86 Propane Gas Train, Burner & Blower (SC-1500 & SC-2000) ..........87 (SC-3000 & SC-4000) ............88...
  • Page 8 APPENDIX E – INSTALLATION AND QUICK REFERENCE ............102 .......................... 102 UPPLY ......................102 LECTRICAL OWER UPPLY .......................... 102 XHAUST ENTING (SC-1500 & SC-2000) ................103 PPLIANCE ONNECTIONS (SC-3000 & SC-4000) ................103 PPLIANCE ONNECTIONS ....................... 104 YDRONICS ATER ......................105...

  • Page 9: Introduction

    If you have any questions on the information contained within, or do not fully and completely understand the content, please contact Harsco Industrial, Patterson-Kelley Technical Service at It is essential to read, 570.476.7261 or toll free at 877.728.5351.

  • Page 10: Purpose Of This Document

    Harsco Industrial manufactures quality products. The primary concern of all Harsco Industrial, Patterson-Kelley equipment installation procedures is Safety. Safety instructions and considerations are presented and repeated throughout the document as needed. If you have any questions on the information 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.

  • Page 11: Site Preparation

    Insufficient clearance can restrict the service access, increasing the possibility of injury.  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved. Released: June 2, 2017 Owners Manual (Rev F Jun-2017).docx...

  • Page 12: Compliance With Codes

    Boilers. ® The P-K SONIC SC-1500, SC-2000, SC-3000 and SC-4000 heat exchangers are constructed and stamped in accordance with ASME Boiler and Pressure Vessel Code, Section IV for 160 psig maximum pressure and 210°F maximum temperature. Other codes or approvals which apply will be labeled on the boiler.

  • Page 13: Location Setup

    NOTICE! The appliance may be installed on a combustible floor; however, the appliance must NEVER be installed on carpeting. NOTICE! This appliance is certified for INDOOR use only!  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved.

  • Page 14: Clearances

    Note: Failure to provide recommended service clearances may make it difficult to perform service on the boiler(s).  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved.

  • Page 15: Inlet Air And Exhaust Venting Considerations

    Faulty vent installation can allow toxic fumes to be released into living areas. This may cause property damage, injury, or death.  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved. Released: June 2, 2017 Owners Manual (Rev F Jun-2017).docx...

  • Page 16: Category Ii/Iv Flue Gas Exhaust Vent Planning

    (Exhaust Only) 220 °F (gross) 9.2% 10.4% SC-3000, SC-4000 +0.01” to +0.4” W.C.  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved. Released: June 2, 2017 Owners Manual (Rev F Jun-2017).docx...

  • Page 17: Venting Materials For Flue/Exhaust Systems

    NOTE 2: When this material is used for venting, it must be listed to either UL- 1738 or ULC-S636 (depending on the local requirements). Consult the local boiler codes for more information.  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved.

  • Page 18: Required Clearances

    Improper interconnection of venting systems may result in leakage of flue gases into occupied spaces.  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved. Released: June 2, 2017 Owners Manual (Rev F Jun-2017).docx...
  • Page 19 3.5. The appliance connector should incorporate provisions to drain condensate formed in the vent system. The connector should include an appropriate drain section (not provided).  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved.

  • Page 20: Gas Piping Considerations

    4” Grooved (Stainless Steel) HWR Connection 3” Grooved (Stainless Steel) 4” Grooved (Stainless Steel) HWS Connection  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved. Released: June 2, 2017 Owners Manual (Rev F Jun-2017).docx...

  • Page 21: Appliance Connections (Sc-1500 & Sc-2000)

    P-K SONIC Gas Fired Boiler Technical Service 1.877.728.5351 Appliance Connections (SC-1500 & SC-2000) All connections must be in compliance with national, state, and local code requirements. Appliance Connections (SC-3000 & SC-4000) All connections must be in compliance with national, state, and local code requirements.

  • Page 22: Electrical Connections

    Single Phase Power Supply Connection (SC-1500 & SC-2000) The SC-1500 and SC-2000 models feature four dedicated power terminals on the High Voltage (TB2) terminal block for the 208-240VAC, single phase, and 60 hertz electrical supply. The image below...

  • Page 23: Power Requirements (Sc-3000 & Sc-4000)

    208 VAC main voltage. Refer to Section 7.1, for proper wiring and configuration of the internal control transformer.  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved. Released: June 2, 2017 Owners Manual (Rev F Jun-2017).docx...
  • Page 24 Do not over-tighten the hot lead terminal screws. Maximum tightening torque = 13 in-lbs! NOTE: The hot lead terminals can accommodate maximum 12AWG wire. The ground terminal can accommodate maximum 8AWG wire.  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved.

  • Page 25: High Voltage (Tb2) Terminal Block (Sc1500 & Sc2000)

    208-240VAC, single phase, 60Hz electrical service to the TB2-2 terminal. NEUTRAL – Connect the neutral lead of the 208-240VAC, single phase, 60Hz electrical service to the TB2-3 terminal.  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved.
  • Page 26 NURO control. The normally-open contacts on this relay have a maximum voltage rating of 240VAC and maximum current capacity of 1/2 Amp.  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved.

  • Page 27: High Voltage (Tb2) Terminal Block (Sc3000 & Sc4000)

    120VAC. The appliance ships with a factory-installed jumper across Start Interlock #1 and Start Interlock #2 terminals. Remove the jumper(s) if using any auxiliary safety devices.  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved.
  • Page 28 NURO control. The normally-open contacts on this relay have a maximum voltage rating of 240VAC and maximum current capacity of 1/2 Amp.  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved.

  • Page 29: Low Voltage (Tb1) Terminal Block

    This analog signal can be used to change the boiler’s operating setpoint/firing rate. Spare Analog Input – TB1-5 and TB1-6 are reserved for future use.  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved.
  • Page 30 The wireless receiver should be installed at or near the boiler, and the wireless temperature sensor should be installed on the North face of the building and shielded from direct sunlight exposure.  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved.

  • Page 31: Combustion Air

    3000 6000 1000 1500 SC-4000 4000 8000 1334 1000 1000 2000  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved. Released: June 2, 2017 Owners Manual (Rev F Jun-2017).docx Page 22...

  • Page 32: Air Inlet Requirements - Canada

    SC-2000 2,000,000 64,516 6,452 SC-3000 3,000,000 86,451 13.4 6,452 SC-4000 4,000,000  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved. Released: June 2, 2017 Owners Manual (Rev F Jun-2017).docx Page 23...

  • Page 33: P-K Sonic ® Combustion Air Requirements

    For example, joints in PVC or CPVC piping must be cemented. For galvanized duct, wrap each joint and seam with adhesive aluminum tape or other sealant. Harsco Industrial Patterson-Kelley recommends installing a 1” x 1” or larger bird screen on the exterior termination.

  • Page 34: Motorized Combustion Air Dampers

    If the combustion air intake ductwork and the exhaust vent terminate on the same wall of NOTE: the building, they must utilize the same type of termination fitting. Harsco Industrial Patterson-Kelley recommends including a motorized combustion air NOTE: damper in each appliance’s air intake ductwork. Refer to 3.4.5...
  • Page 35  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved. Released: June 2, 2017 Owners Manual (Rev F Jun-2017).docx...

  • Page 36: Flue Gas / Exhaust Venting

    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 cannot be responsible for the effects such adverse conditions may have on the operation of the appliances.

  • Page 37: Vent Termination

    This is illustrated in the following diagram. Additionally the boiler vent shall terminate at least 3 ft. above a forced air inlet located within 10 ft.  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved.

  • Page 38: Venting For Multiple Boilers

    In addition, Harsco Industrial, Patterson-Kelley also recommends the use of motorized combustion air dampers in the combustion air intake ductwork of each individual appliance. When an appliance is offline, its combustion air damper will remain closed which will also help prevent the backflow of flue gases from online appliances.

  • Page 39: Sealed Combustion/Direct Vent Systems

    There are several requirements for reliable operation of the boilers under Category II conditions:  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved.
  • Page 40 Category IV vent installations. 120VAC motorized dampers with end limit switches are available for purchase from Harsco Industrial, Patterson-Kelley. Other damper motor voltages are acceptable, provided they do not exceed 240VAC. The Air Damper Interlock circuit for the end limit switch is always 120VAC which is sourced from the boiler itself.

  • Page 41: Category Iv Installations

    Vent Size Sch. 40 Sch. 80 4-1/2 4-1/2 5-1/2 5-1/2 6-1/2  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved. Released: June 2, 2017 Owners Manual (Rev F Jun-2017).docx Page 32...

  • Page 42: Removing An Existing Boiler

    3,000 cubic feet per 11 of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or hour. CAN/CSA B149.1 Natural Gas and Propane Installation Code.  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved.

  • Page 43: Piping

    (CFH) 1,500,000 1500 2,000,000 2000 3,000,000 3000 1180 4,000,000 4000 1574  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved. Released: June 2, 2017 Owners Manual (Rev F Jun-2017).docx Page 34...

  • Page 44: Natural Gas Piping

    If using soap and water or a similar leak test method, make sure to clean off all moisture from the gas pipe fittings prior to placing the appliance into service.  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved.

  • Page 45: Boiler Water Piping

    All water connections should be in compliance with national, state, and local code requirements. Adapters from Victaulic to NPT are available from Harsco Industrial, Patterson-Kelley. The bottom rear connection to the boiler is the INLET and must be used for the return from the system. The top rear connection to the boiler is the OUTLET and must be connected as the supply to the system.

  • Page 46: Boiler Water Piping (For Installer)

    The SC-1500, SC-2000, SC-3000, and SC-4000 boilers require an ASME Section IV relief valve to be installed on the top of the OUTLET (Supply) connection. The spindle of the relief valve must be vertical.

  • Page 47: Water Quality

    The condensate is acidic (pH between 3.0 and 5.0) and may be corrosive to some building drain systems. A condensate neutralization system may be required and is available from Harsco Industrial, Patterson- Kelley. If the condensate drainage system is exposed to freezing temperatures, it must be field heat traced.

  • Page 48: Pre-Start Checklist

    The low water cut-out circuit board is located inside the boiler’s front door, toward the top of the control panel and is identified with a yellow label.  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved.

  • Page 49: Manual Reset High Temperature Limit Test

    When the main gas shutoff/control valve opens to attempt ignition, the low gas pressure switch will trip, causing the NURO touchscreen to display 10012: “Low Gas Limit”. Even after re-opening the main  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved.

  • Page 50: Fuel/Air Adjustments

    The air flow is pre-set at the factory prior to shipment. Gas flow is dependent primarily on fan speed not upstream gas pressure. The automatic gas valve may have to be adjusted to obtain proper  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved.

  • Page 51: Manual Control Mode For High And Low Fire Adjustment

    NOTICE! For high altitude adjustments (greater than 2,000 feet above sea level), see Appendix B – Boiler Altitude Derate Schedule at the end of this manual.  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved.

  • Page 52: Adjusting High Fire

    (units = V) as measured by the ignition electrode/ionization probe. When the boiler is in standby, prepurge, or postpurge the flame signal should read 0V. During main flame, a strong flame signal should read between 20-50V.  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved.

  • Page 53: Initial Nuro Control Setup And Adjustment

    When the boiler or water heater 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 HARSCO Industrial representative.  HARSCO Industrial, Patterson-Kelley 2017...

  • Page 54: Home Screen

    NOTE For more information on any value, please refer to the NURO Boiler Controller: Advanced User’s Guide, Part Number is 1004905979.  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved. Released: June 2, 2017 Owners Manual (Rev F Jun-2017).docx...

  • Page 55: Setup Wizard

    Less than 20 SC-4000 4,000,000 3889 1600 3,840,000 440-480 Three Less than 20  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved. Released: June 2, 2017 Owners Manual (Rev F Jun-2017).docx Page 46...

  • Page 56: Dual Fuel Boiler Operation

    Refer to through for model-specific information on the location of the gas trains, the fuel selector switch and the dual fuel wiring diagrams.  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved.

  • Page 57: P-K Sonic Sc1500Gg & Sc2000Gg

    CLOSED. If operating with Propane Gas, ensure the Natural Gas valve/cock is CLOSED. Failure to do so could result in equipment damage, injury, and/or death.  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved.

  • Page 58: Fuel Selector Switch Location

    CLOSED. If operating with Propane Gas, ensure the Natural Gas valve/cock is CLOSED. Failure to do so could result in equipment damage, injury, and/or death.  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved.

  • Page 59: P-K Sonic Sc3000-Sc4000

    CLOSED. If operating with Propane Gas, ensure the Natural Gas valve/cock is CLOSED. Failure to do so could result in equipment damage, injury, and/or death.  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved.

  • Page 60: Fuel Selector Switch Location

    CLOSED. If operating with Propane Gas, ensure the Natural Gas valve/cock is CLOSED. Failure to do so could result in equipment damage, injury, and/or death.  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved.

  • Page 61: Operations

    ANSI Z21.13/CSA 4.9, latest edition. (See "Factory Firetest" label on the rear surface of the boiler).  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved.

  • Page 62: Normal Lighting And Shut-Down Procedures

    See the image to the right for the locations of the Natural Gas valve (lower) or Propane Gas valve (upper). Propane Gas Natural Gas  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved. Released: June 2, 2017 Owners Manual (Rev F Jun-2017).docx...

  • Page 63: Maintenance

    NOTICE! Proper maintenance schedule and record unit. Failure to do so could result keeping is critical for optimum performance and to in electrocution, injury, or death. maintain the Harsco Industrial, Patterson-Kelley warranty. Label all wires prior to NOTE: The combustion blower motor is permanently disconnection when servicing lubricated and does not require periodic lubrication.

  • Page 64: Monthly Preventative Maintenance

    6. Take a sample of the system fluid and verify the water quality is in compliance as defined in Appendix C – Water Quality Standards Quality Standards for Hydronic Boilers in Multi- Metal Systems.  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved.

  • Page 65: Maintenance And Inspection Schedule

    This schedule applies when the boiler is in constant use. The section is divided into critical Semi- Annual and Annual Maintenance followed by scheduled routine maintenance. 6.3 Cleaning the Burner & Combustion Chamber Harsco Industrial, Patterson-Kelley recommends cleaning the burner and combustion chamber once annually: Required Replacement Parts...
  • Page 66 Once secured to the burner flange, bolt the burner transition piece to the blower transition piece. Ensure the gasket between the burner transition piece and blower transition piece is in place. Reinstall the ignition electrode assembly (if previously removed).  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved.

  • Page 67: After Repairs Or Maintenance

    Installation and service must be performed by a qualified installer or service agency that has been trained on the Harsco Industrial, Patterson-Kelley boiler.  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved.

  • Page 68: Sequence Of Operations

    9. When the outlet water temperature is reduced by the load on the system, a heat request is generated. The operating sequence will recycle to Step 3.  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved.

  • Page 69: Troubleshooting

    An error related to the air switch does not necessarily mean that the air switch is defective.  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved.

  • Page 70: Flame Failure

    When the blockage is removed, the boiler will automatically restart. If no blockage is found, it may be necessary to replace the high exhaust back pressure switch.  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved.

  • Page 71: Parts/Technical Support

    Technical Service 1.877.728.5351 7 Parts/Technical Support Spare parts and replacement parts can be ordered from Use of Non-Factory Authorized Harsco Industrial, Patterson-Kelley by calling toll free (877) replacement parts are not 728-5351. Reach us by fax at (570) 476-7247. recommended for this equipment.

  • Page 72: Terminal Block Assignments

    ENABLE / DISABLE Contact Closure Enables Comfort Heat Operation ENABLE / DISABLE Open Circuit Disables Comfort Heat Operation  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved. Released: June 2, 2017 Owners Manual (Rev F Jun-2017).docx...

  • Page 73: Terminal Block Assignments - High Voltage (Tb2) Terminal Block

    N1 for 208-240VAC, Single phase, 60Hz HOT L2 L2 for 208-240VAC, Single phase, 60Hz HOT L1 L1 for 208-240VAC, Single phase, 60Hz  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved. Released: June 2, 2017 Owners Manual (Rev F Jun-2017).docx...

  • Page 74: Wiring Diagrams

    ® P-K SONIC Gas Fired Boiler Technical Service 1.877.728.5351 7.2 Wiring Diagrams SC-1500 & SC-2000 Natural Gas or Propane Gas  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved. Released: June 2, 2017 Owners Manual (Rev F Jun-2017).docx...
  • Page 75 ® P-K SONIC Gas Fired Boiler Technical Service 1.877.728.5351  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved. Released: June 2, 2017 Owners Manual (Rev F Jun-2017).docx Page 66...

  • Page 76: Sc-1500 & Sc-2000 Dual Fuel

    ® P-K SONIC Gas Fired Boiler Technical Service 1.877.728.5351 SC-1500 & SC-2000 Dual Fuel  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved. Released: June 2, 2017 Owners Manual (Rev F Jun-2017).docx...
  • Page 77 ® P-K SONIC Gas Fired Boiler Technical Service 1.877.728.5351  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved. Released: June 2, 2017 Owners Manual (Rev F Jun-2017).docx Page 68...
  • Page 78 ® P-K SONIC Gas Fired Boiler Technical Service 1.877.728.5351  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved. Released: June 2, 2017 Owners Manual (Rev F Jun-2017).docx Page 69...

  • Page 79: Wiring Diagram - Power Box (Sc-3000 And Sc-4000 Only)

    ® P-K SONIC Gas Fired Boiler Technical Service 1.877.728.5351 Wiring Diagram – Power Box (SC-3000 and SC-4000 Only)  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved. Released: June 2, 2017 Owners Manual (Rev F Jun-2017).docx...

  • Page 80: Sc-3000 & Sc-4000 Control Transformer Diagrams

    Improper configuration of the control transformer could result in serious injury or death. SC-3000 & SC-4000: 220-240 VAC, Three Phase, 60 Hertz  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved.
  • Page 81 ® P-K SONIC Gas Fired Boiler Technical Service 1.877.728.5351 SC-3000 & SC-4000: 440-480 VAC, Three Phase, 60 Hertz  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved. Released: June 2, 2017 Owners Manual (Rev F Jun-2017).docx...

  • Page 82: Sc-3000 & Sc-4000 240V Natural Gas Or Propane Gas

    ® P-K SONIC Gas Fired Boiler Technical Service 1.877.728.5351 SC-3000 & SC-4000 240V Natural Gas or Propane Gas  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved. Released: June 2, 2017 Owners Manual (Rev F Jun-2017).docx...
  • Page 83 ® P-K SONIC Gas Fired Boiler Technical Service 1.877.728.5351  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved. Released: June 2, 2017 Owners Manual (Rev F Jun-2017).docx Page 74...

  • Page 84: Sc-3000 & Sc-4000 240V Dual Fuel

    ® P-K SONIC Gas Fired Boiler Technical Service 1.877.728.5351 SC-3000 & SC-4000 240V Dual Fuel  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved. Released: June 2, 2017 Owners Manual (Rev F Jun-2017).docx...
  • Page 85 ® P-K SONIC Gas Fired Boiler Technical Service 1.877.728.5351  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved. Released: June 2, 2017 Owners Manual (Rev F Jun-2017).docx Page 76...
  • Page 86 ® P-K SONIC Gas Fired Boiler Technical Service 1.877.728.5351  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved. Released: June 2, 2017 Owners Manual (Rev F Jun-2017).docx Page 77...

  • Page 87: Sc-3000 & Sc-4000 480V Natural Gas Or Propane Gas

    ® P-K SONIC Gas Fired Boiler Technical Service 1.877.728.5351 SC-3000 & SC-4000 480V Natural Gas or Propane Gas  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved. Released: June 2, 2017 Owners Manual (Rev F Jun-2017).docx...
  • Page 88 ® P-K SONIC Gas Fired Boiler Technical Service 1.877.728.5351  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved. Released: June 2, 2017 Owners Manual (Rev F Jun-2017).docx Page 79...

  • Page 89: Sc-3000 & Sc-4000 480V Dual Fuel

    ® P-K SONIC Gas Fired Boiler Technical Service 1.877.728.5351 SC-3000 & SC-4000 480V Dual Fuel  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved. Released: June 2, 2017 Owners Manual (Rev F Jun-2017).docx...
  • Page 90 ® P-K SONIC Gas Fired Boiler Technical Service 1.877.728.5351  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved. Released: June 2, 2017 Owners Manual (Rev F Jun-2017).docx Page 81...
  • Page 91 ® P-K SONIC Gas Fired Boiler Technical Service 1.877.728.5351  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved. Released: June 2, 2017 Owners Manual (Rev F Jun-2017).docx Page 82...

  • Page 92: Boiler Parts Identification (Sc-1500 & Sc-2000)

    ® P-K SONIC Gas Fired Boiler Technical Service 1.877.728.5351 7.3 Boiler Parts Identification (SC-1500 & SC-2000) Main Boiler Assembly (SC-1500 & SC-2000) Mark Description Mark Description Heat Exchanger Front Door / NURO Touchscreen Burner/Blower Assembly NURO Control Panel Cabinet Base...

  • Page 93: Nuro Control Panel (Sc-1500 & Sc-2000)

    ® P-K SONIC Gas Fired Boiler Technical Service 1.877.728.5351 NURO Control Panel (SC-1500 & SC-2000) Mark Description Mark Description Push to Test LWCO Button NURO Touchscreen Assembly Manual Reset Hi Temp Limit Clear Plastic Protective Cover Circuit Breaker High Voltage (TB2) Terminal Block...

  • Page 94: Heat Exchanger Assembly (Sc-1500 & Sc-2000)

    ® P-K SONIC Gas Fired Boiler Technical Service 1.877.728.5351 Heat Exchanger Assembly (SC-1500 & SC-2000) Mark Description Mark Description Flow Switch Condensate Trap Outlet Coupling (3” Victaulic) High Exhaust Pressure Switch Port Relief Valve Port Heat Exchanger Supply Temperature Sensor Heat Exch.

  • Page 95: Natural Gas Train, Burner & Blower Assembly (Sc-1500 & Sc-2000)

    ® P-K SONIC Gas Fired Boiler Technical Service 1.877.728.5351 Natural Gas Train, Burner & Blower Assembly (SC-1500 & SC-2000) Mark Description Mark Description Stainless Steel Mesh Burner Blower Transition Piece External (Upstream) Gas Cock Combustion Blower / Fan Gas Piping & Supports...

  • Page 96: Propane Gas Train, Burner & Blower (Sc-1500 & Sc-2000)

    ® P-K SONIC Gas Fired Boiler Technical Service 1.877.728.5351 Propane Gas Train, Burner & Blower (SC-1500 & SC-2000) Mark Description Mark Description Stainless Steel Mesh Burner Blower Transition Piece External (Upstream) Gas Cock Combustion Blower / Fan Gas Piping & Supports...

  • Page 97: Boiler Parts Identification (Sc-3000 & Sc-4000)

    Front Door / NURO Touchscreen Cabinet Base NURO Control Panel Natural Gas Train Sheet Metal Cabinet  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved. Released: June 2, 2017 Owners Manual (Rev F Jun-2017).docx...

  • Page 98: Nuro Control Panel (Sc-3000 & Sc-4000)

    Low Voltage (TB1) Terminal Block SOLA Mainboard Transformer XFMR2 (40VA) Ignition Cable Transformer XFMR1 (20VA)  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved. Released: June 2, 2017 Owners Manual (Rev F Jun-2017).docx...

  • Page 99: Main Power Box (Sc-3000 & Sc-4000)

    (Incoming Three Phase Power) Grounding Terminal Power Lead to Blower Motor Control Transformer Blower Motor Relay  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved. Released: June 2, 2017 Owners Manual (Rev F Jun-2017).docx...

  • Page 100: Heat Exchanger Assembly (Sc-3000 & Sc-4000)

    Section IV Boiler Condensate Pan Manual Reset High Limit Probe Condensate Trap Automatic Air Vent  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved. Released: June 2, 2017 Owners Manual (Rev F Jun-2017).docx...

  • Page 101: Natural Gas Train, Burner & Blower Assembly (Sc-3000 & Sc-4000)

    Ignition Electrode & Gasket Low Gas Pressure Switch Outer Burner Gasket Main Gas Shutoff/Control Valve Inner Burner Gasket  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved. Released: June 2, 2017 Owners Manual (Rev F Jun-2017).docx...

  • Page 102: Propane Gas Train (Sc-3000 & Sc-4000)

    Gas Piping & Supports High Gas Pressure Switch Flexible Gas Hose Main Gas Shutoff/Control Valve Low Gas Pressure Switch  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved. Released: June 2, 2017 Owners Manual (Rev F Jun-2017).docx...

  • Page 103: K Sonic Specific Limited Warranty

    Last Updated 12/12/2016 Subject to the terms and conditions herein and the Terms and Conditions of Sale (as defined herein), Harsco Industrial Patterson-Kelley (“Seller”) warrants to the purchaser of the product (“Buyer”) that the heat exchanger and burner are free of defects in material and...

  • Page 104: 1004905978 P-K Sonic Nuro Installation And

    No sales representative, agent, or employee of Seller or any reseller in the chain of sale of the product is authorized to make any modification, extension, or addition to this Specific Limited Warranty, unless agreed to in writing by Seller.  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved.

  • Page 105: Boiler Fire-Test Report

    Start Up Certification # ________________ (Print Name) A copy must be returned within 30 days of startup to Harsco Industrial Patterson-Kelley Harsco Industrial Patterson-Kelley • 155 Burson Street • E. Stroudsburg, PA 18301 P) 570-476-7261 F) 570-476-7247 pkboilers@harsco.com  HARSCO Industrial, Patterson-Kelley 2017...

  • Page 106: Appendix A - Maintenance Log

    Appendix A – Maintenance Log Hi Fire / Stack Date Action Low Fire Temp  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved. Released: June 2, 2017 Owners Manual (Rev F Jun-2017).docx Page 97...

  • Page 107: Appendix B - Boiler Altitude Derate Schedule

    Although the appliance’s capacity is reduced due to the lower air density, the combustion tuning should follow the standard combustion guidelines of 3.11. Tune the combustion for the same O and CO levels as discussed in 3.11.2.  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved.

  • Page 108: Appendix C - Water Quality Standards Quality Standards For Hydronic Boilers In Multi-Metal Systems

    Treatment programs should also comply with the standard water quality guidelines listed above.  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved.

  • Page 109: Appendix D - Best Practices For New & Retrofit Systems

    9. Well in advance of the equipment startup, turn off all circulation pumps and close the isolation valves on each boiler’s inlet (return) and outlet (supply) pipe runs. Connect a hose to the purge  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved.

  • Page 110: 1004905978 P-K Sonic Nuro Installation And

    This will help limit the amount of dissolved Oxygen and particulates that are brought in direct contact with the boiler’s heat exchanger.  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved.

  • Page 111: Appendix E - Installation And Quick Reference

    W.C. W.C. NOTE: Harsco Industrial, Patterson-Kelley recommends installing an individual lock-up type gas regulator in the gas supply piping to each boiler. For installations where one master lock-up type gas pressure regulator will service multiple boilers, Patterson-Kelley recommends contacting the local regulator representative for application assistance specifying the appropriate lock-up type regulator and gas pipe sizing.

  • Page 112: Appliance Connections (Sc-1500 & Sc-2000)

    P-K SONIC Gas Fired Boiler Technical Service 1.877.728.5351 Appliance Connections (SC-1500 & SC-2000) All connections must be in compliance with national, state, and local code requirements. Appliance Connections (SC-3000 & SC-4000) All connections must be in compliance with national, state, and local code requirements.

  • Page 113: Hydronics/Water Flow

    ® SONIC SC-1500 through SC-4000 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, valves, strainers, couplings, flanges, etc.

  • Page 114: Propylene Glycol Flow

    228 GPM 51 ft 345 GPM 26 ft 456 GPM 45 ft  HARSCO Industrial, Patterson-Kelley 2017 Revised: June 2, 2017 1004905978 P-K SONIC NURO Installation and All Rights Reserved. Released: June 2, 2017 Owners Manual (Rev F Jun-2017).docx Page 105...

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