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Harsco Industrial MODU-FIRE FORCED DRAFT N750 Installation & Owner's Manual

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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 #:_______
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
©2010 Harsco Industrial, Patterson-Kelley
Printed: 1/21/2010

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Summary of Contents for Harsco Industrial MODU-FIRE FORCED DRAFT N750

  • Page 1 Complies with ANSI Z21.13/CSA 4.9 Gas-Fired Low Pressure Steam and Hot Water Boilers 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 ©2010 Harsco Industrial, Patterson-Kelley Printed: 1/21/2010...

  • Page 2: Table Of Contents

    MODU-FIRE® Forced Draft Gas-Fired Boiler INTRODUCTION ....................4 SAFETY ......................4 General ..........................4 Training ..........................4 Safety Features ........................ 5 Safety Labels ........................5 Safety Precautions ......................6 INSTALLATION ....................8 Receiving and Storage ..................... 8 Compliance with Codes ....................8 Setup ..........................
  • Page 3 MODU-FIRE® Forced Draft Gas-Fired Boiler WARNING Improper use may result in fire or injury. Read instructions/safety manual before installing, operating or servicing boiler. 1998 HCS, Inc. 800-748-0241 Reorder No. 6020-V2WHPK If the information in this manual is not followed exactly, a fire or explosion may result causing proper- ty damage, personal injury or loss of life.

  • Page 4: Introduction

    Harsco Industrial, Patterson-Kelley cannot be responsible for the design or operation of such systems and a qualified engineer or contractor must be consulted.

  • Page 5: Safety Features

    If any of the provisions of this manual are not fully and complete- ly understood, contact the Harsco Industrial, Patterson-Kelley Technical Service toll free at (877) 728-5351. AFETY EATURES It is the responsibility of the customer to maintain the safety features of this machine, such as: guards, safety la- bels, safety controls, interlocks, lockout devices, etc., in place and operable.

  • Page 6: Safety Precautions

    MODU-FIRE® Forced Draft Gas-Fired Boiler AFETY RECAUTIONS Provide a suitable location for the boiler, away from normal personnel traffic, with adequate working space, ade- quate clearances, proper ventilation and lighting, with a structure sufficiently strong and rigid to support the weight of the boiler, all piping, and accessories.
  • Page 7 MODU-FIRE® Forced Draft Gas-Fired Boiler • Gas leak hazard! All threaded gas connections must be made using a pipe compound that is resistant to liquefied petroleum. Do not use Teflon tape on threaded gas piping. • Gas leak hazard! Check entire gas train for leaks after installation. If there is a smell of gas, shut down the boiler, close all gas valves and obtain immediate assistance from factory-trained personnel and/or your local fire department.

  • Page 8: Installation

    MODU-FIRE® Forced Draft Gas-Fired Boiler 2.5.6 General Hazards • Tripping hazard! Do not install piping on floor surfaces. Maintain clear path around boi- ler. • Slip and fall hazard! Use drip pan to catch water while draining the boiler. Maintain dry floor surfaces.

  • Page 9: Setup

    MODU-FIRE® Forced Draft Gas-Fired Boiler 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 absence of such requirements, in the U.S. to the National Fuel Gas Code, ANSI Z223.1/NFPA 54, latest edition.

  • Page 10: Electrical Connections

    ** Service access need be only on one side of a boiler or row of boilers. Boilers may be installed immediately adjacent to each other. However, Harsco Industrial, Patterson-Kelley recommends this clearance between each boiler when there is insuffi- cient access at the rear to allow for service and adjustment.
  • Page 11 The outdoor air sensor and programming help are available from the ENVI™ Advanced User’s Guide (ENVI™ 09) or from your local Harsco Industrial, Patterson- Kelley Representative. This circuit is energized by the boiler with a 5V potential. The temperature sensor must be a NTC having 12k@25°...

  • Page 12: Inlet Air And Exhaust Venting

    MODU-FIRE® Forced Draft Gas-Fired Boiler DHW Flow Switch – LV13 is energized by the boiler with a 5V potential. This circuit connects through a flow switch on the domestic side of a domestic hot water system. The flow switch should close upon flow to provide a closed circuit back to LV14.
  • Page 13 MODU-FIRE® Forced Draft Gas-Fired Boiler For correct installation of vent system, read all of these instructions and re- fer to vent manufacturer’s instructions. Failure to use a proper vent system (types and materials), as described in this manual will void the boiler warranty and may result in rapid deterioration of the venting system, creating a health or life safety hazard.
  • Page 14 MODU-FIRE® Forced Draft Gas-Fired Boiler These chemicals, when burned, form acids which quickly attack the boiler and the boiler stack. The result is im- proper combustion and premature boiler failure. Under no circumstances shall the boiler room ever be under a negative pressure.
  • Page 15 MODU-FIRE® Forced Draft Gas-Fired Boiler Table of US Minimum area of ventilation openings per boiler (sq inches) AIR SOURCE INDOOR AIR SUPPLY OUTDOOR AIR SUPPLY TWO OPENINGS SAME FLOOR DIFF FLOORS ONE OPENING VERT HORIZ MODEL DIRECT DUCT DUCT N750 1500 N1000 1000...
  • Page 16 MODU-FIRE® Forced Draft Gas-Fired Boiler Table of Canadian Minimum Area of Combustion and Ventilation Air Openings Required Combustion Air Opening Ventilation Air Opening Model # Input (Btu/Hr) N750 750,000 16,129 6,452 N1000 1,000,000 21,290 6,452 N1500 1,500,000 32,258 6,452 N2000 2,000,000 43,226 6,452...
  • Page 17 MODU-FIRE® Forced Draft Gas-Fired Boiler 3.5.3.2 Required Clearances Provide clearances between combustion air intake, exhaust vent, roof and wall surfaces, doors and window, and snow line. Refer to Figure below: Termination Clearances – Forced Draft and Direct Vent Installations. Do not locate intake or exhaust terminations directly above a walkway; dripping of condensation can cause icing of the walking surface.
  • Page 18 MODU-FIRE® Forced Draft Gas-Fired Boiler 3.5.3.2.3 Interior Component Installation Clearances All vent system components shall be installed so as to maintain the vent manufacturer’s required minimum clear- ances to combustibles and non-combustibles. 3.5.3.3 Flue Connection The boiler vent should not be connected into any portion of another me- chanical draft system without consulting the vent manufacturer.
  • Page 19 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 operation of the boilers. Dimensions listed above are minimums and may not be sufficient for conditions at a specific job site.
  • Page 20 3.5.3.4.2 Sidewall Venting Harsco Industrial, Patterson-Kelley requires a “T” or 90 degree elbow to be used on the termination end of sidewall venting on these models. The venting connection for this “T” or Thru the roof Thru the roof 90 degree elbow should extend a minimum of 12”...

  • Page 21: Gas Piping

    MODU-FIRE® Forced Draft Gas-Fired Boiler Minimum Air Requirements – SCFM MFD MODEL Min Required SCFM 1000 1500 2000 3.5.6 Removing an Existing Boiler When an existing boiler is removed from a common venting system, the common venting system is likely to be too large for proper venting of the appliances remaining connected to it.
  • Page 22 MODU-FIRE® Forced Draft Gas-Fired Boiler components are certified to handle a maximum inlet pressure of 14 inches W.C. (1/2 psig.). If the available gas pressure exceeds 14 inches W.C., a suitable additional intermediate gas pressure regulator of the "lock up" type must be provided to reduce the pressure to less than 14 inches W.C.

  • Page 23: Boiler Water Piping

    MODU-FIRE® Forced Draft Gas-Fired Boiler NOTICE! A sediment trap (drip leg) and a union connection should be installed downstream of the primary manual shutoff valve on the boiler. Gas piping should be installed in accordance with Na- tional Fuel Gas Code, ANSI Z223.1 and any other local codes which may apply. In Canada, please refer to CSA-B.149.
  • Page 24 MODU-FIRE® Forced Draft Gas-Fired Boiler 3.7.1.2 Piping with Refrigeration Machines When used with a refrigeration system, the boiler shall be installed so that chilled medium is piped in parallel with the boiler. Valves should be installed to prevent chilled water from entering the boiler when the system is operat- ed in the cooling mode.
  • Page 25 MODU-FIRE® Forced Draft Gas-Fired Boiler 3.7.3 Boiler Water Piping by Installer 3.7.3.1 Strainer 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 material to eventually reduce the performance of the heat exchanger.

  • Page 26: Burner And Ignition System

    MODU-FIRE® Forced Draft Gas-Fired Boiler 3.7.5 Water Quality The boiler is designed to operate in a closed-loop system using water or water/glycol only. As such, the system should be tight and not require make-up water. A high percentage of untreated make-up water can cause premature failure due to build up of scale.

  • Page 27: Safety Checks

    MODU-FIRE® Forced Draft Gas-Fired Boiler 3.10 S AFETY HECKS The following checks of safety systems must be made before putting the boiler into normal operation. Before firing the boiler refer to Sections 4.1 and 4.2 for information on the use of the controls, lighting, and shut- down procedures.

  • Page 28: 3.11 Boiler Operating Control

    MODU-FIRE® Forced Draft Gas-Fired Boiler temperature control (see Section 3.11 for instructions on setting this control). After completion of these tests, re- adjust the operating thermostat to the desired operating temperature and set high-limit temperature, typically 20º F above operating temperature. 3.10.4 Test of Low Gas Pressure Switch Manual Reset Hi/Low Gas Pressure Switch...
  • Page 29 MODU-FIRE® Forced Draft Gas-Fired Boiler The user should become thoroughly familiar with the operation of the boiler and controls before attempting to make any adjustments. The boiler control has a text display panel. The display panel is used to setup and monitor boiler operation by means of six push buttons MENU, BACK, ENTER, UP, DOWN, and RESET as shown above.

  • Page 30: Burner Adjustment

    MODU-FIRE® Forced Draft Gas-Fired Boiler NOTICE! Changing parameters requires an understanding of the parameters and the functionality of the boiler. The boiler may not function properly if parameters are changed from the factory values. 3.12 B URNER DJUSTMENT There are no required start-up or field adjustments for air flow control. DO NOT attempt to change any parameters in the blower speed control (inverter).

  • Page 31: Operation

    MODU-FIRE® Forced Draft Gas-Fired Boiler OPERATION ENERAL Pop-Latch (2) Instructions The front of the control panel shows Operating Instruc- tions and a series of illuminated indicator lights and the temperature control. The boiler operating controls are accessed by turning the pop-latches ¼ turn, and opening the front cover.

  • Page 32: Maintenance

    All weekly, monthly and annual maintenance checks should be performed by qualified and knowledgeable personnel. Installation and service must be performed by a qualified and knowledgeable individual, such as a Harsco Industrial, Patterson-Kelley representative, qualified installer, service agency, or gas supplier. Proper lockout / tagout procedures must be employed when servicing this unit.
  • Page 33 6. Perform combustion analysis and adjust if necessary (See 3.12.3). 7. Leak test gas valves. Leak Test must be performed only by qualified Harsco Industrial, Patterson-Kelley certi- fied personnel, who have been trained in this procedure. This procedure is available on request from the...

  • Page 34: Cleaning The Burner

    MODU-FIRE® Forced Draft Gas-Fired Boiler LEANING THE URNER 5.2.1 Burner Assembly Air-Gas Mixing Head Blower Ignition Assembly Burner Grid Follow proper lockout / tagout procedures for the electrical, gas, and water connections. Use caution when lifting heavy parts. 2. Remove top and side covers from the boiler. 3.

  • Page 35: Removing The Heat Exchanger

    MODU-FIRE® Forced Draft Gas-Fired Boiler 5.2.2 Ignition Assembly UV Detector High Exhaust Back Ignitition Pressure Electrode Switch Spark Gap 1/8” +1/16, -0 NOTICE! The electrode height is not adjustable. If adjustment is necessary, only the ground rod should be adjusted. Check for cracking of the electrode. Do NOT over tighten the electrode (finger tight plus a quarter turn).

  • Page 36: Sequence Of Operation

    MODU-FIRE® Forced Draft Gas-Fired Boiler EQUENCE OF PERATION 1. In order for the boiler to start, the following limits must be satisfied: a) Water flow switch b) High & low gas pressure switches c) High temperature limit d) High back pressure switch e) High stack temperature switch 2.

  • Page 37: Troubleshooting

    MODU-FIRE® Forced Draft Gas-Fired Boiler ROUBLESHOOTING If any “Manual Reset” limit device trips, DO NOT RESET without determining and correcting the cause. (Manual Reset Limits include: Flame safeguard, high or low gas pressure, high temperature limit, stack temperature.) 5.6.1 Loss of Power In the event of loss of power, the entire boiler system is de-energized, closing all automatic valves and halting all boiler operations.
  • Page 38 MODU-FIRE® Forced Draft Gas-Fired Boiler When AIR SWITCH NOT OPEN is shown on the display, check that the air switch is open when the fan is off. Check that there is no air flow through the boiler when the fan is off. When AIR SWITCH NOT CLOSE is shown on the display, check that the air switch is closed when the fan is running.

  • Page 39: Manual Reset Error Codes - A

    MODU-FIRE® Forced Draft Gas-Fired Boiler – A## ANUAL ESET RROR ODES Code ENVI Display Lockout Description Unassigned No Error Description, Call For Service IGNITION FAILURE Ignition Failure During an attempt to light, no flame was detected FLAME FAILURE Flame Failure During run, the flame was lost The temperature in the boiler exceeded the setting on HIGH LIMIT...

  • Page 40: Auto-Reset Error Codes - E

    MODU-FIRE® Forced Draft Gas-Fired Boiler – E## RESET RROR ODES Code ENVI Display Lockout Description OUT TEMP SENS OPEN Outlet Temperature Sensor Open Boiler outlet water temperature sensor open circuit IN TEMP SENS OPEN Inlet Temperature Sensor Open Boiler inlet water sensor temperature open circuit FLUE TMP SENS OPEN Flue Temperature Sensor Open Boiler flue gas temperature sensor open circuit DHW TEMP SENS...

  • Page 41: Parts/Technical Support

    MODU-FIRE® Forced Draft Gas-Fired Boiler PARTS/TECHNICAL SUPPORT Spare and replacement parts can be ordered from your local representative or Harsco Industrial, Patterson-Kelley by calling (877) 728-5351. The fax number is (570)476-7247. Refer to the parts list shown on the assembly drawing provided with this manual.
  • Page 42 MODU-FIRE® Forced Draft Gas-Fired Boiler 6.1.2 Terminal Block Assignments – Low Voltage Circuit (LV) Terminal Number Label Description Enable / Disable Boiler Enable, Contact Closure. DO NOT ENERGIZE. Auxiliary Low Water Cutoff External Limit, Contact Closure. DO NOT ENERGIZE. Start Interlock External Limit, Contact Closure.
  • Page 43 MODU-FIRE® Forced Draft Gas-Fired Boiler 6.1.3 MODU-FIRE® Forced Draft Boiler Wiring Diagram L1 208-240V ENABLE DISABLE L2 208-240V AUXILIARY N 208-240V LOW WATER 120V AC CUTOFF SWITCHED OUTPUT EXTERNAL INTERLOCK 3 WAY VALVE DHW PUMP RELAY CIRC PUMP RELAY DAMPER RELAY GROUND 120V AC SWITCHED...
  • Page 44 MODU-FIRE® Forced Draft Gas-Fired Boiler 6.1.4 Main Control Panel Components Main Control Panel Rear) Mark Description Mark Description ENVI™ Display Panel Neutral Terminal Block ENVI™ Main Board ENVI™ Interface Board Inverter Fuses Air Switch Blower/Inverter Control Ignition Transformer On/Off Switch High Water Temp Limit Circuit Breaker Remote/Local Enable...
  • Page 45 MODU-FIRE® Forced Draft Gas-Fired Boiler 6.1.5 Main Control Panel Point to Point Left Side Alarm Flame Enable...
  • Page 46 MODU-FIRE® Forced Draft Gas-Fired Boiler 6.1.6 Main Control Panel Point to Point Right Side...
  • Page 47 MODU-FIRE® Forced Draft Gas-Fired Boiler 6.1.7 Junction Box Point to Point and Customer Connections...
  • Page 48 MODU-FIRE® Forced Draft Gas-Fired Boiler 6.1.8 Customer Connections Details...
  • Page 49 MODU-FIRE® Forced Draft Gas-Fired Boiler 6.1.9 Gas Train Mark Description Main Gas Valve Low Gas Pressure Switch Leak Test Ports Automatic Dual Gas Valve Solenoid Coils Gas Union High Gas Pressure Switch Secondary Gas Shutoff Valve Air Gas Mixer Head Blue Dot (attach Blue Hose Here)
  • Page 50 MODU-FIRE® Forced Draft Gas-Fired Boiler 6.1.10 Blower/Burner/Ignition Assembly Mark Description Burner Grid Burner Gasket Mounting Plate Blower Gasket Blower w/Motor Ignition Gasket Ignition Electrode UV Scanner Backpressure Switch...
  • Page 51 MODU-FIRE® Forced Draft Gas-Fired Boiler 6.1.11 Heat Exchanger and Combustion Chamber Mark Description Front Wrapper Heat Exchanger Gasket Set Removable Top Head...
  • Page 52 MODU-FIRE® Forced Draft Gas-Fired Boiler 6.1.12 Cabinet Assembly Mark Description Front Door Side Covers Top Cover Control Panel Relief Valve Flow Switch Low Water Cutoff Switch (optional) Air Inlet Assembly...

  • Page 53: Limited Warranty

    LIMITED WARRANTY Subject to the terms and conditions herein, Harsco Industrial, Patterson-Kelley, Seller warrants to the original owner at the original installation site that products manufactured by Seller will be free from defects in materials and workmanship for a period of one (1) years from date of start up (the "Warranty Period"), provided that startup is completed within six months from the date of shipment.

  • Page 54: Modu-Fire® Forced Draft Boiler Fire Test Report

    F) Silicon piping or tubing, and then trapped: YES or NO Performed by: Additional Comments: Please return a copy to Harsco Industrial, Patterson-Kelley, ATTN: Boiler Technical Service Harsco Industrial, Patterson-Kelley · 100 Burson Street · E. Stroudsburg, PA 18301 Phone: (570) 476-7261 Fax: (570) 476-7247...

This manual is also suitable for:

Modu-fire forced draft n1500Modu-fire forced draft n1000Modu-fire forced draft n2000

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