Harsco Industrial P-K THERMIFIC N700 Installation & Owners Manual
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Harsco Industrial P-K THERMIFIC N700 Installation & Owners Manual

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P-K THERMIFIC
GAS-FIRED BOILER
Model#: __________________________
Serial#: __________________________
Start-up Date:
__________________________
Harsco Industrial, Patterson-Kelley
100 Burson Street
East Stroudsburg, PA 18301
Telephone: (570) 476-7261
Fax: (570) 476-7247
www.harscopk.com
©1989-2012 Harsco Industrial, Patterson-Kelley
Printed 11/4/2011
THERM201_2-19-12
®
P-K THERMIFIC® (All Models) 700-2000
Rev. 1.2 (2/29/2012)
1004905903

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Summary of Contents for Harsco Industrial P-K THERMIFIC N700

  • Page 1 Rev. 1.2 (2/29/2012) 1004905903 P-K THERMIFIC ® GAS-FIRED BOILER Model#: __________________________ Serial#: __________________________ Start-up Date: __________________________ Harsco Industrial, Patterson-Kelley 100 Burson Street East Stroudsburg, PA 18301 Telephone: (570) 476-7261 Fax: (570) 476-7247 www.harscopk.com ©1989-2012 Harsco Industrial, Patterson-Kelley Printed 11/4/2011 THERM201_2-19-12...
  • Page 2 ® P-K THERMIFIC Gas-Fired Boiler...

  • Page 3: Table Of Contents

    ® P-K THERMIFIC Gas-Fired Boiler INTRODUCTION ..................5     SAFETY ..................... 5     2.1  General ....................... 5  2.2  Training ....................... 5  2.3  Safety Features ................... 6  2.4  Safety Labels ....................6  2.5  Safety Precautions ..................7  INSTALLATION ..................9  ...
  • Page 4 ® P-K THERMIFIC 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 property damage, personal injury or loss of life.

  • Page 5: Introduction

    Additional equipment such as temperature sensors, pumps, flow switches, balancing valves 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 engineer or contractor must be consulted.

  • Page 6: Safety Features

    If any of the provisions of this manual are not fully and completely understood, contact the Harsco Industrial, Patterson-Kelley Technical Service Department toll-free at (877) 728-5351 for assistance.

  • Page 7: Safety Precautions

    P-K THERMIFIC Gas-Fired Boiler The safety labels shown above are affixed to your boiler. Although the labels are of high quality, they may become dislodged or unreadable over time. Contact Harsco Industrial, Patterson-Kelley toll-free at (877) 728-5351 for replacement labels. AFETY...
  • Page 8 ® P-K THERMIFIC Gas-Fired Boiler  Gas leak hazard! Make sure all connections and unions to main burner are tight when reassembling the burner. These connections cannot be tested after the burner is assembled.  Gas leak hazard! All threaded gas connections must be made using a pipe compound that is resistant to liquefied petroleum.

  • Page 9: Installation

    ® P-K THERMIFIC Gas-Fired Boiler 2.5.6 Slip, Fall Hazards  Tripping hazard! Do not install piping on floor surfaces. Maintain clear path around boiler.  Slip and fall hazard! Use drip pan to catch water while draining the boiler. Maintain dry floor surfaces.

  • Page 10: Setup

    ® P-K THERMIFIC 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. In Canada, the equipment shall be installed in accordance with the current Installation Code for Gas Burning Appliances and Equipment, CAN/CGA-B.149, and applicable Provincial Regulations, which should be carefully followed in all cases.

  • Page 11: 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 insufficient access at the rear to allow for service and adjustment.
  • Page 12 ® P-K THERMIFIC Gas-Fired Boiler UL 441 Type B Gas Vent (Category I) These codes and standards contain information for the venting of gas fired appliances, including, but not limited to vent sizing, location, clearance to combustibles, and safe installation practices. The installation must comply with all applicable national, state, provincial and local codes.
  • Page 13 B-Vent Chimney Metal Pipe Vent System Vent System Cat II/III/IV United States N700-N1000 N1500-N2000 On-Off N1500-N2000 LHL N700-N2000 Sealed Combus- tion Canada N700-N1000 N1500-N2000 On-Off N1500-N2000 LHL N700-N2000 Sealed Combus- tion 3.5.2 Combustion Air Combustion air must be free from dust, lint, etc. The presence of such materials in the air supplied to the burner could cause nuisance "Low Air"...
  • Page 14 AIR SOURCE INDOOR AIR SUPPLY OUTDOOR AIR SUPPLY TWO OPENINGS ® P-K THERMIFIC SAME FLOOR DIFF FLOORS ONE OPENING VERT HORIZ MODEL DIRECT DUCT DUCT N700 1400 N1000 1000 2000 N1500 1500 3000 N1700 1700 3400 N2000 2000 4000 1000...
  • Page 15 ® P-K THERMIFIC Gas-Fired Boiler 3.5.2.2 Air Inlet Requirements – Canada (CAN/CSA B149.1) A. Ventilation of the space occupied by fuel burning appliance(s) or equipment shall be supplied by a ventilation opening at the highest practicable point communicating with the outdoors. The total cross sectional area of the ventilation opening must be either 10% of the net free area required for combustion air or 10 sq.
  • Page 16 P-K THERMIFIC Gas-Fired Boiler Table of Canadian Minimum Area of Combustion and Ventilation Air Openings Required Combustion Air Input Ventilation Air Opening ® THERMIFIC Opening Model # Btu/Hr N700 700,000 64,516 6,452 N1000 1,000,000 92,257 14.3 9,226 N1500 1,500,000 115,484 17.9...
  • Page 17 ® P-K THERMIFIC Gas-Fired Boiler Approximate Equivalent Length of Fittings Fitting Description Equivalent Length 90º Elbow 10 feet 45º Elbow 5 feet Rain Cap* 10 feet Open Termination 10 feet Boot Tee/135º Tee 10 feet Standard Tee used as a Vent Termination 10 feet * Low loss rain cap (see illustration in Section 3.5.3.5) 3.5.3.2...
  • Page 18 ® P-K THERMIFIC Gas-Fired Boiler Be sure that the damper is mounted horizontally (never vertically). Be sure to remove all three red stops from the damper before start-up. The damper door should swing freely. Carefully follow all the instructions provided with the barometric damper. To avoid spillage into the boiler room of dangerous flue gas containing carbon monoxide, the opening in the damper (draft control gate) must never face against the flow of flue gas.
  • 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 cannot be responsible for the effects such adverse conditions may have on the operation of the boilers.
  • Page 20 ® P-K THERMIFIC Gas-Fired Boiler A sealed combustion system employs an air intake duct leading directly from outdoors to the boiler and an exhaust vent terminating outdoors. Air flow through the system is maintained by the combustion air fan and the stack draft. An exhaust fan is not required. 3.5.5.1 Sealed Combustion Intake Duct Materials and Sizes The air intake duct can be fabricated from PVC, CPVC, single wall galvanized steel, or other suitable...
  • Page 21 ® P-K THERMIFIC Gas-Fired Boiler The sealed combustion boiler is equipped with a special collar attached to the air inlet opening on the back of the unit (at the blower housing on the 700 and 1000; at the back of the cabinet on the 1500, 1700 and 2000.).
  • Page 22 ® P-K THERMIFIC Gas-Fired Boiler Incorrect Correct Listed Termination Termination (too restrictive) 3.5.5.5 Sealed Combustion Inlet Damper and Control Panel (optional) The inlet damper assembly and control panel prevents the flow of cold air through the boiler during the off cycle and helps prevent freeze up. These two items are optional in all installations. The damper must be field installed into a section of horizontal or vertical inlet ductwork.
  • Page 23 ® P-K THERMIFIC Gas-Fired Boiler 3.5.5.6 Sealed Combustion Exhaust Vent Materials and Sizes All flue gas outlet (exhaust vent) material must comply with UL-1738 or ULC S636 (Category II/III/IV listed vent systems). The exhaust vent may be run horizontally or vertically. This boiler is certified for a 12”...
  • Page 24 ® P-K THERMIFIC Gas-Fired Boiler 3.5.5.8 Sealed Combustion Flue Gas Termination 3.5.5.8.1 Sidewall Termination Outside Plate Centering Support Cover Plate Plate Fastener Recommended Sealant termination (refer to text). Sealant 12" Min. The exhaust vent termination must be one of the following four approved sidewall terminations: ...
  • Page 25 ® P-K THERMIFIC Gas-Fired Boiler 3.5.5.9 Sealed Combustion/Direct Vent System Configurations Four basic configurations are allowable for the combustion air inlet and flue gas exhaust vent, and are shown below. Exhaust Air Inlet Sidewall Vent Roof Exhaust Vent Air Inlet 1.

  • Page 26: Gas Piping

    ® P-K THERMIFIC Gas-Fired Boiler 3.5.6 Venting for Multiple Boilers The venting instructions in this manual apply to a single boiler. Venting systems for multiple boilers must be designed by experienced and knowledgeable professionals. The venting system must prevent backflow of exhaust gas through idle boilers. 3.5.7 Removing an Existing Boiler (from a common venting system) When an existing boiler is removed from a common venting system, the common venting system is likely...
  • Page 27 ® P-K THERMIFIC Gas-Fired Boiler NOTICE! The gas train components are certified to handle a maximum inlet pressure of 14" W.C. (1/2 psig.). All threaded connections must be made using a pipe compound that is resistant to the action of liquefied petroleum gases. Do not use Teflon tape on gas line threads. 3.6.1 Gas Supply Piping by Installer Gas Piping Schematic Remote Gas...
  • Page 28 ® P-K THERMIFIC Gas-Fired Boiler The boiler and all gas piping connections must be pressurized and checked for leaks before being placed into service. Pressurize with compressed air or inert gas if possible. The boiler must be disconnected at the boiler manual shut-off valve (located at the end of the supplied gas train) from the gas supply piping system during any pressure testing of the system at pressures in excess of 1/2 psig (14”...

  • Page 29: Boiler Water Piping

    Multiple zones and pumps may result in different flow rates at different times. Consideration must be given to all possible conditions and their consequences. ® Water Flow Parameters – P-K THERMIFIC N700-N1000 Boilers ® P-K THERMIFIC Minimum Flow Delta T (°F)
  • Page 30 ® P-K THERMIFIC Gas-Fired Boiler ® Water Flow Parameters – P-K THERMIFIC N1500-N2000 Boilers ® P-K THERMIFIC Minimum Flow Delta T (°F) Maximum Delta T Model (GPM) Flow (°F) (GPM) N1500 28.3 17.0 N1700 28.9 19.3 N2000 28.3 22.7 ® Pressure Drop Curve - P-K THERMIFIC N1500-N1700-N2000 Boilers...
  • Page 31 ® P-K THERMIFIC 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 operated in the cooling mode.
  • Page 32 ® P-K THERMIFIC Gas-Fired Boiler Never install a valve that can isolate the flow switch (low water cut-off) from the boiler. 3.7.3.4 Drain Valve and Piping An external drain connection is not supplied with the boiler. A drain valve must be provided and installed, by the installing contractor, near the inlet (system return) connection to the boiler and piped to a suitable floor drain.

  • Page 33: Pre-Start Check List

    ® P-K THERMIFIC Gas-Fired Boiler 3.7.5.2 Hot Water Supply Boiler Application (D-Series) A hot water supply boiler is designed to operate in an open system. The water quality should be within the guidelines established by the National Sanitation Foundation (NSF) or the local water authority guidelines.

  • Page 34: Safety Checks

    ® P-K THERMIFIC Gas-Fired Boiler 7. Combustion air openings are not obstructed in any way and have adequate capacity (refer to Section 3.5). 8. The boiler is placed the proper distance from any combustible walls or substances (refer to Section 3.3). 9.

  • Page 35: Initial Adjustments

    ® P-K THERMIFIC Gas-Fired Boiler operate, and a red indicator for "Water Flow" should be illuminated. Do not shut the pump off while the boiler is operating. Perform appropriate tests on any external probe-type low water cutoff. 3.9.3 Test of Temperature Controls Fire the boiler and test the high limit control as follows: With the main burner operating, turn down the temperature setting on the "high-limit"...
  • Page 36 155ºF (170ºF - 15ºF). 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-Kelley service representative for assistance adjusting your Lo-Hi-Lo operating temperature control to meet system requirements. Record settings in the following programming worksheet for future reference.
  • Page 37 ® P-K THERMIFIC Gas-Fired Boiler SIX BUTTON KEYPAD: The 6 button keypad consists of a HOME button, MENU button and left and right arrow (◄ ►) buttons and up and down arrow (▲▼) buttons. Pressing the ◄ or ► arrow buttons from the HOME screen cycles through each modulating output displaying the values (these values can not be changed using this screen).
  • Page 38 NOTICE! Adjustments shall only be performed by service representative specifically trained and ® knowledgeable to perform maintenance on the Harsco Industrial, Patterson-Kelley P-K THERMIFIC boiler. Verify proper operation after servicing. NOTICE! A combustion analyzer must be used to adjust the boiler for local conditions.
  • Page 39 ® P-K THERMIFIC Gas-Fired Boiler the pilot flame doesn’t hold the same size as the tube, looks very lazy, and/or very yellow, you may have too much gas or some of the pilot air holes may be partially restricted with dirt. Correct as needed. If the boiler uses sealed combustion and will use very cold combustion air you may need to use a higher gas pressure for the colder weather to avoid nuisance pilot flame failures.
  • Page 40 ® P-K THERMIFIC Gas-Fired Boiler Lo-Hi-Lo (1500, 1700, 2000 Series) This is a two stage firing arrangement with the mechanical action provided by the two stage gas valve actuator via a vertical rod connected to the damper assembly shown below. The damper shaft is a horizontal shaft that enters the boiler (indicated in photo).
  • Page 41 Put the boiler in low fire (Lo-Hi-Lo only), adjust the air pressure (as shown in Section 3.10.3.3) using the low fire set screw to achieve an analyzer reading of 7.5% O . Record all readings on the field fire test report and send to Harsco Industrial, Patterson-Kelley.
  • Page 42 ® P-K THERMIFIC Gas-Fired Boiler 3.10.3.6 Sealed Combustion Operating Conditions This burner is designed to operate at approximately 50% excess air at room temperature (70ºF). Therefore, when taking combustion air from the outdoors in a direct vent system, adjustment of the combustion should not be made until the carbon dioxide or oxygen reading is referenced to these “standard”...

  • Page 43: Operation

    4.1.2 Tests All Harsco Industrial, Patterson-Kelley boilers are factory fire tested prior to shipment. This procedure includes testing of the limits and adjustment of combustion parameters specified in ANSI Z21.13/CSA 4.9, latest edition. This testing and setup information is recorded on the “Factory Firetest” label located on the back of the boiler.

  • Page 44: Typical Boiler Operating Conditions

    ® P-K THERMIFIC Gas-Fired Boiler 7. The controller will now complete the automatic firing sequence. 4.2.2 Normal Shut Down Procedure 1. Turn off the electric power using the on/off switch on the front of the boiler. 2. Close all manual gas valves (for extended shut- down only).

  • Page 45: Maintenance

    ® P-K THERMIFIC Gas-Fired Boiler MAINTENANCE AINTENANCE AND NSPECTION CHEDULE The Daily and Weekly observations can be done by operating personnel. Monthly, Semi-Annually and Annually observations and any required adjustments, servicing, etc. should be performed by qualified service personnel. This schedule applies when the boiler is in use. Local codes or jobsite conditions may require more frequent servicing.
  • Page 46 7. Inspect and clean the air inlet screen of any accumulated dust or lint. 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...

  • Page 47: Cleaning The Burner

    Check vent pipe for corrosion or deterioration. If any venting needs replacing, do so immediately. 12. Perform combustion analysis and adjust if necessary. 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. LEANING THE URNER 1.

  • Page 48: Removing The Exchanger

    ® P-K THERMIFIC Gas-Fired Boiler 10. Carefully remove the burner. 11. Wash the burner with water. DO NOT wipe or brush the outside of the burner. 12. Check that the ceramic portion of the ignition electrode is not cracked. Verify that the three-armed spider is on the electrode.

  • Page 49: Sequence Of Operation

    ® P-K THERMIFIC Gas-Fired Boiler EQUENCE PERATION Status indicator lights located on the front of the control panel or on the flame safeguard of this boiler are specifically designed to indicate the sequence of operations and the cause of common problems. Careful observation of indicators should provide a guide to most operational conditions and problems.

  • Page 50: Troubleshooting

    ® P-K THERMIFIC 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, low water level.) Loss of Power In the event of a power failure the "Power"...

  • Page 51: Parts/Technical Support

    Gas-Fired Boiler PARTS/TECHNICAL SUPPORT Spare parts and replacement parts can be ordered from Harsco Industrial, Patterson-Kelley by calling (570) 476-7261 or Toll Free (877) 728-5351. Ask for the Heat Transfer Department. The fax number is (570) 476-7247. Refer to the parts list shown on the assembly drawing provided with this manual.
  • Page 52 ® P-K THERMIFIC Gas-Fired Boiler 6.1.1 On-Off 6.1.1.1 On-Off Wiring Diagram (700, 1000, 1500, 1700, 2000)
  • Page 53 ® P-K THERMIFIC Gas-Fired Boiler 6.1.1.2 On-Off Sealed Combustion Diagram (700, 1000)
  • Page 54 ® P-K THERMIFIC Gas-Fired Boiler 6.1.1.3 On-Off Sealed Combustion Diagram (1500, 1700, 2000)
  • Page 55 ® P-K THERMIFIC Gas-Fired Boiler 6.1.2 Lo-Hi-Lo 6.1.2.1 Lo-Hi-Lo Wiring Diagram (1500, 1700, 2000)
  • Page 56 ® P-K THERMIFIC Gas-Fired Boiler 6.1.2.2 Lo-Hi-Lo Sealed Combustion Diagram (1500, 1700, 2000)
  • Page 57 ® P-K THERMIFIC Gas-Fired Boiler 6.1.3 Low Water Cutoff 6.1.3.1 Field Installed Low Water Cut-Off Diagram...
  • Page 58 ® P-K THERMIFIC Gas-Fired Boiler 6.1.3.2 Factory Installed Low Water Cut-Off Diagram...

  • Page 59: Boiler Parts List

    ® P-K THERMIFIC Gas-Fired Boiler OILER ARTS 1500/1700/2000 Lo-Hi-Lo 6.2.1 Main Assembly 700/1000 On/Off 1, 2 14, 15 Part Part Mixer Core, Burner Blower, Wheel Burner Orifice Press./Temp. Gauge Ignition Electrode (w/ 100 PSI relief valve) UV Scanner Damper Rod, Lo-Hi-Lo Thermowell w/Clamp (2x) Damper Bracket Pilot Assembly...
  • Page 60 ® P-K THERMIFIC Gas-Fired Boiler 6.2.2 Control Panel On-Off Panel Lo-Hi-Lo Panel Part Part Switch, On/Off Ignition Transformer Flame Safeguard Programmer with Ignition Cable UV Amplifier & Timing Card Pilot Assembly (incl. Ignition Electrode) Motor Starter Relay UV Scanner Thermostat (Manual Reset) Thermostat Sensor Wells (2) Thermostat (Operating Temp) LHL Two Stage Thermostat (Operating...
  • Page 61 ® P-K THERMIFIC Gas-Fired Boiler 6.2.3 Gas Train N1000 Gas Train N1000 Gas Train N1500-2000 Gas Train N1500-2000 Gas Train Pilot Gas Train Pilot Gas Train Part Main Gas Shut-off Valve Main Gas Regulator Main Gas Valve (Diaphragm) Main Gas Valve Body (On/Off) Main Gas Valve Body (LHL) Main Gas Valve Actuator (On/Off) Main Gas Valve Actuator (LHL)
  • Page 62 ® P-K THERMIFIC Gas-Fired Boiler 6.2.4 Cabinet 700/1000 700/1000 1500/1700/2000 Part Exterior Cabinet, Assy. Exterior Cabinet, Door Exterior Cabinet, Top Sight Glass Sight Glass Bezel Combustion Chamber, Assy. Combustion Chamber, Door Combustion Chamber, Top Control Panel, Label 10 Control Panel, Cover 11 Control Panel, Sub Panel 12 Control Panel, Base Assy.

  • Page 63: 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) year from date of start up (the "Warranty Period"), provided that start up is completed within six months from the date of shipment.
  • Page 64 ® P-K THERMIFIC Gas-Fired Boiler...

This manual is also suitable for:

P-k thermific n1000P-k thermific n1500P-k thermific n1700P-k thermific n2000

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