Test Of Low Water Cut-Out; Test Of High-Limit Control; Test Of Gas Pressure Switches; Operating Temperature Controller - Harsco Industrial P-K SONIC SC-3000 Installation & Owner's Manual

3.8 p
!
WARNING
Before attempting to start the boiler, make sure the following items have
been completed. Refer to the engineering manual for your model for
Never attempt to operate a boiler
additional information.
that has failed to pass all the safety
checks described below.
1. Inspect the gas train, blower, ignition electrode and boiler in general to be sure
there was no damage during shipment or installation.
!
2. Flue gas from the boiler is properly vented;
WARNING
3. Gas connection has been made, pressure tested for leakage and the line
After checking controls by manual
purged of air. Make sure all required vents have been installed.
adjustment, make sure they are
4. Water connections are complete and the boiler and system have been filled
always reset to their proper settings.
and purged of air.
5. The boiler is connected to the correct electrical power source listed on the
n !
oTICe
nameplate, and having a disconnect having adequate overload protection.
If the expected error code(s) do not
6. Combustion air openings are not obstructed in any way and have adequate
appear, call for qualified service.
capacity.
7. The boiler is placed the proper distance from any combustible walls
8. Relief valves have been piped to an acceptable drain at a safe point of discharge.
9. Condensate piping is properly connected.
10. Verify system water quality is within specifications.
3.9 s C
afeTy heCks
The following checks of safety systems must be made before putting the boiler into normal operation.
Before firing the boiler refer to Section 4 for information on the use of the controls, lighting, and shut-down
procedures.
3.9.1 test of Ignition safety system
Test the ignition system safety shutdown as follows:
1. Cycle the boiler on by generating a heat request. (The method for this will depend on your boiler configuration.)
2. Place the boiler in operation at the high fire setting BNR TEST MODE HI.
3. Smoothly close the downstream manual isolation valve to reduce the gas flow and cause flame failure.
4 The display will show LOCKING FLAME FAILURE indicating a flame failure. The lockout will remain until the control is reset.
After completing this test, turn off the boiler and open the downstream manual isolation valve and turn the boiler
back on.

3.9.2 test of low Water Cut-out

The boiler is furnished with a probe-type low water cut-out in the outlet nozzle. Test as follows:
Push and hold the red "Push to test" button for at least 5 seconds. A manual lockout reset error displaying
on the display panel should occur. The
LOCKOUT LOW WATER LEVEL
longer be illuminated.
Optional Test Method: First turn the boiler off, and then turn the pump off. Isolate the boiler from the system.Drain
the water level below the low water cut-off probe. Turn the boiler back on. It should not operate, and a manual
lockout reset error displaying
LOCKOUT LOW WATER LEVEL
on the Low Water cut-off will no longer be illuminated.
Return the system to normal operation by refilling and restarting the boiler and pump.
Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351
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-s C
re TarT heCklIsT
indicator on the Low Water cut-off will no
LED
on the display panel should occur. The
Gas Fired Boiler

3.9.3 test of high-limit Control

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" thermostat until the main
burner shuts off. A manual reset lockout displaying
high-limit switch must be manually reset prior to resetting the boiler at the display panel. Readjust the high-limit
thermostat to the desired setpoint.

3.9.4 test of Gas Pressure switches

low Gas Pressure switch
The boiler is furnished with a low gas pressure switch. The operation of this switch must be checked by slowly
closing the main gas cock while the burner is operating. The switch should shut down the main burner. When
the gas pressure switch opens, a manual reset lockout displaying
panel will occur. Upon re-opening the main gas cock, the
display panel is manually reset.
high Gas Pressure switch
The boiler is furnished with a high pressure switch that must be checked by closing the downstream gas cock
with the boiler off. When the boiler is started, it should enter its normal starting cycle and fail on high gas pressure
when the automatic gas valves open. The high gas pressure switch actuation is evident when a manual reset
lockout displaying
LOCKING HIGH GAS PRESSURE
the
3.10 I a
nITIal djusTMenTs

3.10.1 Operating temperature Controller

SC-3000 and
The
boilers are
SC-4000
equipped with
ENVI®
control; an intelligent
control system
with advanced
features such as
text-based display,
communication
capabilities, and
boiler sequencing.
Errors are date
and time stamped
providing built-in
history of boiler
status and performance.
This control constantly tracks the load by recording burner high, low and mid run hours. One control to do it
all – temperature control, flame safeguard, firing rate control, blocked flue protection, outdoor air reset, freeze
protection, built-in cascade sequencing, MODBUS communication and more.
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
indicator
LED
the bottom are used to navigate through the various screens. The four line screen shows boiler operating
information on various screens. The display screen is back lit for ease of viewing. Pressing any key will illuminate
the back light.
*NOTE 1 - Refer to ENVI® Control Advanced Users Guide (Part # 1004905953) for more information.
LOCKING HIGH LIMIT
LOCKING LOW GAS PRESSURE
LOCKING LOW GAS PRESSURE
on the display panel occurs. Upon re-opening the gas cock,
LOCKING HIGH GAS PRESSURE
indicator will remain on until the display panel is manually reset.
Figure 3.10.1a
, , , , , and
BACK UP DOWN
MENU ENTER RESET
Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351
Gas Fired Boiler
on the display panel will occur. The
on the display
will remain on until the
CAUTION
!
The user should become
thoroughly familiar with the
operation of the boiler and controls
before attempting to make any
adjustments.
CAUTION
!
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.
as shown above. The buttons across
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