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Harsco Industrial 1004905923 Installation & Owner's Manual

Modu-fire forced draft gas-fired boiler
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MODU-FIRE
®
GAS-FIRED BOILER
2500 - 3000
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 Harsco Industrial, 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 #:_______
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
© 2011 Harsco Corporation, All Rights Reserved
MFD 202
FORCED DRAFT
Serial #______________________
MODU-FIRE® FD 2500-3000
Rev. 1.01 (2/7/12)
PART # 1004905923

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  • Page 1 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 Harsco Industrial, 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 #:_______...
  • Page 2 ® MODU-FIRE Forced Draft Gas-Fired Boiler 2500-3000...

  • Page 3: Table Of Contents

    ® MODU-FIRE Forced Draft Gas-Fired Boiler 2500-3000 1  INTRODUCTION ......................5  2  SAFETY ........................5  General ..........................5     Training ..........................5     Safety Features ........................ 6     Safety Labels ........................6     Safety Precautions ......................6    ...
  • Page 4 Installation and service must be performed by a qualified and knowledgeable individ- ® ual who has been trained on the Harsco Industrial, Patterson-Kelley MODU-FIRE Forced Draft boiler. The same features which permit this boiler to achieve high-efficiency performance make it unlike most other boilers of this general size, so it is important to understand how this boiler operates.

  • Page 5: 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 6: Safety Features

    ® MODU-FIRE Forced Draft Gas-Fired Boiler 2500-3000 the provisions of this manual are not fully and completely understood, contact the Harsco Industrial, Patterson- Kelley Technical Services Department 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 labels, safety controls, interlocks, lockout devices.
  • Page 7 ® MODU-FIRE Forced Draft Gas-Fired Boiler 2500-3000 2.5.2 Burn, Fire, and Explosion Hazards WARNING NOTE NOTE Improper use may Make sure this union is When opening leak test valves, result in fire or injury. always follow instructions in tight before closing cabinet operation and safety manual.

  • Page 8: Installation

    ® MODU-FIRE Forced Draft Gas-Fired Boiler 2500-3000 2.5.3 Crush Hazards  Lifting hazards! Use properly rated lifting equipment to lift and position the boiler. The load is unbalanced. Test balance before lifting more than 3 ft. above the floor. Do not allow personnel beneath the lifted load.

  • Page 9: Compliance With Codes

    ® MODU-FIRE Forced Draft Gas-Fired Boiler 2500-3000 NOTICE! Note any damage, suspected potential damage, or shortage of materials on the freight bill and immediately notify the carrier. File all claims for shortage or damage with the carrier. Claims for hidden damages must be filed with your carrier within 7 days. The boiler carton is equipped with a “Tip (N) Tell”.

  • 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 insufficient access at the rear to allow for service and adjustment.
  • Page 11 ® MODU-FIRE Forced Draft Gas-Fired Boiler 2500-3000 NOTICE! A dedicated earth ground (green wire) is required to avoid nuisance shutdowns. Do not ground through the conduit. It is also important that proper polarity be maintained. The junction box at the rear of the boiler contains terminal strips for all customer connections. A detailed schematic of the connections is shown in 6.1.7.

  • Page 12: Inlet Air And Exhaust Venting

    The outdoor air sensor and programming help are available from the 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°C.
  • Page 13 ® MODU-FIRE Forced Draft Gas-Fired Boiler 2500-3000 Before connecting a boiler to a venting system, it must be determined whether the boiler is to be installed in a conventional or Direct Vent configuration. In the US, provisions for combustion and ventilation air must be in accordance with NFPA 54/ANSI Z223.1, National Fuel Gas Code, latest edition, or applicable provisions of the local building codes.
  • Page 14 ® MODU-FIRE Forced Draft Gas-Fired Boiler 2500-3000 The combustion air supply must be completely free of chemical fumes which may be corrosive when burned in the boiler. Common chemicals which must be avoided are fluorocarbons and other halogenated compounds, most commonly present as refrigerants or solvents, such as freon, trichlorethylene, perchlorethylene, chlorine, etc.
  • Page 15 ® MODU-FIRE Forced Draft Gas-Fired Boiler 2500-3000 NOTICE! 1. The required size of openings for combustion and ventilation air shall be based on the net free area of the opening. 2. Screens shall be not smaller than ¼” 3. Motorized louvers shall be interlocked with the appliance so that they are proven open prior to main burner ignition and operation.
  • Page 16 ® MODU-FIRE Forced Draft Gas-Fired Boiler 2500-3000 NOTICE! 1. The free area of a combustion air supply opening is calculated by deducting the blockage area of any fixed louvers, grilles or screens from the total area of the opening. 2. Screens shall be not smaller than ¼” 3.
  • Page 17 ® MODU-FIRE Forced Draft Gas-Fired Boiler 2500-3000 All boiler venting systems should be designed by a qualified venting professional ex- perienced in venting system design. The information contained herein should be used as a guide only and is not intended to be used in lieu of qualified technical expertise. 3.5.3.2 Required Clearances Provide clearances between combustion air intake, exhaust vent, roof and wall surfaces, doors and window, and...
  • Page 18 ® MODU-FIRE Forced Draft Gas-Fired Boiler 2500-3000  Through the wall terminations shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators, relief valves or other equipment.
  • Page 19 ® MODU-FIRE Forced Draft Gas-Fired Boiler 2500-3000 Building Sidewall Pitch Towards Boiler ¼” per foot min See 3.6.6 for termination details w/Drain Stack Drain w/Trap 4” min height Boiler Outlet 10” OD Boiler Condensate Drain (stainless steel or silicone tubing) 3.5.3.4 Vent Terminations The vent shall extend at least three (3) feet above the roof, or at least two (2) feet above the highest part of any...
  • Page 20 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. Dimensions listed above are minimums and may not be sufficient for conditions at a specific job site.

  • Page 21: Gas Piping

    ® MODU-FIRE Forced Draft Gas-Fired Boiler 2500-3000 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. At the time of removal of an existing boiler, while the other appliances remaining connected to the common venting system are not in operation, the following steps should be followed with each appliance remaining connected to the common venting system placed in operation:...
  • Page 22 ® MODU-FIRE Forced Draft Gas-Fired Boiler 2500-3000 The boiler must be disconnected at the boiler manual shutoff 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 23: Boiler Water Piping

    ® MODU-FIRE Forced Draft Gas-Fired Boiler 2500-3000 OILER ATER IPING 3.7.1 Piping Design 3.7.1.1 Water Flow in System ® Ideal operation of the MODU-FIRE Forced Draft boiler would consist of a 20º F temperature differential across the heat exchanger at high fire. Insufficient flow may result in excessive short cycling of the boiler and eventual damage or premature failure of the equipment.
  • Page 24 ® MODU-FIRE Forced Draft Gas-Fired Boiler 2500-3000 3.7.2 Boiler Water Connections Relief Valve Isolating Valve Outlet to System Inlet from System Strainer Isolating Valve Boiler Drain Drain Schematic showing rear of boiler (for a more detailed view, see section 4.0) Make water connections as the application warrants or, at a minimum, as shown, but always in compliance with the local requirements.
  • Page 25 ® MODU-FIRE Forced Draft Gas-Fired Boiler 2500-3000 3.7.3.2 Relief Valve and Piping Each boiler is supplied with a pressure-relief valve sized in accordance with ASME requirements. The relief valve must be piped to a suitable drain prior to placing the boiler into service and in a manner that prevents water spray from contacting any person.

  • Page 26: Burner And Ignition System

    ® MODU-FIRE Forced Draft Gas-Fired Boiler 2500-3000 Consult your water conditioning or chemical treatment supplier for analysis and recommendations. Employing a conscientious and competently administered program with emphasis on good maintenance practices as outlined by your water treatment specialist is recommended. If water/glycol is to be used in the system, the customer should perform a hazard analysis to determine proper use and disposal.
  • Page 27 ® MODU-FIRE Forced Draft Gas-Fired Boiler 2500-3000 After checking controls by manual adjustment, make sure they are always reset to their proper settings. Verify proper operation after servicing. 3.10.1 Test of Ignition Safety System Test the ignition system safety shutoff as follows: 1.

  • Page 28: Boiler Operating Control

    ® information, the ENVI control manuals may be obtained from the Harsco Industrial, Patterson-Kelley factory. 3.11.1.1 Operation of the control The home page is the default screen that is shown upon startup. This screen shows the date, time, boiler status, supply temperature and setpoint temperature.

  • Page 29: Combustion Adjustment

    ® MODU-FIRE Forced Draft Gas-Fired Boiler 2500-3000 The menu includes access to the STANDBY, INFORMATION, Menu Menu ERRORS, PROGRAM PARAMETERS, CONFIGURATION, CASCADE, and SERVICE menus. The UP and DOWN buttons Standby Standby are used to position the arrow next to the desired option and the Information Information ENTER button is pushed to access that option.
  • Page 30 Once high fire is adjusted, place the boiler in low fire using the control panel and adjust the % O if necessary, by turning the top screw “N” counterclockwise to reduce the % O or clockwise to increase the % O NOTICE! For High altitude adjustments contact Harsco Industrial, Patterson-Kelley Technical service for Service Bulletin No. 05-08.
  • Page 31 ® MODU-FIRE Forced Draft Gas-Fired Boiler 2500-3000 Bias (N) Adjust at Low Fire Ratio (V) Adjust at Hi Fire...

  • Page 32: Operation

    ® MODU-FIRE Forced Draft Gas-Fired Boiler 2500-3000 4 OPERATION ENERAL Pop-Latch (2) The front of the control panel shows Operating Instructions Instructions and the control interface for the boiler. The boiler operating controls are accessed by turning the pop-latches ¼ turn, and opening the front cover. 4.1.1 Normal Operation Under normal operating circumstances, this boiler...

  • Page 33: Maintenance

    All weekly, monthly and annual maintenance checks should be performed by experienced and knowledgeable personnel. Installation and service must be performed by an experienced 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 34 6. Perform combustion analysis and adjust if necessary (See 3.14.1). 7. Leak test gas valves. Leak Test must be performed only by qualified Harsco Industrial, Patterson-Kelley certified personnel, who have been trained in this procedure. This procedure is available on request from the Harsco Industrial, Patterson-Kelley Factory.

  • Page 35: Cleaning The Burner

    ® MODU-FIRE Forced Draft Gas-Fired Boiler 2500-3000 LEANING THE URNER Air-Gas Mixing Head Blower Ignition Assembly Burner Grid Burner Assembly Follow proper lockout / tagout procedures for the electrical, gas, and water connections. Use caution when lifting heavy parts. 1. Remove top and side covers from the boiler. High Exhaust 2.

  • Page 36: Removing The Heat Exchanger

    ® MODU-FIRE Forced Draft Gas-Fired Boiler 2500-3000 9. Check the gray grafoil gaskets around the burner flange for cracking. Replace if necessary. Replace the red silicone gasket on the heat exchanger head. 10. Clean the burner to remove any soot or foreign material that may have accumulated. Blow the burner with compressed air or wash off (do not scrub or use wire brush).

  • Page 37: Troubleshooting

    ® MODU-FIRE Forced Draft Gas-Fired Boiler 2500-3000 6. The controller checks that the air pressure switch is open indicating no airflow. The blower is driven towards the prestart fan speed. When the air pressure switch closes, the 25 second pre-purge time is started. After the pre-purge, the blower is driven to the ignition speed.
  • Page 38 ® MODU-FIRE Forced Draft Gas-Fired Boiler 2500-3000 5.6.3 Low Gas Pressure The low gas pressure switch opens when there is insufficient gas pressure available for proper operation of the boiler. LOW GAS PRESSURE is displayed, and burner operation is interrupted. If a gas-supply shut-off valve is closed for any reason, a low gas condition will result.
  • Page 39 ® MODU-FIRE Forced Draft Gas-Fired Boiler 2500-3000 5.6.10 Flame Error LATE FLAME EARLY FLAME FALSE FLAME These errors signify flame error. This may be caused by a failed or leaky gas valve or a flame detector malfunc- tion. If gas valve leakage is suspected, the unit must be isolated by turning off the main gas supply line. Qualified and knowledgeable service personnel must be called to evaluate and repair/replace the failed parts.

  • Page 40: Manual Reset Error Codes - A

    ® MODU-FIRE Forced Draft Gas-Fired Boiler 2500-3000 – A## ANUAL ESET RROR ODES A Code Error Int. nr Description Three unsuccessful ignition attempts in a row IGNIT ERROR Three times flame was lost during on demand TOO MANY FLAME FAILURES Overheat stat is open T MAX LOCK ERROR Problems with gas valve relay= internal hardware error...

  • Page 41: Auto-Reset Error Codes - E

    ® MODU-FIRE Forced Draft Gas-Fired Boiler 2500-3000 – E## RESET RROR ODES Lock- ® Code ENVI Control Display Description Flow sensor not connected T FLOW OPEN Return sensor not connected T RETURN OPEN Flue sensor not connected T FLUE OPEN DHW sensor not connected T DHW OPEN Heat exchanger sensor not connected...

  • Page 42: Parts/Technical Support

    Forced Draft Gas-Fired Boiler 2500-3000 6 PARTS/TECHNICAL SUPPORT Spare parts 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 43 ® MODU-FIRE Forced Draft Gas-Fired Boiler 2500-3000 6.1.1 High Voltage Terminal Block Assignments (HV) Terminal Label Description Number L1 208-240 VAC Boiler Supply Power, 230 VAC, 1 ph , 60 Hz L2 208-240 VAC Boiler Supply Power, 230 VAC, 1 ph , 60 Hz N 208-240V Boiler Neutral Line 120VAC Switched Output...
  • Page 44 ® MODU-FIRE Forced Draft Gas-Fired Boiler 2500-3000 6.1.2 Terminal Block Assignments – Low Voltage Circuit (TB1) Terminal Label Description Number Enable / Disable Boiler Enable, Contact Closure. DO NOT ENERGIZE. Auxiliary Low Water Cutoff External Limit, Contact Closure. DO NOT ENERGIZE. External Interlock External Limit, Contact Closure.
  • Page 45 ® MODU-FIRE Forced Draft Gas-Fired Boiler 2500-3000 6.1.3 Wiring Schematic...

  • Page 46: Control Panel

    ® MODU-FIRE Forced Draft Gas-Fired Boiler 2500-3000 6.1.4 Control Panel Components ® ENVI Control Panel Mark Description Air Switch Circuit Breaker On-Off Switch ® ENVI Control Display High Limit ® ENVI Control Main Board ® ENVI Control Interface Board Blower Fuses Ignition Transformer...
  • Page 47 ® MODU-FIRE Forced Draft Gas-Fired Boiler 2500-3000 6.1.5 Control Panel Wiring...
  • Page 48 ® MODU-FIRE Forced Draft Gas-Fired Boiler 2500-3000 6.1.6 Rear Junction Box...
  • Page 49 ® MODU-FIRE Forced Draft Gas-Fired Boiler 2500-3000 6.1.7 Customer Connections...
  • Page 50 ® MODU-FIRE Forced Draft Gas-Fired Boiler 2500-3000 6.1.8 Gas Train Mark Description Main Gas Shutoff Valve Low Gas Pressure Switch Leak Test Ports Automatic Dual Gas Valve Solenoid Coils High Gas Pressure Switch Secondary Gas Shutoff Valve Air Gas Mixer...
  • Page 51 ® MODU-FIRE Forced Draft Gas-Fired Boiler 2500-3000 6.1.9 Blower/Burner/Ignition Assembly Mark Description Burner Burner Gasket Mounting Plate Transition Piece Gasket Transition Piece Blower Gasket Blower w/Motor Air/Gas Mixer Gasket Air/Gas Mixer Ignition Gasket Ignition Electrode UV Scanner Backpressure Switch...
  • Page 52 ® MODU-FIRE Forced Draft Gas-Fired Boiler 2500-3000 6.1.10 Heat Exchanger and Combustion Chamber Mark Description Front Wrapper Heat Exchanger Gasket Set Removable Top Head...
  • Page 53 ® MODU-FIRE Forced Draft Gas-Fired Boiler 2500-3000 6.1.11 Cabinet Assembly Mark Description Front Door Side Covers Top Cover Control Panel Relief Valve Flow Switch Low Water Cutoff Switch (optional) Air Inlet Assembly Electrical Junction Box...

  • Page 54: Limited Warranty

    7 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 peri- od of one (1) years from date of start up (the "Warranty Period"), provided that startup is completed within six months from the...

  • Page 55: 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 www.harscopk.com...
  • Page 56 ® MODU-FIRE Forced Draft Gas-Fired Boiler 2500-3000...

This manual is also suitable for:

Modu-fire 2500Modu-fire 3000

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