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Maximum Inlet Pressure = 14.0” w.c. Maximum Inlet Pressure = 14.0” 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...
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• The chart below represents the pressure drop (Ft of Head) versus the water flow rate (GPM) for the SONIC SC-2000. 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 connected piping, valves, strainers, couplings, flanges, etc.
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• The table below summarizes the minimum and maximum flow restrictions for the SC-4000: Flow Condition Boiler Operation Flow Rate Approximate ∆T Maximum Flow High Fire 384 GPM 20°F Minimum Flow Ignition 98 GPM 20°F Minimum Flow Low Fire 76 GPM 20°F Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351...
Do not touch any electrical switch; or do not fully and completely understand the content, please do not use any phone in your contact Harsco Industrial, Patterson-Kelley Technical Service at building. 570.476.7261 or toll free at 877.728.5351. Immediately call your gas supplier gas fired boilers are fully modulating using P-K SONIC™...
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Ga a s s F F i i r r e e d d B B o o i i l l e e r r REVISION NOTES: 1/13/2015 – Revised flame signal information. 12/10/14 – Revised to include SC-2000 & NURO controls. 07/8/14 – Edited text, made grammar corrections. Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351...
2.1 General recommended schedule. Refer to The SC-2000, SC-3000 and SC-4000 gas-fired boilers must be: Section 5.1 of this manual. • Installed, operated, and serviced in accordance with instructions contained in this manual and other supplemental manuals.
Contact Harsco Operating and service personnel must be thoroughly familiar with Industrial, Patterson-Kelley at the basic construction of the SC-2000, SC-3000 SC-4000 570.476.7261 or toll-free at boilers, the use and locations of the controls, the operation of the 877.728.5351 for replacements.
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3.0 to 5.0 can be expected. Use PVC, 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.
The wheels provided with this Hot Water Boilers. boiler are for positioning purposes The SC-2000 heat exchanger is constructed and stamped in only. When positioning this boiler, accordance with ASME Boiler and Pressure Vessel Code, Section maintain positive control of it at all IV (160 psig maximum operating pressure).
** Do not put pipes, ducts, vents, etc in this space. Electrical conduit must be installed vertically so that the side doors can be opened. NOTE: Annual maintenance items can be accessed from the front of the boiler. Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351...
SC-2000 208-240 VAC is indicated on the rating nameplate and the SC-2000 requires less than 15 Amps at full load. Before starting the boiler, check to ensure that the proper electrical service is connected to the boiler. boilers can be manufactured for...
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X4. This supplies the 120 VAC power to the controls from the 208 VAC main voltage. Refer to Section for proper wiring and configuration of the internal control transformer. 6.1.4 NOTE: The hot lead terminals can accommodate maximum 12AWG wire. The ground terminal can accommodate maximum 8 AWG wire. CAUTION: Do not over‐tighten the hot lead terminal screws. Maximum tightening torque = 13 in‐lbs! Low Voltage (TB1) Terminal Block High Voltage (TB2) Terminal Block Main Power Connection Box Control Transformer Figure 3.4.2 Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351...
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Interlock #1 and Start Interlock #2 terminals. Remove the The high voltage (TB2) terminal jumper(s) if using any auxiliary safety devices. block on the SONIC SC-2000 with NURO controls contains two hot NOTE: Both the Start Interlock #1 and Start Interlock #2 circuits must close within 5 minutes of a call for heat.
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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. Refer to Section 6.1 for proper wiring and configuration of the electrical connections. Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351...
hazard. 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 Technical Service 1.877.728.5351...
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Category IV vent installations. motorized dampers with end limit switches 120VAC are available for purchase from Harsco Industrial, Patterson-Kelley. Other damper motor voltages are acceptable, provided they do not exceed . The Air Damper Interlock circuit for the end limit switch is...
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Note 1: When this material is used for venting, it must be listed to ULC-S636. Note 2: When this material is used for venting, it must be listed to UL-1738. Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351...
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AL29-4C Stainless Steel Vent Systems listed and labeled to UL1738 Venting Systems for Gas-Burning Appliances, Categories II, III, and IV 316L Stainless Steel where certified and warranted by the vent manufacturer for venting of Category II, III, or IV appliances Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351...
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Boiler Model TWO OPENINGS SAME FLOOR DIFF FLOORS ONE OPENING DIRECT VERT DUCT HORIZ DUCT SC-2000 2000 4000 1000 SC-3000 3000 6000 1000 1500 SC-4000 4000 8000 1334 1000 1000 2000 Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351 ...
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Table 3.5.2.2 Canadian Minimum Area of Combustion and Ventilation Air Openings P-K SONIC™ Boiler Required Combustion Air Opening Ventilation Air Opening Model Input (Btu/Hr) SC-2000 2,000,000 43,032 4,303 SC-3000 3,000,000 64,516 6,452 SC-4000 4,000,000 86,451 13.4 8,645 Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351 ...
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10 ft. horizontally or 3 ft. vertically from the air intake of of sufficient strength to withstand another appliance. the weight of the vent system and any bending forces imposed by the venting system. Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351 ...
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This drain stub should be connected with the condensate drain on the boiler. The condensate drains shall have a 4” tall trap to prevent the passage of flue gases through the condensate system. 4” Tall Condensate Trap Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351 ...
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In addition, Harsco Industrial, Patterson-Kelley also recommends the use of motorized dampers in the combustion air intake duct to help prevent the backflow of flue gases from online boilers through offline boilers.
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Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers. Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351 ...
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.
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This drain valve is factory installed for draining the boiler water only, The SC-2000, SC-3000 and SC-4000 boilers require an ASME Section IV relief valve to be installed on the top of the OUTLET not the entire system. Draining of (Supply) connection.
The boiler’s heat exchanger is made of stainless steel. The heat exchanger requires proper water conditions to remain efficient and function properly. For information, please refer to Harsco Industrial Patterson Kelley Multi- Metal Systems Water Quality Standards as it appears in Appendix 3 as this applies to the warranty of your heat exchanger.
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When the low gas pressure switch opens, the NURO touchscreen will display 10012: “Low Gas Limit”. Even after re-opening the main gas cock, 10012: “Low Gas Limit” will remain on until the NURO display until the boiler is manually reset. Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351 ...
Home Screen (Figure 3.10c). The Home Screen shows a snapshot of the boiler’s current operating conditions: Outlet (Supply) Temperature Inlet (Return) Temperature Exhaust Temperature Firing Rate, etc. Figure 3.10a: Startup Screen Figure 3.10b: Rep Information Screen Figure 3.10c: Home Screen Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351 ...
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1. Use the slider bar for quick, large temperature adjustments. 2. Use the UP or DOWN arrows for fine-tuning the temperature. 3. Touch the numeric value directly which will load a 10-digit keypad for precise control settings. Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351 ...
3.11 Fuel/Air Adjustment Figure 3.11 The SC-2000, SC-3000 and SC-4000 boilers are equipped with a gas/air ratio control valve and a gas safety shut off control valve, combined into one valve assembly. The valve functions in series with the variable speed combustion blower to supply the correct gas/air mixture for optimum firing performance and efficiency.
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“Flame Signal” value. This value displays the strength of the combustion flame (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 Technical Service 1.877.728.5351 ...
Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on this boiler when the boiler underwent factory tests specified in ANSI Z21.13/CSA 4.9 latest edition. (See "Factory Firetest" label.) Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351...
1,920,000 208-240 Three Less than 20 2913 1200 2,880,000 SC-3000 3,000,000 440-480 Three Less than 20 208-240 Three Less than 20 3883 1600 3,840,000 SC-4000 4,000,000 440-480 Three Less than 20 Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351 ...
3.11.2. If an adjustment to the combustion is necessary, call a qualified and knowledgeable installer or service agency that has been trained on the Harsco Industrial, Patterson- Use care when servicing boiler to Kelley boilers. prevent the accumulation of gas in 5.1.3 Monthly...
Perform a leak test of the gas valves in accordance with the manufacturer's instructions. 5.2 Cleaning the Burner & Combustion Chamber Harsco Industrial, Patterson-Kelley recommends cleaning the burner and combustion chamber at least once annually: Lockout/tagout gas supply to the boiler.
O % or CO % are out of range. NOTE: 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 Technical Service 1.877.728.5351...
Ensure there is no air flow through the boiler when the blower is offline. An excessive negative draft in the flue piping can cause air flow through the offline boiler which may be strong enough to maintain closure of the air switch. Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351 ...
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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 Technical Service 1.877.728.5351 ...
Drawings specific to your particular boiler can also be supplied by boiler. your local Harsco Industrial, Patterson-Kelley representative. 6.1 Wiring Diagrams 6.1.1 Terminal Block Assignments – Power Box (SC-3000 & SC-4000 Only) The power box is located in the front of the boiler, at the lower left corner. This power box houses the control transformer, fuses, the power box terminal strip circuit breakers, and the blower motor relay.
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GROUND G1 for 208-240VAC, Single phase, 60Hz NEUTRAL 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 Technical Service 1.877.728.5351 ...
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4-20mA Analog Input Configurable for Setpoint or Firing Rate Control 4-20mA ANALOG INPUT [+] ENABLE / DISABLE Contact Closure Enables Comfort Heat Operation Open Circuit Disables Comfort Heat Operation ENABLE / DISABLE Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351 ...
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220-240V, three phase, 60Hz 440-480V, three phase, 60Hz Improper configuration of the control transformer could result in serious injury or death. Figure 6.1.4b SC-3000 & SC-4000: 220-240 VAC, three phase, 60 hertz: Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351 ...
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Gas Fired Boiler Figure 6.1.4c SC-3000 & SC-4000: 440-480 VAC, three phase, 60 hertz: Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351 ...
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Gas Fired Boiler 6.1.4 SC-2000 Wiring Diagram Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351 ...
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Gas Fired Boiler Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351 ...
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Gas Fired Boiler 6.1.5 SC-3000 & SC-4000 240V Wiring Diagram Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351 ...
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Gas Fired Boiler Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351 ...
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Gas Fired Boiler 6.1.6 SC-3000 & SC-4000 480V Wiring Diagram Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351 ...
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Gas Fired Boiler Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351 ...
Gas Fired Boiler 6.2 Boiler Parts Identification (SC-2000) 6.2.1 Main Boiler Assembly (SC-2000) 6 5 Mark Description Mark Description 1 Heat Exchanger Front Door / NURO Touchscreen 2 Burner/Blower Assembly NURO Control Panel 3 Cabinet Base Sheet Metal Cabinet 4 Natural Gas Train Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351...
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Gas Fired Boiler 6.2.2 NURO Control Panel (SC-2000) 1 2 8 12 11 10 9 Mark Description Mark Description 1 Push to Test LWCO Button NURO Touchscreen Assembly 2 Manual Reset Hi Temp Limit Clear Plastic Protective Cover 3 Circuit Breaker High Voltage (TB2) Terminal Block 4 On/Off Switch Low Voltage (TB1) Terminal Block 5 SOLA Mainboard Transformer XFMR2 (40VA) 6 Ignition Cable Transformer XFMR1 (20VA) Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351...
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Gas Fired Boiler 6.2.3 Heat Exchanger Assembly (SC-2000) 15 4 14 5 13 12 11 10 9 Mark Description Mark Description 1 Outlet Coupling (3” Victaulic) High Exhaust Pressure Switch Port 2 Relief Valve Port Heat Exchanger 3 Supply Temperature Sensor Heat Exch. Temperature Sensor 4 Inlet Coupling (3” Victaulic) Burner Flange / Hole 5 Manual Drain Valve Low Water Cutoff Probe 6 10” Flue Adapter Manual Reset High Limit Probe 7 ...
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Gas Fired Boiler 6.2.4 Natural Gas Train, Burner & Blower Assembly (SC-2000) 12 11 10 15 9 8 7 5 6 Mark Description Mark Description 1 Stainless Steel Mesh Burner Blower Transition Piece 2 External (Upstream) Gas Cock Combustion Blower / Fan 3 Gas Piping & Supports Burner Transition Piece 4 Air Intake Transition Piece Ignition Electrode & Gasket 5 Low Gas Pressure Switch Flame/Ionization Rod & Gasket...
6.3 Boiler Parts Identification (SC-3000 & SC-4000) 6.3.1 Main Boiler Assembly (SC-3000 & SC-4000) 7 6 Mark Description Mark Description 1 Heat Exchanger Main Power Box 2 Burner/Blower Assembly Front Door / NURO Touchscreen 3 Cabinet Base NURO Control Panel 4 Natural Gas Train Sheet Metal Cabinet Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351 ...
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2 6 12 11 10 9 Mark Description Mark Description 1 Push to Test LWCO Button NURO Touchscreen Assembly 2 Manual Reset Hi Temp Limit Clear Plastic Protective Cover 3 Fuse Holder & Fuse High Voltage (TB2) Terminal Block 4 On/Off Switch Low Voltage (TB1) Terminal Block 5 SOLA Mainboard Transformer XFMR2 (40VA) 6 Ignition Cable Transformer XFMR1 (20VA) Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351 ...
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Gas Fired Boiler 6.3.3 Main Power Box (SC-3000 & SC-4000) 1 5 Mark Description Mark Description 1 20A Three Phase Breaker Fuse Holder (Incoming Three Phase Power) 2 Grounding Terminal Power Lead to Blower Motor 3 Control Transformer Blower Motor Relay Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351 ...
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11 10 Mark Description Mark Description 1 Outlet Coupling (4” Victaulic) High Exhaust Pressure Switch Port 2 ASME Section VIII Relief Valve (150#) Section VIII Economizer 3 Supply Temperature Sensor Interconnecting Elbows 4 Nuts/Bolts Internal Couplings (2‐1/2” Victaulic) 5 Inlet Coupling (4” Victaulic) Burner Flange / Hole 6 Manual Drain Valve Low Water Cutoff Probe 7 10” Flue Adapter Section IV Boiler 8 Condensate Pan Manual Reset High Limit Probe 9 Condensate Trap Automatic Air Vent Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351 ...
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11 14 10 9 8 7 6 Mark Description Mark Description 1 Stainless Steel Mesh Burner High Gas Pressure Switch 2 External (Upstream) Gas Cock Blower Transition Piece 3 Gas Piping & Supports Burner Transition Piece 4 Blower Motor Splash Guard Flame/Ionization Rod & Gasket 5 Combustion Blower / Fan Ignition Electrode & Gasket 6 Low Gas Pressure Switch Outer Burner Gasket 7 Main Gas Shutoff/Control Valve Inner Burner Gasket Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351 ...
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Gas Fired Boiler 6.3.6 Propane Gas Train (SC-3000 & SC-4000) 7 6 5 Mark Description Mark Description 1 External (Upstream) Gas Cock Internal (Downstream) Gas Cock 2 Gas Piping & Supports High Gas Pressure Switch 3 Flexible Gas Hose Main Gas Shutoff/Control Valve 4 Low Gas Pressure Switch Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351 ...
Gas Fired Boiler Appendix 1: Maintenance Log Hi Fire / Stack Date Action Low Fire Temp Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351 ...
This procedure should only be performed by factory trained personnel. If the O2% is too low, then the gas valve settings should be reduced. This procedure is also described in • Bulletin 06-08. Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351 ...
Gas Fired Boiler Appendix 3: Water Quality Standards for Hydronic Boilers in Multi-Metal Systems Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351 ...
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