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Harsco Industrial SC-1500 Owner's Manual

P-k sonic® / nuro® gas fired boiler
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P-K SONIC
SC-1500/SC-2000
SC-3000/SC-4000
Natural Gas/Propane/Dual Fuel
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 Number:
Serial Number:
Start-Up Date:
Harsco Industrial, Patterson-Kelley
155 Burson Street
East Stroudsburg, PA 18301
Telephone: 570.476.7261
Toll Free: 877.728.5351
Fax: 570.476.7247 www.harscopk.com
The information in this manual is the property of Harsco Industrial Patterson-Kelley. The descriptions and specifications contained in this manual were in
effect at the time this manual was approved for publication. While Harsco Industrial Patterson-Kelley will continue to support earlier model boilers to
within a reasonable time limit, we reserve the right to discontinue models and replacement parts at any time or change specifications or design without
®
®
/ NURO
GAS FIRED BOILER
Part # 1004905978
Revised August 1, 2015
© © © © HARSCO Industrial, Patterson-Kelley 2015: All Rights Reserved.
notice and without incurring any obligation.
INSTALLATION
& O W N E R'S
MANUAL
INSTALLATION
& O W N E R'S
MANUAL
INSTALLATION
& O W N E R'S
MANUAL
INSTALLATION
& O W N E R'S
MANUAL
INSTALLATION
& O W N E R'S
MANUAL
INSTALLATION
& O W N E R'S
MANUAL
INSTALLATION
& O W N E R'S
MANUAL
INSTALLATION
& O W N E R'S
MANUAL

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Summary of Contents for Harsco Industrial SC-1500

  • Page 1 © © © © HARSCO Industrial, Patterson-Kelley 2015: All Rights Reserved. The information in this manual is the property of Harsco Industrial Patterson-Kelley. The descriptions and specifications contained in this manual were in effect at the time this manual was approved for publication. While Harsco Industrial Patterson-Kelley will continue to support earlier model boilers to within a reasonable time limit, we reserve the right to discontinue models and replacement parts at any time or change specifications or design without notice and without incurring any obligation.

  • Page 2: Safety Precautions

    Service 1.877.728.5351 Safety General OTICE Each safety device must be P-K SONIC SC-1500, SC-2000, SC-3000 and SC-4000 maintained and checked per the All P-K SONIC SC-1500, SC-2000, SC-3000 and SC-4000 recommended schedule. Refer to Gas-Fired Boilers must be: Section 5 Maintenance.

  • Page 3: Hazard Warnings

    Failure to do so could result in fire or explosion and become dislodged or unreadable serious injury, death, and/or property damage. over time. Contact Harsco Industrial, Operating and service personnel must be thoroughly familiar with Patterson-Kelley at 570.476.7261 or...
  • Page 4 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.

  • Page 5: Table Of Contents

    LECTRICAL ONNECTIONS 3.2.1 Power Requirements (CM300-CM399-CM500) ............. 12 3.2.2 Single Phase Power Supply Connection (SC-1500 and SC-2000 Only) ....13 3.2.3 Three Phase Power Supply Connection (SC-3000 & SC-4000 Only) ....14 3.2.4 High Voltage (TB2) Terminal Block ................ 15 3.2.5 Low Voltage (TB1) Terminal Block .................
  • Page 6 P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 3.4.5 Category II Installations ..................23 3.4.6 Category IV Installations ..................25 3.4.7 Stainless Steel Venting ..................25 3.4.8 CPVC Vent System Installation ................25 ..................
  • Page 7 6.1.7 Main Boiler Assembly (SC-1500 & SC-2000) ............58 6.1.8 NURO Control Panel (SC-1500 & SC-2000) ............59 6.1.9 Heat Exchanger Assembly (SC-1500 & SC-2000) ..........60 6.1.10 Natural Gas Train, Burner & Blower Assembly (SC-1500 & SC-2000) ....61 (SC-3000 & SC-4000) ..........62 OILER ARTS DENTIFICATION 6.2.1 Main Boiler Assembly (SC-3000 &...
  • Page 8 Service 1.877.728.5351 echnical Service 1.877.728.5351 APPENDIX D – INSTALLATION AND QUICK REFERENCE ..........73 ......................... 73 UPPLY ....................73 LECTRICAL OWER UPPLY ......................... 73 XHAUST ENTING (SC-1500 / SC-2000) ..............74 YDRONICS ATER (SC-3000 / SC-4000) ..............75 YDRONICS ATER...

  • Page 9: Purpose Of This Document

    1.2 Using This Manual The primary concern of all HARSCO Industrial, Patterson-Kelley equipment installation procedures is Safety. Following a title page Safety instructions and considerations are presented and repeated throughout the document as needed. If you have any questions on the information contained within, or do not fully and completely understand the content, please contact Harsco Industrial, Patterson-Kelley Technical Service at 570.476.7261 or toll free at 877.728.5351.

  • Page 10: Site Preparation

    Gas-Fired Low Pressure Steam and Hot Water Boilers. boiler or cause any bodily The P-K SONIC SC-1500, SC-2000, SC-3000 and SC-4000 injury while lifting or handling. heat exchangers are constructed and stamped in accordance with When positioning this boiler, ASME Boiler and Pressure Vessel Code, Section IV.

  • Page 11: Location Setup

    P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 2.3 Location Setup 2.3.1 Placement The boiler must be level to function properly. Six 9/16” holes in the base may be used for 3/8” anchor bolts. Ensure the boiler is securely connected to the floor.

  • Page 12: Inlet Air And Exhaust Venting Considerations

    Combustion air Size Size Vent Adapter adapter Combustion N.C. Motorized size Air inlet Damper For correct installation of vent system, read all of these SC-1500 10” 2640000133 10” 12” 1004906946 12” instructions and refer to vent manufacturer’s instructions. SC-2000 10” 2640000133 10”...

  • Page 13: Gas Vent Category Planning

    P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 2.4.2 Gas Vent Category Planning Several codes and standards have categorized appliances in accordance with the flue gas temperature and pressure produced by the appliance.

  • Page 14: Required Clearances

    The use of external insulation on plastic vent pipe is prohibited. • Acceptable Venting Materials Model Country AL29-4C 316L SS PVC CPVC POLYPROPYLENE SC-1500 US Note 2 NOTE 1: When this material is SC-2000 US Note 2 used for venting, it must...

  • Page 15: Interior Component Clearances

    2.6 Water Quality Standard 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 refer to Harsco Industrial, Patterson-Kelley Multi- Metal Systems Water Quality Standards in Appendix...

  • Page 16: Installation

    SC-2000 208-240 VAC operating amperage is indicated on the rating nameplate and the SC-1500 and 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.

  • Page 17: Single Phase Power Supply Connection (Sc-1500 And Sc-2000 Only)

    3.2.2 Single Phase Power Supply Connection (SC-1500 and SC-2000 Only) The SC-1500 and SC-2000 must be supplied with 208-240VAC, single phase, 60 hertz electrical service. The SC-1500 and SC-2000 feature four dedicated power terminals on the High Voltage (TB2) terminal block.

  • Page 18: Three Phase Power Supply Connection (Sc-3000 & Sc-4000 Only)

    P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 3.2.3 Three Phase Power Supply Connection (SC-3000 & SC-4000 Only) Main Power Connection Box Check the rating nameplate of the SC-3000 or SC-4000 boiler to determine the required electrical service: 208-240VAC, three phase, 60 hertz •...

  • Page 19: High Voltage (Tb2) Terminal Block

    NOTE The high voltage (TB2) terminal block on the SONIC Both the Start Interlock #1 and Start Interlock #2 circuits SC-1500 and SC-2000 with must close within 5 minutes of a call for heat. Failure to NURO controls contains two close the Start Interlock circuit will cause the boiler to hot leads (HOT L1 &...

  • Page 20: Low Voltage (Tb1) Terminal Block

    P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 NOTE Refer to Section 6 Parts and Tech Support for proper wiring and configuration of the electrical connections. Relays A thru D can be user-configured through the NURO touch screen interface to control devices such the Comfort Heat (CH) Pump, Domestic Hot Water (DHW) Pump, Air Damper, System Pump, etc.

  • Page 21: Combustion Air

    (and acceptable equivalent length) in order to carry the required SCFM with a maximum friction loss of 0.22” W.C. Required SCFM P-K SONIC™ Boiler Model SC-1500 SC-2000 SC-3000 SC-4000 Acceptable Materials for Venting Systems Manufactured Venting Systems...

  • Page 22: Air Inlet Requirements

    P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 3.3.1 Air Inlet Requirements 3.3.1.1 United States Considerations When air is supplied from inside the building, the total required volume shall be the sum of the required volume for all the appliances located in the mechanical room.

  • Page 23: Canadian Considerations

    AIR SOURCE INDOOR AIR SUPPLY OUTDOOR AIR SUPPLY SONIC Boiler TWO OPENINGS MODEL SAME DIFF VERT HORIZ FLOOR FLOORS OPENING DIRECT DUCT DUCT SC-1500 1500 3000 SC-2000 2000 4000 1000 SC-3000 3000 6000 1000 1500 SC-4000 4000 8000 1334 1000...

  • Page 24: Flue Venting Installation

    See the below table for vent design parameters P-K SONIC™ Boiler Model Frictional Resistance Stack Temperature CO2 Natural Gas CO2 LP Gas SC-1500, SC-2000, SC- 0.22” wc 220 ° F 9.2% 10.4% 3000, SC-4000...

  • Page 25: Vent Termination

    Horizontal vents must be terminated as illustrated in Section 3.4.2 Sealed Combustion/Direct Vent Systems. A bird screen with 1” x 1” openings is recommended for the termination. Harsco Industrial, Patterson- Kelley does not recommend using a vent rain cap of any type.

  • Page 26: Venting For Multiple Boilers

    W.C. the exhaust gases from an online boiler does not backflow through offline boiler(s). 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.

  • Page 27: Inlet Duct Connection To Boiler

    Category IV vent installations. 120VAC motorized dampers with end limit switches are available for purchase from Harsco Industrial, Patterson-Kelley. Other damper motor voltages are acceptable, provided they do not exceed 240VAC. The Air Damper Interlock circuit for the end limit switch is always 120VAC which is sourced from the boiler itself.
  • Page 28 P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 Motorized dampers must be powered from an external power supply other than the boiler. The figure below shows a sample installation in which Relay C is user-selected to operate a motorized air 120VAC...

  • Page 29: Category Iv Installations

    P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 3.4.6 Category IV Installations If the vent installation is designed for Category IV conditions only (condensing – positive pressure) as it is defined in ANSI Z21.13/CSA 4.9, latest edition.

  • Page 30: Removing An Existing Boiler

    P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 3.5 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 31: Piping

    P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 3.6 Piping 3.6.1 Gas Piping Overview Before making the gas hook-up, make sure the boiler is being supplied with the type of fuel shown on the boiler nameplate.

  • Page 32: Boiler Water Piping

    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.

  • Page 33: Relief Valve Piping

    The SC-1500, SC-2000, SC-3000 and SC-4000 boilers require an ASME Section IV relief valve to be installed on the top of the OUTLET (Supply) connection. The spindle of the relief valve must be vertical. The ASME Section IV relief valves are available for purchase from Harsco Industrial, Patterson-Kelley.

  • Page 34: Pre-Start Checklist

    P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 Patterson-Kelley Multi- Metal Systems Water Quality Standards as it appears in Appendix C as this applies to the warranty of your heat exchanger. Under no circumstances should Soften Water be used in boiler. OTICE The chemical manufacturer for use must certify glycol or other treatment chemicals added to the system in multi-metal systems that include cast...

  • Page 35: Ignition Safety System Test

    P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 controls, lighting, and shut-down procedures. The user should become thoroughly familiar with the 3.10.1 Ignition Safety System Test operation of the boiler and Test the ignition system safety shutdown as follows: controls before attempting to make any adjustments.

  • Page 36: Manual Reset High Temperature Limit Test

    P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 3.10.3 Manual Reset High Temperature Limit Test The boiler is furnished with a manual reset high temperature limit which features a probe installed near the boiler’s outlet in order to measure the outgoing supply water temperature.

  • Page 37: Initial Nuro Control Setup And Adjustment

    P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 3.11 Initial NURO Control Setup and Adjustment 3.11.1 Introduction This section covers basic NURO control setup and adjustment. For a basic walkthrough of the control setup, please refer to the NURO Getting Started Guide which is helpful for basic boiler installations.

  • Page 38: Information Screen

    P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 3.11.4 Information Screen The Information Screen contains real-time read-only boiler values such as temperatures, relay states, etc. Scroll through the Information Screen by sliding your finger up or down.

  • Page 39: Comfort Heat Operation

    P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 The next step of the Setup Wizard is to define how the boiler is enabled. This will prompt the user to “Check All That Apply”.

  • Page 40: Combustion Setup And Adjustment

    P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 3.12.2 Combustion Setup and Adjustment To adjust/tune combustion, use the NURO’s “Manual Control Firing Rate” mode. To access, touch the “Info” button in the lower left corner of the screen, and then touch “Service”...

  • Page 41: Adjusting Low Fire

    P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 3.12.4 Adjusting Low Fire Required Tools: 2.5 mm hex wrench and combustion analyzer. Start the boiler and observe proper operating parameters for the system. Set boiler to the “Manual Control , as described above, and decrease the firing rate to 1%.

  • Page 42: Operations

    (on/off) switch located in the upper left hand corner of the service technician to inspect the NURO control panels. boiler and to replace any part of The SC-1500, SC-2000 and the SC-3000 and SC-4000 below: the control system and any gas control which has been under water.

  • Page 43: Normal Lighting And Shut-Down Procedures

    Gas Flow Rate (CFH) Model Input Rating Voltage Phase Total Natural Output Number (BTU/Hr) Amperage Capacity (Btu/hr) (2500 Btu/ft^3) (1030 Btu/ft^3) SC-1500 1,500,000 110-120 Single Less than 15 1456 1,440,000 SC-2000 2,000,000 110-120 Single Less than 15 1942 1,920,000 208-240...

  • Page 44: Maintenance

    Proper maintenance schedule and record keeping is disconnection when servicing critical for optimum performance and to maintain the controls. Wiring errors can HARSCO Industrial, Patterson-Kelly blower warranty. cause improper and dangerous operation. The boiler motor is permanently lubricated and does not require periodic lubrication.

  • Page 45: Preventive Maintenance

    12. Perform a leak test of the gas valves in accordance with the manufacturer's instructions. 5.2 Preventive Maintenance OTICE Proper maintenance schedule and record keeping is critical for optimum performance and to maintain the HARSCO Industrial, Patterson-Kelly warranty. NOTE The blower motor is permanently lubricated and does not require periodic lubrication.

  • Page 46: Monthly Preventive Maintenance

    T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 and knowledgeable installer or service agency that has been trained on the Harsco Industrial, Patterson- Kelley boilers. Refer Section 3.12.2 Combustion Setup and Adjustment.

  • Page 47: After Repairs Or Maintenance

    P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 10. Carefully remove the triangular burner from the boiler and clean with pressurized water (approximately 40 psig). NOTE Do not attempt to wash the burner while installed in the boiler. When cleaning the burner, use a mild detergent such as Simple Green to help loosen built-up debris trapped in the burner mesh.

  • Page 48: Sequence Of Operations

    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. 5.5 Sequence of Operations 1. When the Boiler On/Off switch is turned on, power is provided If any “Manual Reset”...

  • Page 49: Troubleshooting

    P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 5.6 Troubleshooting The NURO control will display graphical and/or text based error descriptions to announce any problems with the boiler. There are two types of lockouts: manual reset lockouts which require the operator to physically press the on-screen or device’s reset button, and automatic reset lockouts which will self reset when the error condition clears.

  • Page 50: Flame Failure

    P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 When 66: “Interrupted Airflow Switch ON” is displayed, check that the air switch is open when the blower is offline. 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.

  • Page 51: Terminal Block Assignments And Wiring Diagrams

    Typical schematic drawings are shown on the following pages. Drawings specific to your particular boiler can also be supplied by your local Harsco Industrial, Patterson-Kelley representative. 6.1 Terminal Block Assignments and Wiring Diagrams 6.1.1 Wiring Diagram – Power Box (SC-3000 and SC-4000 Only...

  • Page 52: Terminal Block Assignments - High Voltage (Tb2) Terminal Block

    P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 6.1.2 Terminal Block Assignments — High Voltage (TB2) Terminal Block SC-3000 SC-1500 SC-2000 SC-4000 Label Description Terminal Terminal Number Number...

  • Page 53: Terminal Block Assignments - Low Voltage (Tb1) Terminal Block

    P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 6.1.3 Terminal Block Assignments — Low Voltage (TB1) Terminal Block Terminal Number Label Description ECOM 3 ECOM 2 Wireless Outdoor Air Receiver ECOM 1 MODBUS SHIELD MODBUS COM B...

  • Page 54: Sc-3000 & Sc-4000 Control Transformer Diagrams

    P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 6.1.4 SC-3000 & SC-4000 Control Transformer Diagrams Before making any electrical 6.1.4.1 SC-3000 & SC-4000: 208 VAC, Three Phase, 60 Hertz connections to the boiler, verify that the control transformer is properly configured for the applicable...

  • Page 55: Sc-3000 & Sc-4000: 440-480 Vac, Three Phase, 60 Hertz

    P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 6.1.4.3 SC-3000 & SC-4000: 440-480 VAC, Three Phase, 60 Hertz...

  • Page 56: Sc-1500 & Sc-2000 Wiring Diagram

    P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 6.1.5 SC-1500 & SC-2000 Wiring Diagram...
  • Page 57 P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351...
  • Page 58 P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351...
  • Page 59 P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351...

  • Page 60: Sc-3000 & Sc-4000 480V Wiring Diagram

    P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 6.1.6 SC-3000 & SC-4000 480V Wiring Diagram...
  • Page 61 P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351...

  • Page 62: Main Boiler Assembly (Sc-1500 & Sc-2000)

    P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 6.1.7 Main Boiler Assembly (SC-1500 & SC-2000) Mark Description Mark Description Heat Exchanger Front Door / NURO Touchscreen Burner/Blower Assembly...

  • Page 63: Nuro Control Panel (Sc-1500 & Sc-2000)

    P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 6.1.8 NURO Control Panel (SC-1500 & SC-2000) Mark Description Mark Description Push to Test LWCO Button NURO Touchscreen Assembly...

  • Page 64: Heat Exchanger Assembly (Sc-1500 & Sc-2000)

    P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 6.1.9 Heat Exchanger Assembly (SC-1500 & SC-2000) Mark Description Mark Description Outlet Coupling (3” Victaulic) High Exhaust Pressure Switch Port...

  • Page 65: Natural Gas Train, Burner & Blower Assembly (Sc-1500 & Sc-2000)

    P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 6.1.10 Natural Gas Train, Burner & Blower Assembly (SC-1500 & SC-2000) Mark Description Mark Description Stainless Steel Mesh Burner...

  • Page 66: Boiler Parts Identification (Sc-3000 & Sc-4000)

    P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 6.2 Boiler Parts Identification (SC-3000 & SC-4000) 6.2.1 Main Boiler Assembly (SC-3000 & SC-4000) Mark Description Mark Description Heat Exchanger Main Power Box Burner/Blower Assembly Front Door / NURO Touchscreen...

  • Page 67: Nuro Control Panel (Sc-3000 & Sc-4000)

    P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 6.2.2 NURO Control Panel (SC-3000 & SC-4000) Mark Description Mark Description Push to Test LWCO Button NURO Touchscreen Assembly Manual Reset Hi Temp Limit Clear Plastic Protective Cover Fuse Holder &...

  • Page 68: Main Power Box (Sc-3000 & Sc-4000)

    P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 6.2.3 Main Power Box (SC-3000 & SC-4000) Mark Description Mark Description 20A Three Phase Breaker Fuse Holder (Incoming Three Phase Power) Grounding Terminal Power Lead to Blower Motor Control Transformer...

  • Page 69: Heat Exchanger Assembly (Sc-3000 & Sc-4000)

    P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 6.2.4 Heat Exchanger Assembly (SC-3000 & SC-4000) Mark Description Mark Description Outlet Coupling (4” Victaulic) High Exhaust Pressure Switch Port ASME Section VIII Relief Valve (150#) Section VIII Economizer Supply Temperature Sensor...

  • Page 70: Natural Gas Train, Burner & Blower Assembly (Sc-3000 & Sc-4000)

    P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 6.2.5 Natural Gas Train, Burner & Blower Assembly (SC-3000 & SC-4000) Mark Description Mark Description Stainless Steel Mesh Burner High Gas Pressure Switch External (Upstream) Gas Cock Blower Transition Piece...

  • Page 71: Propane Gas Train (Sc-3000 & Sc-4000)

    P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 6.2.6 Propane Gas Train (SC-3000 & SC-4000) Mark Description Mark Description External (Upstream) Gas Cock Internal (Downstream) Gas Cock Gas Piping &...

  • Page 72: Limited Warranty

    P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 7 Limited Warranty...

  • Page 73: Boiler Fire-Test Report

    P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 8 Boiler Fire-Test Report...

  • Page 74: Appendix A - Maintenance Log

    P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 Appendix A – Maintenance Log Hi Fire / Stack Date Action Low Fire Temp...

  • Page 75: Appendix B - Boiler Altitude Derate Schedule

    P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 Appendix B – Boiler Altitude Derate Schedule For installations over 2000 ft. elevations, a derate schedule is applied. The boiler input rating must be reduced by 4% per 1000 ft.

  • Page 76: Appendix C - Water Quality Standards Quality Standards For Hydronic Boilers In Multi-Metal Systems

    P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 Appendix C – Water Quality Standards Quality Standards for Hydronic Boilers in Multi-Metal Systems...

  • Page 77: Appendix D - Installation And Quick Reference

    W.C. 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 gas pressure regulator will service multiple boilers, Patterson-Kelley recommends contacting the local regulator representative for application assistance specifying the appropriate lock-up type regulator and gas pipe sizing.

  • Page 78: H /W F (Sc-1500 / Sc-2000)

    The chart below represents the pressure drop (Ft of Head) versus the water flow rate (GPM) for the SONIC SC-1500 and SC-2000 boilers. 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 connecting piping, valves, strainers, couplings, flanges, etc .

  • Page 79: Hydronics /Water Flow (Sc-3000 / Sc-4000)

    P-K SONIC Gas Fired Boiler T T T T echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 echnical Service 1.877.728.5351 Hydronics/Water Flow (SC-3000 / SC-4000) The chart below represents the pressure drop (Ft of Head) versus the water flow rate (GPM) for the SONIC SC-3000 and SC-4000 boilers.

This manual is also suitable for:

Sc-2000Sc-3000Sc-4000

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