Harsco Industrial SC-2000, Installation & Owner'S Manual

Page 1: ...ALLATION O W N E R S M A N U A L INSTALLATION O W N E R S M A N U A L CE RTIF IE D C S A Design Certified Complies with ANSI Z21 13 CSA 4 9 Gas Fired Low Pressure Steam and Hot Water Boilers INSTALLAT...

Page 2: ...ct the boiler s nameplate labels which describe the power supply requirements Provide an appropriate power feed to the boiler with overcurrent protection Boiler Model Power Supply Requirements SC 2000...

Page 3: ...tion 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 coup...

Page 4: ...only additional consideration is needed for any connected piping valves strainers couplings flanges etc The table below summarizes the minimum and maximum flow restrictions for the SC 3000 Flow Condit...

Page 5: ...l NURO Control Setup Adjustment 32 3 11 Fuel Air Adjusment 34 4 Operations 36 4 1 General 36 4 2 Normal Lighting and Shut down Procedures 37 4 3 Emergency Shut Off 37 4 4 Typical Boiler Operating Cond...

Page 6: ...nd yet because of poor circulation control or other operating characteristics may not deliver heat to the desired location Additional equipment such as temperature sensors pumps flow switches balancin...

Page 7: ...y Technical Service 1 877 728 5351 7 Ga as s F Fi ir re ed d B Bo oi il le er r REVISION NOTES 1 13 2015 Revised flame signal information 12 10 14 Revised to include SC 2000 NURO controls 07 8 14 Edit...

Page 8: ...nd lighting with a structure sufficiently strong and rigid to support the weight of the boiler all piping and accessories NOTICE Each safety device must be maintained and checked per the recommended s...

Page 9: ...boiler or any electrical components Electrical Hazard Do not alter wiring connections 2 4 2 Crush Hazards Lifting Hazards Use properly rated lifting equipment to lift and position the boiler The load...

Page 10: ...g boiler Fire and Explosion Hazards Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other gas fired appliance Burn hazard Possible hot surfaces Do not...

Page 11: ...NFPA 54 latest edition in the U S In Canada the equipment shall be installed in accordance with the current Installation Code for Gas Burning Appliances and Equipment CAN CSA B 149 latest edition and...

Page 12: ...y be used for 3 8 anchor bolts 3 3 3 Clearances If the boiler is to be installed near combustible surfaces the minimum clearances shown in Table 3 3 3 and Figure 3 3 3 must be maintained Failure to pr...

Page 13: ...t be installed and grounded in accordance with local codes or in the absence of such requirements in the U S with National Electrical Codes ANSI NFPA No 70 latest edition or in Canada to the Canadian...

Page 14: ...steps down two hot leads from the incoming three phase power in order to supply 110 120VAC single phase power to the boiler s control system Be aware that SC 3000 SC 4000 boilers ordered in the 240V c...

Page 15: ...configurable relay output 1 The normally open contacts on this relay have a maximum voltage rating of 240VAC and maximum current capacity of 1 2 Amp Relay B User configurable relay output 2 The normal...

Page 16: ...irect sunlight exposure This circuit is energized by the boiler with a 5VDC potential Night Setback TB1 13 and TB1 14 can be used to connect a day night or occupancy timer Closure of the Night Setback...

Page 17: ...2 1004906989 14 NOTE This table is for information only Combustion air dampers and vent adapters are listed for use of design and may or may not be specific to your application Design and installation...

Page 18: ...ceived Relay C closes the 120VAC circuit external power supply which provides power to the damper motor opening the damper Once the motorized damper is fully open its end limit switch completes the Ai...

Page 19: ...TM 493 Canada CPVC Pipe Fitting and Sealant listed and labeled to ULC S 636 Standard for Type BH Venting Systems Polypropylene Venting US and Canada Polypropylene such as InnoFlue from Centrotherm or...

Page 20: ...uction while the possibility of drywall dust demolition dust etc exists The combustion air supply must be completely free of chemical fumes which may be corrosive when burned in the boiler Common chem...

Page 21: ...han the sum of the areas of all vent connectors in the room When using two permanent openings one opening shall commence within 12 inches above the floor and the other within 12 inches below the ceili...

Page 22: ...on air opening defined in paragraph A D When combustion air is supplied by natural airflow into a space containing both types of appliance described in paragraphs B and C the cross sectional area of t...

Page 23: ...into any building The bottom of the vent terminal shall be at least 12 in above grade or highest expected snow line if applicable Through the wall terminations shall not terminate over public walkway...

Page 24: ...tub 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 The bo...

Page 25: ...nd using a vent rain cap of any type 3 5 4 Venting for Multiple Boilers While the vent design parameters outlined in Section 3 5 3 still apply achieving those same parameters in a combined vent system...

Page 26: ...be fabricated from PVC CPVC single wall galvanized steel or other suitable materials The duct must be rigid enough to maintain the full required cross sectional area under all operating conditions Pr...

Page 27: ...le a maximum inlet pressure of 14 w c 1 2 psig Typical gas pressure supply for natural gas is 7 w c 11 w c for propane If the available gas pressure exceeds 14 w c a suitable additional intermediate g...

Page 28: ...a hot water heating boiler connected to heating coils located in air handling units where they may be exposed to refrigerated air circulation must be equipped with flow control valves or other automa...

Page 29: ...mit controls may be required by certain codes or in certain installations Review applicable local codes for details Drain Valve and Piping A drain valve is factory installed in the boiler inlet system...

Page 30: ...llowing 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 d...

Page 31: ...the manual reset high temperature limit by a thin metal capillary tube The manual reset high temperature limit is located inside the boiler s front door toward the top of the control panel and is iden...

Page 32: ...it will remain on the NURO display until the boiler is manually reset 3 10 Initial NURO Control Setup Adjustment This manual covers basic NURO control setup and adjustment For a basic walkthrough of t...

Page 33: ...Pump Flame Detected and Air Damper to the relays NOTE The relay assignments must agree with the wiring to from the boiler For example if Relay A is user configured to enable disable the Boiler Pump th...

Page 34: ...operation must be greater than the minimum indicated on the rating plate Nominal gas supply pressure is 7 w c for natural gas The gas pressure must not exceed 14 w c which is the maximum allowable pr...

Page 35: ...ed above and decrease the firing rate to 1 Once the boiler has reached low fire operation check combustion readings using the combustion analyzer If combustion readings are not in accordance with Tabl...

Page 36: ...can be opened by pinching the clasp and swinging open to the left 4 1 3 Factory Tests Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on this...

Page 37: ...ror is indicated refer to the NURO Advanced User s Guide to troubleshoot the problem and take necessary corrective action before proceeding 3 Set the desired high temperature limit and operating tempe...

Page 38: ...Volts Typical flame signals should read between 20 50V If the flame signal is below 20V the ignition electrode may need to be replaced 2 Test the low water level cut off Refer to Section 3 9 2 3 Test...

Page 39: ...pen the lid and inspect the limestone rocks If they are absent or have been significantly worn away replace them with new limestone rocks Use high calcium or pure limestone 7 Examine the venting syste...

Page 40: ...ashing turn off the hose and allow all the wash water to drain from the boiler 18 Reinstall the plugs into the two washout ports if applicable 19 Reconnect the condensate tubing to the condensate neut...

Page 41: ...ition the fan is driven to low fire and the CH LOW FIRE HOLD TIME timer is started Once the LOW FIRE HOLD TIME timer expires the boiler is released to modulation 7 The NURO control modulates the firin...

Page 42: ...Gas Limit close the gas valve and lock the boiler out When proper gas pressure is restored and the on screen reset button is pressed the boiler will reset and resume the sequence of operation at Step...

Page 43: ...Period 107 Flame Lost Early in Run or 108 Flame Lost in Run is displayed the boiler lost the flame signal during operation Check that combustion is adjusted properly the gas pressure is correct and th...

Page 44: ...ox 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 a...

Page 45: ...Voltage 1 2Amp Max Current 18 15 RELAY C 17 14 RELAY D User Configurable Normally Open Dry Contact D 240VAC Max Voltage 1 2Amp Max Current 16 13 RELAY D N A 12 GROUND Ground Terminals for I O Devices...

Page 46: ...4mA 15 4 20mA ANALOG OUTPUT 14 NIGHT SETBACK Contact Closure Enables Night Setback Operation Open Circuit Disables Night Setback Operation 13 NIGHT SETBACK 12 OUTDOOR TEMP SENSOR Outdoor Air Temperatu...

Page 47: ...Figure 6 1 4b SC 3000 SC 4000 220 240 VAC three phase 60 hertz Before making any electrical connections to the boiler verify that the control transformer is properly configured for the applicable inc...

Page 48: ...Gas Fired Boiler Harsco Industrial Patterson Kelley Technical Service 1 877 728 5351 48 Figure 6 1 4c SC 3000 SC 4000 440 480 VAC three phase 60 hertz...

Page 49: ...Gas Fired Boiler Harsco Industrial Patterson Kelley Technical Service 1 877 728 5351 49 6 1 4 SC 2000 Wiring Diagram...

Page 50: ...Gas Fired Boiler Harsco Industrial Patterson Kelley Technical Service 1 877 728 5351 50...

Page 51: ...Gas Fired Boiler Harsco Industrial Patterson Kelley Technical Service 1 877 728 5351 51 6 1 5 SC 3000 SC 4000 240V Wiring Diagram...

Page 52: ...Gas Fired Boiler Harsco Industrial Patterson Kelley Technical Service 1 877 728 5351 52...

Page 53: ...Gas Fired Boiler Harsco Industrial Patterson Kelley Technical Service 1 877 728 5351 53 6 1 6 SC 3000 SC 4000 480V Wiring Diagram...

Page 54: ...Gas Fired Boiler Harsco Industrial Patterson Kelley Technical Service 1 877 728 5351 54...

Page 55: ...5351 55 6 2 Boiler Parts Identification SC 2000 6 2 1 Main Boiler Assembly SC 2000 Mark Description Mark Description 1 Heat Exchanger 5 Front Door NURO Touchscreen 2 Burner Blower Assembly 6 NURO Cont...

Page 56: ...Description 1 Push to Test LWCO Button 7 NURO Touchscreen Assembly 2 Manual Reset Hi Temp Limit 8 Clear Plastic Protective Cover 3 Circuit Breaker 9 High Voltage TB2 Terminal Block 4 On Off Switch 10...

Page 57: ...taulic 9 High Exhaust Pressure Switch Port 2 Relief Valve Port 10 Heat Exchanger 3 Supply Temperature Sensor 11 Heat Exch Temperature Sensor 4 Inlet Coupling 3 Victaulic 12 Burner Flange Hole 5 Manual...

Page 58: ...wer Transition Piece 2 External Upstream Gas Cock 10 Combustion Blower Fan 3 Gas Piping Supports 11 Burner Transition Piece 4 Air Intake Transition Piece 12 Ignition Electrode Gasket 5 Low Gas Pressur...

Page 59: ...Parts Identification SC 3000 SC 4000 6 3 1 Main Boiler Assembly SC 3000 SC 4000 Mark Description Mark Description 1 Heat Exchanger 5 Main Power Box 2 Burner Blower Assembly 6 Front Door NURO Touchscr...

Page 60: ...rk Description 1 Push to Test LWCO Button 7 NURO Touchscreen Assembly 2 Manual Reset Hi Temp Limit 8 Clear Plastic Protective Cover 3 Fuse Holder Fuse 9 High Voltage TB2 Terminal Block 4 On Off Switch...

Page 61: ...vice 1 877 728 5351 61 6 3 3 Main Power Box SC 3000 SC 4000 Mark Description Mark Description 1 20A Three Phase Breaker Incoming Three Phase Power 4 Fuse Holder 2 Grounding Terminal 5 Power Lead to Bl...

Page 62: ...SME Section VIII Relief Valve 150 11 Section VIII Economizer 3 Supply Temperature Sensor 12 Interconnecting Elbows 4 Nuts Bolts 13 Internal Couplings 2 1 2 Victaulic 5 Inlet Coupling 4 Victaulic 14 Bu...

Page 63: ...teel Mesh Burner 8 High Gas Pressure Switch 2 External Upstream Gas Cock 9 Blower Transition Piece 3 Gas Piping Supports 10 Burner Transition Piece 4 Blower Motor Splash Guard 11 Flame Ionization Rod...

Page 64: ...51 64 6 3 6 Propane Gas Train SC 3000 SC 4000 Mark Description Mark Description 1 External Upstream Gas Cock 5 Internal Downstream Gas Cock 2 Gas Piping Supports 6 High Gas Pressure Switch 3 Flexible...

Page 65: ...Gas Fired Boiler Harsco Industrial Patterson Kelley Technical Service 1 877 728 5351 65 7 Limited Warranty...

Page 66: ...Gas Fired Boiler Harsco Industrial Patterson Kelley Technical Service 1 877 728 5351 66 Boiler Fire Test Report...

Page 67: ...Gas Fired Boiler Harsco Industrial Patterson Kelley Technical Service 1 877 728 5351 67 Appendix 1 Maintenance Log Date Hi Fire Low Fire O2 CO CO2 Stack Temp pH Action By...

Page 68: ...adjust the gas valves as described in Section 3 10 4 to get 5 O2 in the flue gas If this cannot be achieved perform the following steps If the O2 is too high then the inlet gas pressure should be adj...

Page 69: ...Gas Fired Boiler Harsco Industrial Patterson Kelley Technical Service 1 877 728 5351 69 Appendix 3 Water Quality Standards for Hydronic Boilers in Multi Metal Systems...