Harsco Industrial SC-2000 Operating instructions

&
&
&
&
&
&
&
&
&
Revised January 13, 2015


INS T ALL A TION
OWNER ’ S
MAN U A L

P-K SONIC™ GAS FIRED BOILER
SC-2000/SC-3000/SC-4000
Natural Gas/Propane/Dual Fuel

INS T ALL A TION
OWNER ’ S
MAN U A L

Part # 1004905978





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

INS T ALL A TION
OWNER ’ S
MAN U A L

INS T ALL A TION
OWNER ’ S
MAN U A L

INS T ALL A TION
OWNER ’ S
MAN U A L





CERTIFIED


C.S.A Design-Certified
Complies with ANSI Z21.13/CSA 4.9
Gas-Fired Low Pressure Steam and Hot Water Boilers

INS T ALL A TION
OWNER ’ S
MAN U A L





Model Number:

INS T ALL A TION
OWNER ’ S
MAN U A L
Serial Number:
Start-Up Date:

Harsco Industrial, Patterson-Kelley
155 Burson Street
East Stroudsburg, PA 18301
Telephone: [phone]
Toll Free: 877.728.5351
Fax: [phone]
www.harscopk.com
©2015 Harsco Industrial, Patterson-Kelley
Released: 1/13/15

INS T ALL A TION
OWNER ’ S
MAN U A L

INS T ALL A TION
OWNER ’ S
MAN U A L

Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351
2
Gaass FFiirreedd BBooiilleerr

Installation and Operation Quick Reference
Fuel/Gas Supply
• Refer to Section 3.6 for information on proper sizing of the gas supply piping. Undersized gas
piping with too much pressure drop will negativelyimpact the boiler’s performance.
• Install a lock-up type gas regulator to supply an appropriate gas pressure as described below:
Natural Gas Propane Gas
Minimum Inlet Pressure = 4.0” w.c.
Maximum Inlet Pressure = 14.0” w.c. Minimum Inlet Pressure = 7.0” 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
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.
Electrical/Power Supply
• Carefully inspect 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 (240V) 208-240VAC, single phase, 60Hz sized for 15 Amps.
SC-3000 / SC-4000 (240V) 208-240VAC, three phase, 60Hz sized for 20 Amps.
SC-3000 / SC-4000 (480V) 460-480VAC, three phase, 60Hz sized for 20 Amps.
• NOTE: The SC-3000 & SC-4000 MUST be ordered to the correct voltage! IT IS NOT
POSSIBLE to convert an SC-3000 or SC-4000 between the 240V and 480V configurations in
the field.
• Prior to startup, carefully check all electrical connections for tightness as
connections can come lose during shipping.

Exhaust Venting
• The P-K SONIC boilers are dual-certified as Category II & Category IV appliances,
capable of operating with slightly negative to slightly positive exhaust pressure. It is
critical to ensure the flue venting material is suitable for use with the boiler.
• For Category II installations, ensure the flue venting system is designed to maintain
a slightly negative exhaust pressure which does not exceed -0.04” w.c.
• For Category IV installations, ensure the flue venting system is designed to maintain
a slightly positive exhaust pressure which does not exceed +0.22” w.c.

 

Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351
3
Gaass FFiirreedd BBooiilleerr

Hydronics/Water Flow (SC-2000)
• 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.


• The table below summarizes the minimum and maximum flow restrictions for the SC-2000:
Flow Condition Boiler Operation Flow Rate Approximate ∆T
Maximum Flow High Fire 192 GPM 20°F
Minimum Flow Ignition 48 GPM 20°F
Minimum Flow Low Fire 38 GPM 20°F


Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351
4
Gaass FFiirreedd BBooiilleerr

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 & SC-4000. 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.


• The table below summarizes the minimum and maximum flow restrictions for the SC-3000:
Flow Condition Boiler Operation Flow Rate Approximate ∆T
Maximum Flow High Fire 285 GPM 20°F
Minimum Flow Ignition 72 GPM 20°F
Minimum Flow Low Fire 57 GPM 20°F
• 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
5
Gaass FFiirreedd BBooiilleerr

Table of Contents
1 Introduction 6
2 Safety 8
2.1 General 8
2.2 Safety Precautions 8
2.3 Training 9
2.4 Hazard Warnings 9
3 Installation 11
3.1 Receiving and Storage 11
3.2 Compliance with Codes 11
3.3 Setup 12
3.4 Electrical Connections 13
3.5 Inlet Air and Exhaust Venting 17
3.6 Gas Piping 27
3.7 Boiler Water Piping 28
3.8 Pre-Start Checklist 30
3.9 Safety Checks 30
3.10 Initial 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 Conditions 37
5 Maintenance 38
5.1 Maintenance and Inspections Schedule 38
5.2 Cleaning the Burner & Combustion Chamber 39
5.3 After Repairs or Maintenance 40
5.4 Sequence of Operation 41
5.5 Troubleshooting 42
6 Parts/Tech Support 44
6.1 Wiring Diagrams 44
6.2 Boiler Parts Identification (SC-2000) 55
6.3 Boiler Parts Identification (SC-3000 & SC-4000) 59
7 Warranty 65
Boiler Fire-Test Report 66
Appendix 1: Maintenance Log 67
Appendix 2: Boiler Altitude Derate Sch. 68
Appendix 3: Water Quality Standards 69









Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351
6
Gaass FFiirreedd BBooiilleerr


1 INTRODUCTION
This manual describes the installation and operation of the
following P-K SONIC™ boilers featuring NURO controls:
SC-2000:
Natural Gas, 208-240V (single phase)
Propane Gas, 208-240V (single phase)
SC-3000:
Natural Gas, 240V (three phase)
Natural Gas, 480V (three phase)
Propane Gas, 240V (three phase)
Propane Gas, 480V (three phase)
SC-4000:
Natural Gas, 240V (three phase)
Natural Gas, 480V (three phase)
Propane Gas, 240V (three phase)
Propane Gas, 480V (three phase)
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.
The P-K SONIC™ gas fired boilers are fully modulating using
variable speed combustion blowers, sophisticated
microprocessor controls, modulating gas safety shut off/control
valves and a unique stainless steel heat exchanger capable of
operating in a fully condensing mode to provide maximum
efficiency in a minimum amount of space.

While specific details may differ slightly, basic operation is the
same for all models. Check the rating plate for correct fuel
usage and gas pressures.
The boiler is only a part of the complete heating system. This
boiler may be fully operational and 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, balancing
valves, and check valves will be required for satisfactory
operation of any system. Harsco Industrial, Patterson-Kelley
cannot be responsible for the design or operation of such
systems and a qualified engineer or contractor must be
consulted.

It is essential to read, understand,
and follow the recommendations of
this manual before installing,
operating or servicing this
equipment. Failure to do so could
result in personal injury or death.

Installation and service must be
performed by a qualified and
knowledgeable individual who has
been certified on the P-K Sonic™
Boiler. The features which permit
this boiler to achieve high-
efficiency performance can be
misused which could result in
personal injury or death.
Do not store or use gasoline or
other flammable vapors or
liquids in the vicinity of this or
any other appliance.
Installation and service must be
performed by a qualified
installer, service agency, or the
gas supplier.
WHAT TO DO IF YOU SMELL GAS:
Do not try to light any appliance.
Do not touch any electrical switch;
do not use any phone in your
building.
Immediately call your gas supplier
from a neighbor’s phone. Follow
the gas supplier’s instructions.
If you cannot reach your gas
supplier, call the fire department.
WARNING: If the information
in this manual is not
followed, a fire or explosion
may result causing property
damage, personal injury or
loss of life.

Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351
7
Gaass FFiirreedd BBooiilleerr


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.

Gas Fired Boile
r
8
Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351


2 S AFETY
2.1 General
The SC-2000, SC-3000 and SC-4000 gas-fired boilers must be:
• Installed, operated, and serviced in accordance with instructions
contained in this manual and other supplemental manuals.
• Installed by qualified personnel in accordance with designs prepared by
qualified facility engineers including: structural, mechanical, electrical, and
other applicable disciplines.
• Operated and serviced in accordance with a comprehensive safety
program determined and established by the customer. Do not attempt to
operate or service until such a program has been established.
• Operated and serviced by experienced, qualified, and properly trained
personnel in accordance with all applicable codes, laws, and regulations.

2.2 Safety Precautions
Provide a suitable location for the boiler, away from normal personnel
traffic, with adequate working space, adequate clearances, proper
ventilation and lighting, with a structure sufficiently strong and rigid to
support the weight of the boiler, all piping, and accessories.
N OTICE !
Each safety device must be
maintained and checked per the
recommended schedule. Refer to
Section 5.1 of this manual.
Safety Features
It is the responsibility of the
customer to ensure external safety
provisions, such as but not limited
to: guards, safety labels, safety
controls, interlocks, lockout devices,
are in place and operable.
Safety Labels
The following words are used in this
manual to denote the degree of
seriousness of the individual
hazards.

Indicates an imminently hazardous
situation which, if not avoided, will
result in death or serious injury. This
signal word is to be limited to the
most extreme situations.

Indicates a potentially hazardous
situation which, if not avoided, could
result in death or serious injury.
Indicates a potentially hazardous
situation which, if not avoided, may
result in minor or moderate injury. It
may also be used to alert against
unsafe practices.
N OTICE /N OTE - N OTICE
Is the preferred signal word to
address practices not related to
personal injury. The safety alert
symbol is not used with this signal
word.

Gas Fired Boile
r
9
Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351


2.3 Training
Proper training is the best protection against accidents. It is
essential to read, understand, and follow the recommendations of
this manual before installing, operating, or servicing this
equipment. Failure to do so could result in fire or explosion and
serious injury, death, and/or property damage.
Operating and service personnel must be thoroughly familiar with
the basic construction of the SC-2000, SC-3000 and SC-4000
boilers, the use and locations of the controls, the operation of the
boilers, adjustment of their various mechanisms, and all applicable
safety precautions. If any of the provisions of this manual are not
fully and completely understood, contact Harsco Industrial,
Patterson-Kelley Technical Service at 570.476.7261 or toll free at
877.728.5351.
2.4 Hazard Warnings
2.4.1 Electrical Hazards
Shock Hazard! Properly lockout/tagout the electrical
service and all other energy sources before working on
or near the boiler.
Shock Hazard! Do not spray water directly on this
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 is unbalanced.
Test the balance before lifting off the floor. Do not
allow personnel beneath the lifted load. Refer to the
approximate weights in the table.
2.4.3 Bump Hazard from Overhead Ductwork and Piping
Injury Hazard! Install components with adequate
vertical clearance.
2.4.4 Pressure Hazards
Pressure Hazard! Hot fluids. Install isolation valves on boiler water inlet and outlet. Make sure
isolation valves are closed before servicing boiler.
Pressure Hazard! Hot fluids. Annually test safety relief valve(s) for proper operation. Do not operate
boiler with faulty relief valve(s).
Boiler Model Weight in Pounds
SC-2000 1,450 lbs
SC-3000 1,850 lbs
SC-4000 1,900 lbs
NOTICE!
The safety labels shown below are
affixed to your boiler. Although the
labels are of high quality, they may
become dislodged or unreadable
over time. Contact Harsco
Industrial, Patterson-Kelley at
570.476.7261 or toll-free at
877.728.5351 for replacements.





Gas may lose its odor. Proper gas
sensing equipment and procedures
should be used for leak checks.
Failure to detect gas leaks could
result in injury or death.

Gas Fired Boile
r
10
Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351


2.4.5 Slip, Fall Hazards
Tripping Hazard! Do not install piping on floor surfaces. Maintain a clear path around the boiler.
Slip and Fall Hazard! Use a drip pan to catch water while draining the boiler. Maintain dry floor surfaces.
Slip and Fall Hazard! Do not locate intake or exhaust terminations directly above a walkway; dripping of
condensate can cause icing of the walking surface. Refer to Section 3.5.
Fall Hazard! Do not stand on boiler.
2.4.6 Chemical Hazards
Chemical Hazards from Cleaning Products. Use
caution when cleaning the system. The use of
professional assistance is recommended. Use safe
procedures for the disposal of all cleaning solutions.
Combustion Condensate – An acidic pH of
approximately 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.
2.4.7 Burn, Fire and Explosion Hazards
Burn, fire, and explosion hazards! Installation must be in strict conformance to all applicable codes and
standardsincluding NFPA 54,ANSI Z223.1 and CAN/CSA B.149.Install all required vent linesfor gas
devices. Refer to Section 3.5.
Hazard from Incorrect Fuels! Possible fire, explosion, overheating, and damage. Do not use any fuels
except the design fuels for the unit.
Overfire Hazards! High pressure in gas supply could result in overfiring of this or other devices supplied
from the same source.
Fire and ExplosionHazards! Close the main gas shutoff before servicing 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 touch gasvent during firing operation. Use only factory
recommended vent components.
Burn Hazard! Pipes, vents, and boiler components could be hot. Do not touch piping or stack surfaces
during operation or immediately after shutdown of the boiler.
Burn Hazard! Hot flue! Use caution when servicing or draining boiler.
Fire and Explosion Hazards! Use caution when servicing burner. Propane (LPG) is heavier than air and
may linger in the combustion chamber, vent lines, or elsewhere.
Gas Leak Hazard! Make sure the burner is installed correctly and blower/transition is securely fastened
following any maintenance performed on them. These connections may leak gas if assembled incorrectly.
Gas Leak Hazard! All threaded gas connections must be made using a pipe compound that is resistant to
liquefied petroleum gas. Do not use Teflon™ tape on threaded gas piping.
Gas Leak Hazard! Check entire gas train for leaks after installation. If there is a smell of gas, shut down the
boiler and obtain immediate assistance from trained service personnel and/or your local fire department.
Overfire Hazard! Possible fire and explosion from excess gas pressure. Make sure that gas inlet pressure
does not exceed 14 inches w.c.
Overfire Hazard! Possible fire and explosion. Possible malfunction of regulators and/or gas safety shut
off/control valves. Maintain all gas train components in good condition. Do not alter wiring connections.
Annual inspection by factory-trained personnel for proper set-up and operation is recommended.
Overfire and Underfire Hazards! Possible fire, explosion, overheating, and component failure. Do not
attempt to adjust firing rate of the boiler. The firing rate must be adjusted only by factory trained personnel.

Gas Fired Boile
r
11
Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351


3 I NSTALLATION
3.1 Receiving and Storage
3.1.1 Initial Inspection
Upon receiving the boiler, inspect it for signs of shipping damage.
Some damage may be hidden. Unpack the boiler, open the front
and side doors and inspect the boiler. Verify that the total number
of pieces shown on the packing slip agrees with those actually
received.
3.1.2 Storage Prior to Installation
If the boiler is not installed immediately, it must be stored in a
location adequately protected from the weather, preferably indoors.
If this is not possible, then it should remain in the shipping container
and be covered by a tarpaulin or other waterproof covering.
3.2 Compliance with Codes
The boiler with standard components and with many options
complies with American National Standard/CSA Standard ANSI
Z21.13/CSA 4.9, latest edition, Gas-Fired Low Pressure Steam and
Hot Water Boilers.
The SC-2000 heat exchanger is constructed and stamped in
accordance with ASME Boiler and Pressure Vessel Code, Section
IV (160 psig maximum operating pressure).
The SC-3000 and SC-4000 contain two separate heat exchangers
constructed and stamped in accordance with ASME Boiler and
Pressure Vessel Code, Section IV, and Section VIII – Division 1
(160 psig maximum operation pressure).
Installation of the boiler must conform to all the requirements of all
national, state and local codes established by the authorities having
jurisdiction or, in the absence of such requirements, to the National
Fuel Gas Code, ANSI Z223.1/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 applicable
Provincial Regulations for the class, which should be carefully
followed in all cases. Authorities having jurisdiction should be
consulted before making any installation.
Where required by local codes, the installation must conform to
American Society of Mechanical Engineers Safety Code for
Controls and Safety Devices for Automatically Fired Boilers (ASME
CSD-1).
In the Commonwealth of Massachusetts (a) this unit must be
installed by a licensed pipe fitter/plumber, (b) field installed gas
cocks must be “T” handle type, (c) piping of condensate shall
conform to the State Plumbing Code, and (d) refer to the
Massachusetts Supplement for further details.

Installation and service must be
performed by a qualified installer,
service agency, or gas supplier.
Failure to install the equipment in
accordance with this manual could
result in an unsafe operating
condition.
NOTICE!
Controls and other equipment that
are damaged or fail due to weather
exposure are not covered by
warranty.

The wheels provided with this
boiler are for positioning purposes
only. When positioning this boiler,
maintain positive control of it at all
times. Do not attempt to move the
boiler on surfaces that are not
level. Failure to heed this warning
could result in personal injury or
death.

NOTICE!
The boiler may be installed on a
combustible floor; however, the
boiler must never be installed on
carpeting.


Bumping hazard from overhead
ducts! Install all components with
adequate vertical clearances.
Insufficient clearance can restrict
the service access, increasing the
possibility of injury.

Gas Fired Boile
r
12
Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351


Type of Surface Dimensions (inches)
ABCD
Combustible Surfaces Minimum Clearances 30 12* 24† 12**
Recommended Clearances for Service Access 30 12* 24† 12**
3.3 S etup
3.3.1 Foundation
Provide a firm, level foundation, preferably of concrete. Lifting the front of the boiler slightly will allow the boiler
to be rolled off the shipping skid onto the concrete foundation. Once in position, the wheel bolts may be removed
allowing the wheels to recess up into the boiler. The base will sit flat on the provided foundation. If the boiler is
to be pulled out for maintenance, the wheels may be left attached.
3.3.2 Placement
The boiler must be level to function properly. Six 9/16” holes in the base may 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 provide for the service access clearances, even with non-
combustible surfaces, may cause future problems servicing the boiler. Maintain a clearance from the vent to
combustible surfaces of 24” or as specified in the vent manufacturer’s listed installation instructions. The boiler
must be installed in a space large enough in comparison to the boiler as described in the National Fuel Gas
Code, ANSI Z223.1, latest edition.
Table 3.3.3







Figure 3.3.3


















* “B” Clearance depends upon exhaust vent configuration.
† “C” Space required for pipes, ducts, etc. in this area above the boiler.
** 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.

Gas Fired Boile
r
13
Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351


3.4 Electrical Connections
The SC-2000 boiler requires 208-240 VAC, single phase, 60 hertz electrical service. The total operating amperage
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.
The SC-3000 and SC-4000 boilers can be manufactured for 208-240 VAC, three phase, 60 hertz electrical service
OR 440-480VAC, three phase, 60 hertz electrical service. The total operating amperage is indicated on the rating
nameplate and the SC-3000 & SC-4000 boilers require less than 20 Amps at full load. Before starting the boiler,
check to ensure that the proper electrical service is connected to the boiler.
An external electrical disconnect (not supplied with the boiler) is required. Refer to Section 6.1 for proper wiring
and configuration of the electrical connections. The boiler electrical service must 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 Electrical Code, Part I, CSA C22.1, latest edition.
Installed conduit must not block any of the boiler’s openings and must allow the side doors to be opened.
3.4.1 Single Phase Power Supply Connection (SC-2000 Only)
High Voltage (TB2) Terminal Block
The SC-2000 must be supplied with 208-240VAC, single phase, 60 hertz electrical service. The SC-2000
features four dedicated power terminals on the High Voltage (TB2) terminal block. Figure 3.4.1 shows the
Low Voltage (TB1) and High Voltage (TB2) terminal blocks on the SC-2000 with the front door hidden for
clarity:
TB2 Terminal 1 = HOT L1
TB2 Terminal 2 = HOT L2
TB2 Terminal 3 = NEUTRAL
TB2 Terminal 4 = GROUND
NOTE: The SC-3000 & SC-4000 MUST be ordered to the correct voltage! IT IS NOT POSSIBLE to convert
an SC-3000 or SC-4000 between the 240V and 480V configurations in the field.
LowVoltage(TB1)TerminalBlock
HighVoltage(TB2)TerminalBlock
NOTE:Theseterminalscan
accommodatemaximum10AWG
wire.
CAUTION:Donotover‐tighten
theterminalscrews.Maximum
tighteningtorque=6in‐lbs!
Figure3.4.1

Gas Fired Boile
r
14
Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351


3.4.2 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
440-480VAC, three phase, 60 hertz
The incoming three phase power for the SC-3000 & SC-4000 boilers is connected to the over-current safety
device (rated for 20 Amps) and the Ground terminal located in the main power connection box. Figure 3.4.2
shows the Low Voltage (TB1) and High Voltage (TB2) terminal blocks, plus the Main Power Connection Box
on the SC-3000 & SC-4000 with the front door hidden for clarity:
Terminal 1 = HOT L1
Terminal 3 = HOT L2
Terminal 5 = HOT L3
Terminal G = GROUND
The Main Power Connection Box features a Control Transformer which 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 configuration, are pre-wired from the factory for
operation with 240 VAC three phase incoming power.
If 208 VAC three phase power is supplied to the boiler, the internal control transformer must be re-wired for
operation at this lower voltage. The wire in terminal X3 on the load side of the internal control transformer must
be moved to terminal X4. This supplies the 120 VAC power to the controls from the 208 VAC main voltage.
Refer to Section 6.1.4 for proper wiring and configuration of the internal control transformer.
ControlTransformer
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!
MainPowerConnectionBox
HighVoltage(TB2)TerminalBlock
LowVoltage(TB1)TerminalBlock
Figure3.4.2

Gas Fired Boile
r
15
Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351


3.4.2 High Voltage (TB2) Terminal Block
Start Interlock #1 – The Start Interlock #1 terminals can be used
for auxiliary safety devices such as damper end limit switches,
control valve end limit switches, emergency stop buttons, and low
water cutoff devices. This circuit is energized with 120VAC, so the
contacts on any auxiliary safety devices must be rated for a
minimum of 120VAC.
Start Interlock #2 – The Start Interlock #2 terminals are in series
with Start Interlock #1 and provide additional connection points for
auxiliary safety devices. This circuit is energized with 120VAC, so
the contacts on any auxiliary safety devices must be rated for
minimum 120VAC.
The boiler ships with a factory-installed jumper across Start
Interlock #1 and Start Interlock #2 terminals. Remove the
jumper(s) if using any auxiliary safety devices.
NOTE: Both the Start Interlock #1 and Start Interlock #2 circuits
must close within 5 minutes of a call for heat. Failure to close
the Start Interlock circuit will cause the boiler to lockout on
alarm.
Auxiliary Input #1 – These terminals are reserved for future use.
This circuit is energized with 120VAC.
Auxiliary Input #2 – These terminals are reserved for future use.
This circuit is energized with 120VAC.
Air Damper Interlock – The Air Damper Interlock provides
dedicated terminals for proof of open end limit switch on a
motorized air damper. This circuit is energized with 120VAC, so the
contacts on the end limit switch must be rated for minimum 120VAC.
The boiler ships with a factory-installed jumper across the Air
Damper Interlock terminals. Remove the jumper if connecting
a motorized air damper with end limit switch.
Relay A – User-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 normally-open
contacts on this relay have a maximum voltage rating of 240VAC
and maximum current capacity of 1/2 Amp.
Relay C – User-configurable relay output #3. The normally-open
contacts on this relay have a maximum voltage rating of 240VAC
and maximum current capacity of 1/2 Amp.
Relay D – User-configurable relay output #4. The normally-open contacts on this relay have a maximum voltage
rating of 240VAC and maximum current capacity of 1/2 Amp.
NOTE: 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.
Master Alarm Relay – The Master Alarm Relay terminals are normally-open dry contacts that close in the event
of an alarm output from the boiler control.
Refer to Section 6.1 for proper wiring and configuration of the electrical connections.

Be sure to check the nameplate on
the boiler before connecting the
electrical supply.
N OTICE !
A dedicated earth ground (green
wire) is required to avoid nuisance
shutdowns. Do not ground through
the conduit!

The high voltage (TB2) terminal
block on the SONIC SC-2000 with
NURO controls contains two hot
leads (HOT L1 & HOT L2), a neutral
lead (NEUTRAL) and a ground lead
(GROUND) for 208- 240 VAC,
single phase 60Hz electrical
supply. This terminal block (TB2)
also contains dry-contact relays
with a maximum voltage rating of
240VAC and 1/2 Amp maximum
current capacity. Incorrect wiring
can result in equipment damage,
injury or death.

The high voltage (TB2) terminal
block on the SONIC SC-3000 &
SC-4000 with NURO controls
contains dry-contact relays with a
maximum voltage rating of 240VAC
and 1/2 Amp maximum current
capacity. Incorrect wiring can
result in equipment damage, injury
or death.

Gas Fired Boile
r
16
Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351


3.4.3 Low Voltage (TB1) Terminal Block
Enable/Disable –TB1-1 and TB1-2 can be used to remotely enable or disable the boiler. The functionality of
these terminals is user-configurable through the NURO controls, but generally closure of the Enable/Disable
circuit provides a call for heat to the boiler. Opening this circuit prevents the boiler from running.
The boiler ships with a factory-installed jumper across the Enable/Disable terminals. This circuit is energized
with a 24VAC potential, so the contacts on any remote enable devices must be rated for minimum 24VAC.
4-20mA Analog Input – TB1-3 and TB1-4 can be used to provide a remote analog 4-20mA control signal to the
boiler. This analog signal can be used to change the boiler’s operating setpoint or firing rate.
Spare Analog Input – TB1-5 and TB1-6 are reserved for future use.
HDR Temp Sensor – TB1-7 and TB1-8 can be used to connect a remote header temperature sensor, installed
in the primary hydronic system piping, downstream of all the boilers. This temperature sensor must be a 2-wire
12kΩNTC thermistor. This circuit is energized by the boiler with a 5VDC potential.
DHW Stat/Sensor – TB1-9 and TB1-10 can be used to connect either an aquastat or remote DHW temperature
sensor installed in a domestic hot water storage tank. If using an aquastat, use a SPST normally-closed, break
on rise type with either a fixed or adjustable deadband above and below the setpoint.
Alternatively, if using a temperature sensor, it must be a 2-wire 12kΩNTC thermistor and be of sufficient length
to measure an accurate storage tank temperature. This circuit is energized by the boiler with a 5VDC potential.
Outdoor Temp Sensor – TB1-11 and TB1-12 can be used to connect an outdoor air temperature sensor which
allows the NURO control to be programmed to run an outdoor air schedule. The outdoor air temperature sensor
must be a 2-wire 12kΩNTC thermistor and should be installed on the North face of the building and shielded
from direct 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 circuit enables the Night Setback mode which reduces the boiler’s operating setpoint. Opening
this circuit resumes normal operation. This circuit is energized by the boiler with a 5VDC potential, so the contacts
on the day/night timer must be rated for minimum 5VDC.
4-20mA Analog Output – TB1-15 and TB1-16 provide a 4-20mA analog output signal which tracks the boiler’s
firing rate. When operating at full power (maximum firing rate), the boiler will provide a 20mA output. When
operating at mimimum power (minimum firing rate), the boiler will provide a 4mA output.
Ground – TB1-17 provides an equipment (frame) ground connection for input, output, or communication
connections. For independently powered control devices, it may be necessary to create a common ground.
Cascade Shield & Cascade – TB1-18,TB1-19 and TB1-20 can be used to setup a cascade system with multiple
SONIC boilers with NURO controls. Terminals TB1-19 and TB1-20 are reserved for the cascade communication
between the master and member boilers. Terminal TB1-18 should be used to connect the cascade
communication wiring shield between all boilers. The cascade and shielding must be wired from the master
boiler to each individual member boiler in a daisy-chain fashion. NOTE: Only ground the shield at the master
boiler.
MODBUS COM & MODBUS Shield – TB1-22,TB1-23 and TB1-24 can be used to integrate the boiler with a
Building Management System (BMS), Protocol Converter, or other device capable of RS-485 2-wire MODBUS
communication. Terminals TB1-22 and TB1-23 are reserved for MODBUS and terminal TB1-18 provides a
connection for the MODDBUS communication wire shield. NOTE: Only ground the shield at the master boiler.
ECOM 1, 2 & 3 – TB1-25, TB1-26 and TB1-27 can be used to connect a wireless outdoor air temperature sensor.
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.

Gas Fired Boile
r
17
Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351


3.5 Inlet Air and Exhaust Venting
3.5.1 Applicable Codes and Standards
Codes
United States:
NFPA 54/ANSI Z223.1 National Fuel Gas Code
NFPA/ANSI 211 Chimneys, Fireplaces, Vents and Solid
Fuel Burning Appliances
Canada:
CAN/CSA B149.1 Installation Codes for Gas Burning
Equipment
Standards
UL 1738 Venting Systems for Gas-Burning
Appliances, Categories II, III and IV
ULC S636-95 Standard for Type BH Venting System
Sheet Metal and Thermoplastic Duct
Construction Manual Air Conditioning
Contractors National Association
(SMACNA)
These codes and standards contain information for the venting of
gas fired appliances, including, but not limited to vent sizing,
location, clearance to combustibles, and safe installation practices.
The installation must comply with both the above Federal Codes
and with state, provincial and local codes.
Table 3.5.1
Required Stainless Steel Vent Adapters and Category II Motorized
Dampers

Boiler Size Nom.
vent
Size
Stainless
Vent
Adapter
Vent
adapter
size
Boiler
Combustion
Air inlet
Combustion air
N.C. Motorized
Damper
Size
SC-2000 10” 2640000133 10” 12” 1004906946 12”
SC-3000 10” 2640000133 10” 12” 1004906946 12”
SC-4000 10” 2640000133 10” 12” 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 of venting
systems should be done only be
qualified and knowledgeable
venting systems personnel and in
accordance with vent system
manufacturer’s installation
instructions. Installing a boiler or
vent system using improper
installation methods or materials
can result in serious injury or death
due to fire or asphyxiation.

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 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. In Canada,
combustion and ventilation air
openings shall comply with
CAN/CSA B-149.1 Natural Gas
and Propane Installation Code.

For correct installation of vent
system, read all of these
instructions and refer to vent
manufacturer’s instructions.
Failure to use a proper vent system
(types and materials), as described
in this manual will void the boiler
warranty and may result in rapid
deterioration of the venting system,
creating a health or life safety
hazard.
Faulty vent installation can allow
toxic fumes to be released into
living areas. This may cause
property damage, injury or death.

Gas Fired Boile
r
18
Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351


A normally-closed motorized combustion air damper with end limit switch is required for Category II vent
installations, and is optional for 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. All end limit switches must be rated for a minimum 120VAC.
Motorized dampers must be powered from an external power supply
other than the boiler. Figure 3.5.1 shows a sample installation in
which Relay C is user-selected to operate a 120VAC motorized air
damper. Relay C is normally-open, so when the boiler is in standby,
the combustion air damper remains closed. Once a call for heat is
received, 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 Air Damper Interlock circuit (120VAC) which allows the
boiler to proceed to ignition.
NOTE: The NURO control allows the user to allocate Relay A, B or C for use with a motorized combustion air
damper. Figure 3.5.1 shows Relay C in use for the motorized combustion air damper. Depending on the
user-configuration, Relay A, Relay B, or Relay C can be selected to operate the combustion air damper.
Figure 3.5.1

N OTICE !
Relay A, Relay B and Relay C are
rated for a maximum voltage of
240VAC and a maximum current
capacity of 1/2 Amp. Connecting a
motorized damper which exceeds
the voltage or current capacity of
the relay could cause permanent
damage to the relay.

External power supplies are required for Relay A, Relay B and Relay C. Because power is provided from an
external source, the power is still present when the boiler is turned off. Check all voltage sources have been
disconnected prior to servicing. Failure to do so could result in electrocution, injury, or death.

Gas Fired Boile
r
19
Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351


3.5.1.1 Gas Vent Categories
Several codes and standards have categorized appliances in accordance with the flue gas temperature and
pressure produced by the appliance. The applicable categories are defined as follows:
• Category II: An appliance that operates with a non-positive vent static pressure and with a vent
temperature that may cause excessive condensate production in the vent.
• Category IV: An appliance that operates with a positive vent static pressure and with a vent temperature
that may cause excessive condensate production in the vent.
• Direct Vent: An appliance that is constructed and installed so that all air for combustion is derived directly
from outdoors and all flue gases are discharged to the outdoors.

3.5.1.2 Venting Materials for Flue/Exhaust Systems
The P-K SONIC™ boilers are dual certified as a Category II and Category
IV appliances, which vents with a temperature that is likely to cause
condensation in the vent. Therefore, any venting system used with the P-
K SONIC™ boiler must comply with the requirements for either Category II
or Category IV venting systems as specified in the latest edition of NFPA
54/ANSI Z223.1 in the US or the latest edition of CAN/CSA B-149.1 in
Canada.
CPVC Venting
US: CPVC pipe conforming to ASTM F441. Sch 80 fittings
conforming to ASTM F439. Joints are to be sealed with solvent
conforming ASTM 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
PolyPro from DuraVent or other listed manufacturers. When used, the same
manufacturer's material must be used throughout the system. It is not
permissible to use material from different manufacturers within the same
system.
As per ANSI Z21.13b-2012 * CSA4.9b-2012:
• The use of cellular core PVC, CPVC and Radel as venting materials is
prohibited.
• The use of external insulation on plastic vent pipe is prohibited.

Acceptable Venting Materials
Table 3.5.1.2
Model Country AL29-4C 316L SS PVC CPVC POLYPROPYLENE
SC-2000 US Yes Yes No Yes Note 2
SC-3000 US Yes Yes No Yes Note 2
SC-4000 US Yes Yes No Yes Note 2
SC-2000 Canada Yes Yes No Note 1 Note 1
SC-3000 Canada Yes Yes No Note 1 Note 1
SC-4000 Canada Yes Yes No Note 1 Note 1
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.


The venting materials listed are
intended for the venting of gas
burning appliances only. Do not
use these venting materials for
venting liquid or solid fuel (such as
oil, kerosene, wood or coal)
appliances.
Maintain clearances to
combustibles as listed in the vent
manufacturer’s installation
instructions or as set forth in the
codes and standards listed in this
section.
Do not use these vent pipes for
incinerators of any sort!
This boiler is not certified for
use with PVC venting. Use of
PVC venting may result in vent
failure and possible serious
injury or death.

Gas Fired Boile
r
20
Harsco Industrial, Patterson-Kelley Technical Service 1.877.728.5351


3.5.2 Combustion Air Materials and Sizes
The air intake duct can 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.
Proper sealing of the intake ductwork is necessary to prevent infiltration of air from conditioned space. Joints in
PVC or CPVC must be cemented. For galvanized duct, wrap each joint and seam with adhesive aluminum tape
or other sealant. The installation of a bird screen on the intake termination is recommended. Ensure that the
screen does not become blocked with snow, ice, insects etc. Combustion air duct should be designed with
maximum 0.22” w.c. friction loss.
Combustion air must be free from dust, lint, etc. The presence of such materials in the air supplied to the burner
could cause nuisance "Low Air" shutdowns or premature burner failure. The boiler should not be operated during
construction 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 chemicals which must be avoided are fluorocarbons and other halogenated compounds,
most commonly present as refrigerants or solvents, such as Freon®, trichloroethylene, perchloroethylene,
chlorine, etc. These chemicals, when burned, form acids which quickly attack the boiler and the boiler stack. The
result is improper combustion and premature boiler failure.
Refer to Table 3.5.2 below which summarizes the combustion air requirements for the SONIC boilers. Ensure
the combustion air piping is of sufficient size (and acceptable equivalent length) in order to carry the required
SCFM with a maximum friction loss of 0.22” w.c.
Table 3.5.2
Acceptable Materials for Venting Systems
ManufacturedVentingSystems
US and Canada:
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
P-K SONIC™ Boiler Model Required SCFM
SC-2000 420
SC-3000 629
SC-4000 839