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Patterson-Kelley MACH-05 manual

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  • Page 1

    PATTERSON-KELLEY MACH SERIES BOILER GAS-FIRED BOILER Installation Date : _______________ ________ 100 Burson Street, P.O. Box 458, East Stroudsburg, PA 18301 Telephone: (877) 728-5351, Facsimile: (570) 476-7247 www.pkboilers.com MACH - 0 5 C.S.A Design-Certified Complies with ANSI Z21.13/CSA 4.9 Gas-Fired Low Pressure St eam and Hot Water Boilers A[...]

  • Page 2

    MACH® Series Gas-Fired Boiler[...]

  • Page 3

    MACH® Series Gas-Fired Boiler Table of Contents 1.0 INTRODUCTION ........................................ 1 2.0 SAFETY ...................................................... 1 2.1 General .............................................................. 1 2.2 Training .............................................................. 1 2.3 Safety Feature[...]

  • Page 4

    MACH® Series Gas-Fired Boiler Table of Contents 5.1.3 Monthly (Dur ing Operation) .................... 30 5.1.4 Semi-Annually (every 6 months) ............ 31 5.1.5 A nnually ................................................. 31 5.2 Cleaning the Bur ner ......................................... 31 5.3 After All Repair s or Maintenance .............[...]

  • Page 5

    MACH® Series Gas-Fired Boiler Safety Page 1 1.0 INTRODUCTION The P-K MACH® Series Gas-Fired Boilers are fully modulating using a variable speed combustion blower, sophisticated microprocessor controls, modulating gas safety shut off / control valves and a unique aluminum alloy heat exchanger capable of operating in a fully condensing mode to prov[...]

  • Page 6

    MACH® Series Gas-Fired Boiler Safety Page 2 2.4 S A FETY L AB EL S NOTE Reorder No. 80 32-01NHPK c When opening leak test valves, always follow instruc tions in operation and safety ma nual. 1998 HCS, Inc. 800-748 - 02 41 Reorder No. 6020-V2WHPK Improp er use ma y result in fir e or injury . Read ins tructions/s afety manual before installing, ope[...]

  • Page 7

    MACH® Series Gas-Fired Boiler Safety Page 3 • Burn hazard! Hot fluids. 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 corre[...]

  • Page 8

    MACH® Series Gas-Fired Boiler Safety Page 4 2.5.5 Pressure Hazards Improper u se may result in fire or injury . Read instr uctions/saf ety manua l before insta lling, operating or s ervicing boile r . c ! W ARNING 1998 HCS , Inc. 800- 748-0241 • Pressure hazard! Hot fluids. Install isolation valves on boiler water inlet and outlet. Make sure iso[...]

  • Page 9

    MACH® Series Gas-Fired Boiler Installation Page 5 3.0 INST ALLA TION 3.1 R ECEIVING AND S TORAGE 3.1.1 Initial Inspection Upon receiving the boiler, inspect it for signs of shipping damage. Since some damage may be hidden, we recommend unpacking the boiler and removing the top cover and inspecting the boiler. Verify that the total number of pieces[...]

  • Page 10

    MACH® Series Gas-Fired Boiler Installation Page 6 clearance and prevent distortion of the cabinet, (twisting, etc.) in addition to leveling. Adjustable Legs for Leveling and Floor Clearance 3.3.3 Clearances If the boiler is to be installed near combustible surfaces, the minimum clearances shown in the table below must be maintained. Failure to pro[...]

  • Page 11

    MACH® Series Gas-Fired Boiler Installation Page 7 An external electrical disconnect (not supplied with the boiler) with adequate overload protection is required. The boiler must be 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 and in Canad[...]

  • Page 12

    MACH® Series Gas-Fired Boiler Installation Page 8 If air is taken from another interior space, each opening should have a net fr ee area of 1 square inch for each 1,000 Btu per hour of boiler input (450 square inches for a 450,000 Btu per hour.) 3.6 F LUE V ENTING This boiler requires a special vent system. This boiler is not certified for use wit[...]

  • Page 13

    MACH® Series Gas-Fired Boiler Installation Page 9 WARNING! Do not locate intake or exhaust terminations directly above a walkway; dripping of conden- sation can cause icing of the walking surface. Reference: ANSI Z223.1 - 2002 Sidewall Installa tions Rooftop Installations 3.6.4 Vent Terminations Vent Termination Details The vent should extend at l[...]

  • Page 14

    MACH® Series Gas-Fired Boiler Installation Page 10 3.6.6 Sealed Combustion Air/Venting System The MACH Series Boilers are also certified for operation with a sealed combustion air and pressurized venting system. Such a system employs a sealed combustion air intake duct leading from outdoors and a sealed exhaust vent terminating outdoors. Air flow [...]

  • Page 15

    MACH® Series Gas-Fired Boiler Installation Page 11 Sidewall Inlet, Roof Vent Sidewall Inlet and Ve nt Roof Inlet and Vent Roof Inlet, Side w all Vent Basic Air Inlet/Vent Configu rations Exhaust Vent (type of flue termination optional when roof venting.) Air Inlet (tee mounted horizontally.) Roof Sidewall Exhaust Vent (Sidewall venting requires ve[...]

  • Page 16

    MACH® Series Gas-Fired Boiler Installation Page 12 C750/900/1050 Sidewall Inlet and Vent 3.6.9 Intake Duct Materials and Sizes: Material: PVC, CPVC (Schedule 40), single wall galvanized steel, or other suitable materials. The intake duct must be sized for a maximum pressure drop of 0.22 inches W.C., for the SCFM as specified below. Boiler Size Req[...]

  • Page 17

    MACH® Series Gas-Fired Boiler Installation Page 13 Intake Termination Details 3.6.13 Vent Elbows The turn from horizontal to vertical should be made with two 45º ells or with one long radi us 90º ell for best operation. Do not use "short radius" ells. 3.7 G AS P IPING Before making the gas hook-up, make sure the boiler is being supplie[...]

  • Page 18

    MACH® Series Gas-Fired Boiler Installation Page 14 Pipe Capacity for Natural Gas Equivalent Pipe Le ngth Maximum Capacity in Cubic Feet o f Natu ral Gas per Hour Pressure Drop of 0.5 inch Water Column/Equiv alent Length of Pipe (in feet) Nominal Iron Pipe Size (Inches) Internal Diameter (Inches) 90º Ell (Feet) Tee (Feet) 20 40 60 80 100 150 200 1[...]

  • Page 19

    MACH® Series Gas-Fired Boiler Installation Page 15 Proper flow rates may be achieved through a combination of primary and secondary flow loops. Multiple zones and pumps may result in different flow rates at different times. Consideration must be given to all possible conditions and their consequences. Piping With Refrigeration Machines When instal[...]

  • Page 20

    MACH® Series Gas-Fired Boiler Installation Page 16 3.8.3 Boiler Water Piping by Installer Strainer To avoid possible contamination of t he boiler with dirt, rust or sediment from the system, a strainer near the boiler inlet is strongly recommended. Even new systems may contain sufficient foreign material to eventually reduce the pe rformance of th[...]

  • Page 21

    MACH® Series Gas-Fired Boiler Installation Page 17 untreated make-up water will cause premature failure due to buildup of scale; such failure is not covered by warranty. Scale can also reduce efficiency. For example, a scal e thickness of 1/16" will result in a 12.5% loss of efficiency. Water pH The pH of the hydronic system fluid m ust be be[...]

  • Page 22

    MACH® Series Gas-Fired Boiler Installation Page 18 3.10 P RE -S TA RT C HECK L IST Before attempting to start the boiler, make sure the following items have been completed. 1. Section 3.9.1 Inspection. 2. Flue gas from the boiler is properly vented; (refer to Section 3.6) 3. Gas connecti on has been made, pressure tested for leakage, and the line [...]

  • Page 23

    MACH® Series Gas-Fired Boiler Installation Page 19 3. Smoothly close the downstream manual isolation valve to reduce the gas flow and cause flame failure. 4 The display will flash E-02 indicating a flame failure. The E-02 lockout will remain until reset on the display. After completing this test, turn off the boiler and open the downstream manual [...]

  • Page 24

    MACH® Series Gas-Fired Boiler Installation Page 20 3.12 I NITIAL A DJUSTMENTS 3.12.1 Operating Temperature Controller The MACH boiler is equipped with a combination combustion and temperature control. This control monitors combustion and lighting of the boiler, as well as maintaining temperature of the supply water. The temperature control portion[...]

  • Page 25

    MACH® Series Gas-Fired Boiler Installation Page 21 First Digit Boiler Status delay. No system call for heat. 8 Burner off - Domestic Hot Water pump running on delay. No system call for heat. 9 and b flashing Burner off – auto reset lockout. A code is displayed indic ating the reason for the lockout. (See Troubleshooting Section 5.5. ) A Adjustin[...]

  • Page 26

    MACH® Series Gas-Fired Boiler Installation Page 22 Internal Setpoint: The internal setpoint is set with parameter 4. The boiler temperature control modulates the boiler to maintain this internal setpoint. The upper and lower temperature differentials are used to instruct the boiler at what temperature to turn on and at what temperature to turn off[...]

  • Page 27

    MACH® Series Gas-Fired Boiler Installation Page 23 CAUTION! Terminal 10 and 11 on TB2 are for pilot duty only. they should not be connected directly to the pump. Outdoor Air Reset (o ptio nal): O UT DOOR AI R vs BOIL E R SE TP OI NT 70 80 90 100 110 120 130 140 150 160 170 180 190 0 1 0 2 03 04 0 5 06 0 7 08 09 0 OUTD O O R A IR TE MP °F BOILER S[...]

  • Page 28

    MACH® Series Gas-Fired Boiler Installation Page 24 Analog Input to Adjust Setpoint: Anal o g I nput Setpoi nt 0 50 100 150 200 01 23 4 56789 1 0 Vol ta ge Bo i l er S e t p oi n t B oi l e r Se tpoint Non ad j u st ab l e Cur v e The control must be configured for a remote analog input setpoint according to the following table: Item Parameter Valu[...]

  • Page 29

    MACH® Series Gas-Fired Boiler Installation Page 25 This port is located on the upstream side of the valve body for measuring supply pressure. (See figure below.) Gas Pressure Test Port The supply pressure during main burner operation must be greater than the minimum indicated on the rating plate (3.5". W.C. for natural gas, 7" W.C. for p[...]

  • Page 30

    MACH® Series Gas-Fired Boiler Installation Page 26 Table 3-1 Combustion Reading For Setting Gas Safety Shut Off / Control Valves Nominal High Fire Setting Low Fire Setting Fuel Gas Pressure % O 2 % CO 2 % O 2 % CO 2 Natural Gas 7" W.C 5.0 + 0.2 9.0 + 0.2 5.2 + 0.2 8.8 + 0.2 Propane 11" W.C 5.0 + 0.2 10.4 + 0.3 5.2 + 0.2 10.3 + 0.3 Adjust[...]

  • Page 31

    MACH® Series Gas-Fired Boiler Installation Page 27 MACH C750, C900 & C450 Required Tools: TORX ® T40 or 5 mm hex wrench 3 mm or 7/64 in hex wrench Combustion analyzer The MACH C750,C900 and C1050 boilers are equipped with a Honeywell combined gas/air control and gas safety shut off control valves. The valve functions in parallel with the vari[...]

  • Page 32

    MACH® Series Gas-Fired Boiler Operation Page 28 4.0 OPERA TION 4.1 G ENERAL 4.1.1 Control Panel Front Control Panel Become familiar with the basic operation of the boiler. The front of the control panel shows Operating Instructions. 4.1.2 Tests Safe lighting and other perf ormance criteria were met with the gas manifold and control assembly provid[...]

  • Page 33

    MACH® Series Gas-Fired Boiler Operation Page 29 4.2.3 Emergency Shut-Off The main gas cock should be closed immediately if an emergency situation occurs. 4.3 T YPICAL B OILER O PERATING C ONDITIONS Natural Gas *(1030 Btu/cu. ft.) LP Gas **(2500 Btu/cu. ft.) Model Number Input Rating (Btu/hr) Gas Rate (CFH) Output Capacity (Btu/hr) Gas Rate (CFH) O[...]

  • Page 34

    MACH® Series Gas-Fired Boiler Maintenance Page 30 5.0 MAINTENANCE 5.1 M AINTENANCE A ND I NSPECTION S CHEDULE WARNING! Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. WARNING! Use care when reassembling main gas line to assure all connections are tight. WARNING! Use care whe[...]

  • Page 35

    MACH® Series Gas-Fired Boiler Maintenance Page 31 5.1.4 Semi-Annually (every 6 months) In addition to the recommended monthly service: 1. Clean burner of any accumu lated dust or lint. See Section 5.2 on "Cleaning the Burner." 2. Inspect burner for any signs of deterioration or corrosion. Replace immediately if deterioration or corrosion[...]

  • Page 36

    MACH® Series Gas-Fired Boiler Maintenance Page 32 5.4 S EQUENCE OF O PERATION 1. When the On/Off (Main power) switch is turned on, power is provided through a circuit breaker to the boiler control and the combustion blower. The boiler control powers a 24 V transformer. The boiler control supplies 24 V power through a high limit temperature switch [...]

  • Page 37

    MACH® Series Gas-Fired Boiler Maintenance Page 33 Loss of Water Level The low water switch opens when there is insufficient water level in the boiler. E 12 is shown on the display, and burner operation is interrupted. When the correct water level is re-established, pushing the reset button will return the sequence to Step 5, provided that the othe[...]

  • Page 38

    MACH® Series Gas-Fired Boiler Maintenance Page 34 5.5.1 Manual Reset Service Codes Code Lockout Description E 00 False flame. A flame signal is present when it shouldn’t be. E 02 Flame failure. The burner did not light on startup, or loss of flame dur ing run. E 03 Gas Valve error. Check all gas valves electrical connecti ons. E 04 General locko[...]

  • Page 39

    MACH® Series Gas-Fired Boiler Maintenance Page 35 5.5.2 Auto-reset Service Codes Code Lockout Description b 08 Air pressure switch open. T he air pressure switch failed to close to indicate sufficient air flow to start the boiler. b 18 Outlet high limit temp. The outlet water temperature has exceeded the intern al h igh limit temperature setting. [...]

  • Page 40

    MACH® Series Gas-Fired Boiler Parts and Technical Support Page 36 6.0 P ARTS/TECHNICAL SUPPORT Spare parts and replacement parts can be ordered from Patterson-Kelley by calling toll free (877) 728-5351. Ask for the Heat Transfer Department. The fax number is (570) 476-7247. Refer to the parts list shown on the assembly drawing provided with this m[...]

  • Page 41

    MACH® Series Gas-Fired Boiler Parts and Technical Support Page 37 6.1 W IRING D IA GRA MS 6.1.1 Terminal Block Assignments – High Voltage Circuit (TB2) Terminal Number Label Description 1 115 VAC LINE 2 115 VAC NEUT RAL Boiler Supply Power, 115 VAC, 60 HZ, 1 ph, 8 amp 3 115 VAC NEUT RAL Aux. Switched Output 4 115 VAC NEUTRAL Boiler Circ. Pump 5 [...]

  • Page 42

    MACH® Series Gas-Fired Boiler Parts and Technical Support Page 38 6.1.1a Terminal Block Assignments – Low Voltage Circuit (TB1) Terminal Number Label Description 1 HEAT REQUEST 2 HEAT REQUEST Boiler Enable, Contact Closur e. DO NOT ENERGIZE. 3 INTERLOCK JUMPER 4 INTERLOCK JUMPER External Limit (auto re set), Contact Closure. DO NOT ENERGIZE. 5 D[...]

  • Page 43

    MACH® Series Gas-Fired Boiler Parts and Technical Support Page 39 6.1.2 Wiring Series C-300[...]

  • Page 44

    MACH® Series Gas-Fired Boiler Parts and Technical Support Page 40 6.1.3 Wiring Series C-450[...]

  • Page 45

    MACH® Series Gas-Fired Boiler Parts and Technical Support Page 41 6.1.4 Wiring Series C-750/900/1050[...]

  • Page 46

    MACH® Series Gas-Fired Boiler Parts and Technical Support Page 42 6.2 B OILER P ART S L IST 6.2.1 Main Assembly Mark Description 1 Blower and Gas Train 2 Manifo ld, S ystem Re turn, Boiler Outlet 3 Manifo ld, S ystem Supply, Boiler Inlet 4 Cabinet 5 High T emperature - Aquastat MACH Series 300/450 MACH Series 750/900/1050 Mark Description 1 Heat E[...]

  • Page 47

    MACH® Series Gas-Fired Boiler Parts and Technical Support Page 43 6.2.2 Control Panel Mark Description 1 AM-3 Rel ay Module 2 Boil er Control MACH Series - MCBA 3 Transformer 4 Lo w Water Cutoff 5 Contro l Mounting Plate[...]

  • Page 48

    MACH® Series Gas-Fired Boiler Parts and Technical Support Page 44 6.2.3 Display Panel 3 2 1 5 6 7 4 8 Mark Description 1 Circuit Breaker 2 Air Pressure S witch 3 Fastening Clip 4 Display Panel 5 On/Off Switch 6 Pressure T emperature Gauge 7 Pane l Sheet Metal 8 Stack Pressure S witch[...]

  • Page 49

    MACH® Series Gas-Fired Boiler Parts and Technical Support Page 45 6.2.4 C-300/450 Heat Engine Mark Description 1 Gasket Blower to Burner Hood 2 Burner Hood 3 Inside Burner Hood Gasket 4 Outside Burner Hood Gasket 5 Burner 6 Burner Flange With Insulation 7 Sight Glass 8 Seal Sight Glass 9 Sight Glass Holder 10 Exhaust Pipe Lip Ring 11 Exhaust Manif[...]

  • Page 50

    MACH® Series Gas-Fired Boiler Parts and Technical Support Page 46 6.2.5 C-750/900/1050 Heat Engine MARK DESCRIPTION 1 Gasket Blower to Burner Hood 2 Burner Hood 3 Burner Hood Gasket 4 Burner 5 View Glass Assembly 6 Heat Exchanger Sectional Castings 7 Exhaust Pipe Lip Ring 8 Condense Collector / Exhaust Manifold 9 Inspection Cover & Gasket 10 M[...]

  • Page 51

    MACH® Series Gas-Fired Boiler Parts and Technical Support Page 47 6.2.6 C-300 Boiler Gas Train Mark Description 1 Main Gas Shut-off Valve 2 Low Gas Pressure Switch 3 Gas Safety Shut-off/Control Valve 4 Air/Gas Manifold 5 Swirlplate 6 Blower 7 Gas Leak Test Port 8 Flex Hoses w/ Gas Valve Adaptors[...]

  • Page 52

    MACH® Series Gas-Fired Boiler Parts and Technical Support Page 48 6.2.7 C-450 Boiler Gas Train Mark Description 1 Main Gas Shut-off Valve 2 Low Gas Pressure Switch 3 High Gas Pressure Switch 4 Gas Safety Shut-off/Control Valve 5 Gas Manifold Shut-off Valve 6 Air/Gas Manifold 7 Swirlplate 8 Blower 9 Gas Leak Test Port 10 Flex Hoses with Gas Valve A[...]

  • Page 53

    MACH® Series Gas-Fired Boiler Parts and Technical Support Page 49 6.2.8 C-750/900/1050 Boiler Gas Train Mark Description 1 Main Gas Shut-off Valve 2 Low Gas Pressure Switch 3 High Gas Pressure Switch 4 Gas Safety Shut-off/Control Valve 5 Gas Manifold Shut-off Valve 6 Flex Hose with Gas Valve Adaptor 7 Venturi 8 Premix Combustion Blower 9 Burner Ho[...]

  • Page 54

    MACH® Series Gas-Fired Boiler Limited Warranty Page 50 7.0 LIMITED W ARRANTY Subject to the terms and conditions herein and except as provided below with respect to products or parts not manufactured by Patterson-Kelley Co., Seller warrants to the original owner at the original installation site that products manufactured by Seller ("Products[...]

  • Page 55

    MACH® Series Gas-Fired Boiler Limited Warranty Page 51 charges to return the boiler and or components. Seller's liability under this warranty shall not in any case exceed the amount paid for the Product found to be defective. THIRD PARTY WARRANTIES For goods or components not ma nufactured by Seller, the warranty obligations of Seller shall, [...]

  • Page 56

    MACH® Series Gas-Fired Boiler Appendix Page 52 8.0 APPENDIX Date Hi/Low-Fire O 2 CO CO 2 Stack Temp Action By[...]

  • Page 57

    Parameter Settings for MCBA Controls Parameter Settings for MCBA Controls No. Description Lower Limit Upper Limit Installed MCBA Parameter Settings End User Settings NG LPG NG LPG NG LPG NG LPG NG LPG 1 Setvalue for DHW Water Storage Tank: 68 F Water Storage Tank: 158 F 140 140 140 140 140 140 140 140 140 140 2 DHW system 0 = o f f 00 00000000 1 = [...]

  • Page 58

    Parameter Settings for MCBA Controls No. Description Lower Limit Upper Limit Installed MCBA Parameter Settings MACH 1050 PK Factory Setting for MCBA MACH 300 PK Factory Setting for MCBA MACH 450 PK Factory Setting for MCBA MACH 750 PK Factory Setting for MCBA MACH 900 PK Factory Setting for MCBA 27 DHW detection hysteresis Off -36 F 54 F 5 5 555555[...]

  • Page 59

    Parameter Settings for MCBA Controls No. Description Lower Limit Upper Limit Installed MCBA Parameter Settings MACH 1050 PK Factory Setting for MCBA MACH 300 PK Factory Setting for MCBA MACH 450 PK Factory Setting for MCBA MACH 750 PK Factory Setting for MCBA MACH 900 PK Factory Setting for MCBA 2X = 3 way valve normally closed 36 Manual fanspeed -[...]