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Patterson-Kelley MACH-05 User's Manual

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2. 5 3 1 2 Storage Prior to Installation 5 3 2 Compliance with 5 RECREATE 5 3 3 1 Foundation 5 3 3 2 0242221 5 3 3 3 6 3 4 Electrical 6 3 5 Combustion 7 3 5 1 Air Inlet Requirements 7 3 6 Fue Vonin eki erer se Era ek EEAS 8 3 6 1 Barometric 8 3 6 2 Flue 8 3 6 3 Required Clearances 8 3 6 4 Vent 9 3 6 5 Venting for Multiple Boilers 9 3 6 6 Sealed Combustion Air Venting System 10 3 6 7 Removing an Existing 10 3 6 8 Intake Exhaust Layout 10 3 6 9 Intake Duct Materials and Sizes 12 3 6 10 Sealing the Intake Duct 12 Table of Contents 3 6 11 Intake Duct Connection to Boiler 12 3 6 12 Intake Duct Terminations 12 3 6 13 Vent Elbows eese 13 3 7 GaS i o o set tute 13 3 7 1 Gas Supply Piping by Installer 14 3 8 Boiler Water
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4. 14 3 8 1 Piping Design esssss 14 3 8 2 Boiler Inlet and Outlet Connections 15 3 8 3 Boiler Water Piping by Installer 16 3 8 4 Flushing and Filling 16 3 9 Burner and Ignition System 17 3 9 1 40022221 17 3 10 Pre Start Check List pp 18 3 11 Safety Checks pp 18 3 11 1 Test of Ignition Safety System 18 3 11 2 Test of Low Water Cut out 19 3 11 3 Test of High Limit Control 19 3 11 4 Test of Gas Pressure Switch 19 3 12 Initial Adjustments 20 3 12 1 Operating Temperature Controller 20 3 12 2 Gas Pressure Adjustment 24 3 12 3 Air Flow Adjustments 25 3 12 4 Gas Valve Setup and Adjustment 25 4 0 OPEBATION Riiie een 28 4 1 General etes 28 4 1 1 Control Panel 28 4 1 2 eee tec 28 4 2 Normal Lighting and Shut Down Procedures 28 4 2 1 Lighting Procedures 28 4 2 2 Normal Shut Down Procedures 28 4 2 3 Emergency Shut Off 29 4 3 Typical Boiler Operating Conditions 29 5 0 MAINTENANCE eee 30 5 1 Maintenance and Inspection Schedule 30
5. Se v 52 DHW PUNP 4 e GROUND _ GND SMD 8 X 1 X2 5 i GAS VALVE xe 12 n GAS VALVE 11 E E n 24 LINE X2 10 2 SAFETY IN 25 2 ia 1 HEAT Request 8 8 8 E E E AIR PRESS SWITCH X27 xl ed 9 a BLOCKED FWE 6 j HEE be Q 0 5 N xa2 4 s TACH 1 cp su TB1 DO 2 mu 3 42 2 9 HEAT REQUEST 4102 43 68 1 CRED CNTRL 1 xe 5 m 2 HEAT REQUEST 3 INTERLOCK JUMPER RED X3 4 INTERLOCK JUMPER X3 6 m DHW HEAT SENSOR v PMP CNTRL 6 5 3 x3 5 x2 5 OUTDOOR TEMP SENSOR 2e j 7 CIRC PMP PWM SIGNAL 8 OUTDOOR TEMP mr 8 COMMON COMMON DHW TEMP THERM E PETUR a 0 10 ANALOG INPUT 5 RETURN TEMP 3 28 3 4 31a 11 109 mH x pers 13 2 r xcu 14 OUTSIDE TEMP W FILTER hi BURNER 4 B X374 15 OUTSIDE TEMP W FILTER ANALOG PUT 5 16 SPARE BURNER CNTRL 17 SPARE E FLUE GAS TEMP m gt FLUE GAS TB T TEMP ae k E LL OUTSIDE TEMP 115VAC LINE 2 4 1 Zoe 2 115VAC NEUTRAL a 3 115VAC NEUTRAL 2 Ex a a MODULE Ou 23 Ka 4 115VAC NEUTRAL homm s S 115VAC NEUTRAL n ao a 8 COM 8 4 1 6 GROUND EL C3 x zi EI 7 GROUND a E GROUND lt g m v a 9 nswecswoueu Z
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7. 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 shown on the packing slip agrees with those actually received Important note any damage suspected potential damage or shortage of materials on the freight bill and immediately notify the carrier File all claims for shortage or damage with the carrier Claims for hidden damages must be filed with your carrier within 7 days The boiler carton is equipped with a Tell If Tell arrow point is blue that indicates that the package has been on its side or tipped over in transit 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 Note controls and other equipment that are damaged or fail due to weather exposure are not covered by warranty 3 2 COMPLIANCE WITH CODES Installation Code Section IV for 50 psig maximum operating pressure and or 200 F maximum temperature Other codes or approvals which apply will be labeled on the boiler Installation of the boiler must conform to all the requireme
8. e pos FLUE GAS carros TEMP ads 4 X5 gura 115 LINE dm 5 1 115 NEUTRAL Oa VAC 2 115VAC NEUTRAL ue o RMCI MODULE 8 3 t 115 NEUTRAL t I E 115 NEUTRAL c m 2 8 GROUND 2 5 GROUND 74 2 a l GROUND x g E 115VAG SW OUTPUT d eX X 1 2 Ey ge 2 m o S Fm 11 n54c CHR 3 a F 12 MASTER ALARM RLY rag uo 3s m rg 13 MASTER ALARM RLY cum 8 14 3 WAY VALVE RELAY og 25 5 15 3 WAY VALVE RELAY I m Be og 16 DAMPER RELAY ad in DAMPER RELAY lt e OOS LxETI Series Gas Fired Boiler Parts and Technical Support 6 1 4 Wiring Series C 750 900 1050 gt 5 9 8 8 i e 9 ELSE 1 88 8 9 525 n x Uu 1 N B 5 85544 3956 2 L3 o Ol
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10. CAUTION Bumping hazard from overhead ducts Install all components with adequate vertical clearances Clearance depends upon vent configuration Service access need be only on one side of a boiler or row of boilers Boilers may be installed immediately adjacent to each other However P K recommends this clearance between each boiler when there is insufficient access at the rear to allow for service and adjustment 3 4 ELECTRICAL CONNECTIONS The boiler is wired for 120 volts single phase 60 hertz The total operating amperage is indicated on the rating nameplate All MACH units require less than 8 amps Before starting the boiler check to ensure that the proper electrical service is connected to the boiler Series Gas Fired Boiler 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 Canada to the current Canadian Electrical Code Part I CSA C22 1 Note A dedicated earth ground green wire is required to avoid nuisance shutdowns Do not ground through the conduit It is also important that proper polarity be maintained Note Refer to Terminal Block Assignments Section 6 1 1 Low Voltage Installation when burned form acids which quickly attack the
11. PATTERSON KELLEY MACH SERIES BOILER GAS FIRED BOILER 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 AM 08 Boilers Installation Date Patterson Kelley Harsco 100 Burson Street P O Box 458 East Stroudsburg 18301 Telephone 877 728 5351 Facsimile 570 476 7247 www pkboilers com MACH 05 Series Gas Fired Boiler Series Gas Fired Boiler 1 0 INTRODUCTION 1 SAFETY 1 2 1 o adea 1 2 2 Training ere etapa eet aedis 1 2 3 Safety Features 1 2 4 Safety 2 2 2 5 Safety Precautions 2 2 5 1 Electrical Hazards 2 2 5 2 Burn Fire and Explosion Hazards 2 2 5 3 Crush 3 2 5 4 Chemical Hazards 3 2 5 5 Pressure Hazards 4 2 5 6 Slip Fall 4 3 0 INSTALLATION 5 3 1 Receiving and Storage 5 3 1 1 Initial Inspection
12. L4 Qui 2 5 115v4t CRC m 3 gt 11 Tawc DHW PMP CNIR 5 x 12 MASTER ALARM RLY Ton xo 9 Foul 0 13 MASTER ALARM RLY tye amp mo 2 K371 1413 WAY VALVE RELAY zu K3 2 55 m2 15 3 WAY VALVE RELAY Em og K2 1 DAMPER RELAY gt us id kee 17 DAMPER RELAY lt E B 39 Series Gas Fired Boiler Parts and Technical Support 6 1 3 Wiring Series C 450 5 I y F 8 lo os 124 amp m m r 558 uw 8 7 2 505S D 2 og L3 1 i S z Ecl ul au 8 Rad 5 4 t 51 8 88
13. The flue gas temperature sensor is indicating an open circuit High flue temp The flue temperature has exceeded the maximum allowable setting Air pressure switch closed The air pressure switch failed to open prior to starting the blower Fan speed incorrect The fan is being directed to a higher speed than it is achieving WARNING If any Manual Reset limit device trips DO NOT reset without determining and correcting the cause Page 35 Series Gas Fired Boiler 6 0 PARTS 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 manual Technical information is also available at the above number When ordering replacement parts please have the model number and serial number of your boiler available Page 36 Parts and Technical Support Series Gas Fired Boiler Parts and Technical Support 6 1 WiRING DIAGRAMS 6 1 1 Terminal Block Assignments High Voltage Circuit TB2 Terminal Number Description ages Boiler Supply Power 115 VAC 60 HZ 1 ph 8 amp sr 8 MMSVACSW OUTPUT Aux Switched Output Pilot duty only 1 amp max 115 VAC CIRC PMP Boiler Circ Pump Pilot duty only 1 amp max CONTACTOR C DHW Circ Pump Pilot Duty only 1 amp max CON
14. and make the necessary corrections Notify responsible individuals for required corrective action or repair Page 30 Maintenance WARNING Check daily to be sure that the boiler area is free and clear of any combustible materials including flammable vapors and liquids 5 1 2 Weekly Observe the conditions of the main flame A normal high fire flame is blue If the high fire flame is yellow then corrective action must be taken In normal low fire the burner will glow a yellowish orange Correct air adjustment is essential to the efficient operation of this boiler If an adjustment in the combustion is necessary the flue gas composition should be checked with a carbon dioxide or oxygen O analyzer to set conditions Refer to Table 3 1 Section 3 12 4 for proper combustion readings 5 1 3 Monthly During Operation 1 Test flame detection by voltage reading at the terminal strip Terminal 9 on TB 1 and ground screw The voltage reading should be between 5 and 10 VDC 2 Test high limit Control Refer to Section 3 11 3 3 Test operating temperature controls by reducing or increasing temperature setting as necessary to check burner operation 4 Test the low water level cut out Refer to Section 3 11 2 5 Testlow gas pressure switch Refer to Section 3 11 4 6 Check the condensate drain system Clean and flush as necessary Installation and service must be performed by a qualified insta
15. Use safe procedures for the disposal of all cleaning solutions e Combustion Condensate a pH of approximately 4 to 5 can be expected Use PVC or CPVC piping Collection and disposal must be in accordance with all applicable regulations Series Gas Fired Boiler 2 5 5 Pressure Hazards LA WARNING Improper use may result in fire or injury Read instructions safety manual before installing operating or servicing boiler 1998 HCS Inc 800 748 0241 e Pressure hazard Hot fluids Install isolation valves on boiler water inlet and outlet Make sure isolation valves are closed before servicing boiler e Pressure hazard Hot fluids Annually test safety relief valve for proper operation Do not operate boiler with faulty relief valve Page 4 Safety 2 5 6 Slip Fall Hazards LA WARNING Improper use result in fire or injury Read instructions safety manual before installing operating or servicing boiler 1998 HCS Inc 800 748 0241 Tripping hazard Do not install piping on floor surfaces Maintain clear path around boiler Slip and fall hazard Use 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 condensation can cause icing of the walking surface Series Gas Fired Boiler 3 0 INSTALLATION 3 1 RECEIVING AND STORAGE
16. adjust as follows Using a 2 mm hex wrench adjust the pressure regulator offset adjustment see the figure below item to achieve the O level prescribed in Table 3 Note that equal adjustments must be made to each of the valves Adjustments to the offset pressure regulators should not exceed turn at a time before allowing the readings to respond and stabilize Please note the rotation of the Low Fire adjustment is opposite of the High Fire as follows Clockwise rotation increases gas flow counterclockwise rotation decreases gas flow R D C300 450 Adjusting Low and High Fire Series Gas Fired Boiler MACH C750 C900 amp C450 Required Tools 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 variable speed combustion blower to supply the correct gas air ratio for optimum performance and efficiency The combustion blower speed is controlled automatically and determines the amount of negative pressure felt at the gas safety shut off control valves The gas air regulator adjusts gas flow to maintain the proper pressure at the outlet nozzle of the associated valve Adjustment There must be sufficient load to operate the boiler at high fire to perform the following adjustments
17. and flush the inside of the heat exchanger as required separate from system flush 6 Examine the venting system at least once a year Refer to the vent manufacturer s instructions for requirements in addition to those listed below a Check all joints and pipe connections for tightness b Check pipe for corrosion or deterioration If any piping needs replacing do so immediately Page 31 Maintenance 7 Qualified service personnel should thoroughly inspect the heating system and correct any problems prior to re starting the boiler 8 Perform combustion analysis and readjust to manufacturer s specifications as necessary It is recommended that a copy of this report is filed for future reference 9 Perform a leak test of the gas valves in accordance with the manufacturer s instructions Installation and service must be performed by a qualified installer or service agency who has been trained on the Patterson Kelley MACH boiler 5 2 CLEANING THE BURNER 1 Lockout and tagout gas supply to the boiler 2 Lockout and tagout electrical power to the boiler 3 Remove the top cover of the boiler 4 Disconnect the electrical connections to the blower and gas safety shut off control valves 5 Unbolt burner hood and remove the gas train assembly 6 Carefully remove the burner Use low pressure air to remove any dust or lint from the burner Using a soft clean cloth wipe the inside surface of the burner DO NOT
18. control replacement etc The boiler is factory fire tested and adjusted for proper combustion with natural gas supply pressure of 7 W C Typical gas pressure supply for natural gas is 7 W C 11 W C for propane The gas train components are certified to handle a maximum inlet pressure of 14 W C 1 2 psig If the available gas pressure exceeds 14 W C a suitable additional intermediate gas pressure regulator of the lock up type must be provided to reduce the pressure to less than 14 W C Page 13 Installation WARNING All threaded connections must be made using a pipe compound that is resistant to the action of liquefied petroleum gases Do not use Teflon tape on gas line threads Remote Gas Shutoff Natural Gas Supply Union mE not supplied By Installer mm L1 iy Shutoff Drip Leg on boiler Meter not supplied Gas Piping In the Commonwealth of Massachusetts the gas cock must be a T handle type Note Install a sediment trap drip leg and a union connection ahead of the primary manual shutoff valve on the boiler Gas piping should be installed in accordance with National Fuel Gas Code ANSI 7223 1 latest edition and any other local codes which may apply in Canada see CAN CGA B 149 Note See Pipe Capacity for Natural Gas chart on the following page for required pipe size based on overall length of pipe from meter plus equivalent length of a
19. damper with this boiler This is a positive pressure system combustion gas may leak into the room Page 8 Installation 3 6 2 Flue Connection The connection from the boiler to the vent should be as direct as possible and the upward slope of any horizontal breaching should be at least 1 4 inch per linear foot The 300 and 450 vent connection incorporates a 4 slope toward the boiler to facilitate pitching of the vent for condensate collection This boiler should not be connected into any portion of another mechanical draft system operating under positive pressure without consulting your local venting representative Provisions must be made for supports to prevent contact of the vent with combustible surfaces Note If the vent is erected directly behind the boiler make sure that the weight of the vent is not supported by the boiler vent collar The collar is not designed to support the weight of the vent Structural support and spacing from combustible surfaces must be in accordance with the vent manufacturer s requirements Sidewall Pitch toward AL boiler 1 4 per foot minimum E approx 34 per foot 4 degree slope n toward boiler Flue Connection at Boiler 3 6 3 Required Clearances Provide clearances between combustion air intake exhaust vent roof and wall surfaces doors and window and snow line as shown in the following di
20. main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe 6 Afterit has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous conditions of use Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code ANSI 7223 1 and CSA B149 Installation Code When resizing any portion of the common venting system the common vent system should be resized to approach the minimum size as determined using the appropriate tables 3 6 8 Intake Exhaust Layout Four basic configurations for the intake exhaust may be used Refer to Section 3 6 3 for required clearances for all terminations shown in the four following figures Series Gas Fired Boiler Installation Exhaust Vent s Mu ype of Type of flue termination Hs erminadon optional when roof venting optional when roof Ney venting Air Inlet tee 4 i mounted Roof nd horizontally Air Inlet Type of flue termination a optional E Roof _ Sidewall Sidewall Inlet Roof Vent Roof Inl
21. piping system during any pressure testing of the system at pressures in excess of 1 2 psig 14 W C During any pressure testing of the gas supply piping system at pressures equal to or less than 1 2 psig 14 W C the boiler should be isolated from the gas supply piping system by closing the manual shut off Some leak test solutions including soap and water may cause corrosion These solutions should be rinsed off with water after testing Page 14 3 8 BOILER WATER PIPING 3 8 1 Piping Design Water Flow in System For proper water flow requirements see below Incorrect flow may result in eventual damage or premature failure of the equipment Model Max Flow Min Flow DP ft at GPM GPM max flow 1050 105 52 12 900 90 45 12 750 75 37 12 450 45 22 8 5 300 30 15 8 5 Contact factory for minimum flow at other than maximum firing rate MACH Series Gas Fired Boiler Flow vs DP C750 C900 C1050 T 60 80 100 120 Flow Proper flow rates may be achieved through 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 installed in a two pipe system that provides both chilled and hot water the control system should be configured so as to limit the time rate of
22. times until the display shows PArA The parameters are selected with the STEP key and changed with the plus and minus keys Once the desired value is reached pressing the STORE key accepts the new setting Parameters 1 through 4 are accessible directly at the parameter level Parameters higher than 4 are only accessible by authorized service personnel trained on the P K MACH Series Boiler Upper Parameter Description Lower Limit Limit DHW setpoint 1 if used 68 158 2 DHW system 0 OFF ON OFF 1 2 OFF pump continuous 3 ON pump continuous 3 Comfort heat 0 system 1 ON ON OFF 9 2 OFF pump continuous 3 ON pump continuous Setpoint or max boiler temp outdoor 4 air mode 68 182 Page 21 Installation Information Mode The information mode is used to display the values of the various sensors such as inlet water temp outlet water temp etc The information mode is accessed by pressing the MODE key several times until InFo is displayed The desired sensor is selected with the STEP key The following table indicates the displayed value Step Value 1 Outlet water temp Inlet water temp Domestic Hot Water temp Outdoor air temp Flue gas temp Boiler outlet setpoint Rate of change outlet temp F second CO NI Rate of change inlet temp F second Rate of change Domestic Hot Water 9 F secon
23. to boiler is in accordance with Table 3 1 below Gas flow is dependent primarily on fan speed not upstream gas pressure When set up for natural gas operation the boiler is capable of operating with gas supply pressure as low as 3 5 W C Page 25 Installation Boiler Test Mode The test mode should be used when checking and setting the gas safety shut off control valves on the MACH Series boilers In this mode an automatic heat request is simulated as follows Test Mode High Simultaneously pressing the Mode button and the button for 3 seconds activates the Test Mode High function to drive the boiler output to maximum The display will blink and indicate H in the first digit of the display to indicate the boiler is being driven to the maximum output rating This test mode will automatically terminate after 15 minutes or can be terminated from the control display panel by simultaneously pressing the and buttons for three seconds Test Mode Low Simultaneously pressing the Mode button and the button for 3 seconds activates the Test Mode Low function to drive the boiler output to minimum The display will blink and indicate L in the first digit of the display to indicate the boiler is being driven to the minimum output rating This test mode will automatically terminate after 15 minutes or can be terminated from the control display panel by simultaneously pressing
24. under water Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system and any gas control which has been under water Page 28 Operation 4 2 1 Lighting Procedures Close main gas valve Turn On Off switch to OFF position Wait 5 minutes Open main gas valve Turn On Off switch to ON position Push reset button on display panel if required du conv SUE 2 502 4 Push reset on low gas pressure switch and high gas pressure switch The controller will now complete the automatic firing sequence 4 2 2 Normal Shut Down Procedures 1 Close all manual gas valves 2 Turn off electric power rag Series Gas Fired Boiler Operation 4 2 3 Emergency Shut Off Main Gas Cock The main gas cock should be closed immediately if an emergency situation occurs WARNING If overheating occurs or the gas supply fails to shut off do not turn off or disconnect the electrical supply to the pump Instead shut off the gas supply at a location external to the boiler Emergency Shut Off 4 3 TYPICAL BOILER OPERATING CONDITIONS Model Input Natural Gas LP Gas Total Bumper Rating 1030 Btu cu ft 2500 Btu cu ft Amperage Btu hr Gas Output Gas Output Rate Capacity Rate Capacity CFH Btu hr CFH Btu hr 300 300 000 291 275 000 120 275 000 8 amps or less 450 450 000 437 414 000 180 414 000 8 am
25. wipe the mesh side flame side of the burner 5 3 AFTER ALL REPAIRS OR MAINTENANCE 1 Follow Pre Start Check List Section 3 10 and all Safety Checks Section 3 11 2 Check gas pressure Section 3 12 2 3 Perform combustion check Adjust gas flow if necessary Section 3 12 4 MACH Series Gas Fired Boiler 5 4 SEQUENCE OF OPERATION 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 and a low water level control 2 Thelow water level control is closed when there is water in the boiler up to the probe 3 When the temperature sensed by the high limit temperature control is below the set limit the switch is closed Manual reset of the switch is required following conditions exceeding high limit temperature 4 If either the high limit temperature control or the low water level control is open the boiler control locks out and indicates E 12 on the display 5 Depending on the settings in the boiler control a heat request is generated 6 The controller checks that the low air pressure switch is open indicating no airflow The blower is driven towards the prestart fan speed When the air pressure switch closes the 15 second prepurge time is started and the blower is driven toward
26. 1 115v4C LINE WS NEURAL NEURAL msee NEURAL 115 NEUTRAL mu sub DM 2 4 12 MASTER ALARM RLY 13 MASTER ALARM RLY 14 3 WAY VALVE RELAY 15 3 WAY VALVE RELAY 18 DAMPER RELAY 17 DAMPER RELAY ni H T sil No oH DHW PUMP STARTER DHW QR MB CAUTION Terminal 10 and 11 on TB2 are for pilot duty only they should not be connected directly to the pump Outdoor Air Reset optional OUTDOOR AIR vs BOILER SETPOINT 190 180 170 160 150 140 130 120 110 100 90 0 BOILER SETPOINT F 80 70 10 20 30 40 50 60 70 80 90 OUTDOOR AIR TEMP F Page 23 Installation The control automatically detects the presence of the outdoor air sensor If an outdoor air sensor is present the boiler automatically defaults to outdoor air reset for setting boiler temp The parameters should be set according to the following table Item Parameter Value Allowable F Range F Maximum Setpoint 4 180 68 185 Minimum Setpoint 5 80 60 140 Outdoor Air 6 20 4 50 Minimum Temp Outdoor Air 7 70 59 77 Maximum Temp Boiler Shutoff Temp 10 90 32 140 32 Outdoor Air Offset 12 0 0 144 Boiler Configuration 34 01 The set point of the boiler is controlled by an outdoor temperature sensor As the outdoor temperatur
27. 5 2555 7 ay z5 PIT ssh 9 o 598 13 55 a 9 e zo e 5 gt 7 amp 5 5 5 z LNE vouTAGe w i E a x HEB g lt 9 NEUTRAL Nj hn o o 88 8 5 5 E M amp 0 CH PUMP TP pg E p z z z 8 LL 915 JES HH X i 8 q E 3 o 24 UNE 10 53 g 8 e SAFETY Unit iN 9 2 request 8 9 T g r g AIR PRESS 7 2 2 5 8 5 LE I em i 5 E 0 VAC 2 1 8 HEAT REQUEST 2 HEAT REQUEST 2 210 4 INTERLOCK JUMPER D PMP 6 3 5 5 DHW HEAT SENSOR X3 5h 5 x3 5 3 4 75 TEMP SENSOR 5 aC TS E3 6 7 circ PMP SIGNAL E 4 3 og COMMON M ine TE mU ETT INPUT c WTR TEMP 2 RETURN TEMP 2 28 ___ 5 SUPPLY TEMP 2 SUPPLY coM1 TEMP 73 Tm Su m X23 1141 OUTSIDE TEMP W FILTER CNTRL 4 33 4 15 OUTSIDE TEMP N FLTER ANALOG INPUT zl X4 3 log 29 16 SPARE BURNER CNTRL P 17 SPARE I CSS FLUE GAS TEMP o 5 FLUE GAS auo 88 OUTSIDE TEMP xs 4 1 115 LINE 24 W EWC e 2 115v amp c NEUTRAL 9 vc 3 6 3 tp 8 5 115 NEUTRAL o dt
28. 54 1 Daily siente tee 30 5 1 2 Weekly RN 30 Series Gas Fired Boiler 5 1 3 Monthly During Operation 30 5 1 4 Semi Annually every 6 months 31 5 1 5 Annually 31 5 2 Cleaning the Burner 31 5 3 After All Repairs or Maintenance 31 5 4 Sequence of 32 5 5 Troubleshooting pp 32 5 5 1 Manual Reset Service Codes 34 5 5 2 Auto reset Service Codes 35 6 0 PARTS TECHNICAL SUPPORT 36 6 1 Wiring 37 6 1 1 Terminal Block Assignments High Voltage Circuit TB2 sess 37 6 1 1a Terminal Block Assignments Low Voltage Circuit TB etae 38 6 1 2 Wiring Series 300 39 Improper use may result in fire or injury Read instructions safety manual before installing operating or servicing boiler WARNING 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 The same features which permit this boiler to achieve high efficiency performance make it unlike most other boilers of this general size so it is important to understand how this boiler operates WARNING Do not st
29. Cutoff Control Mounting Plate Page 43 ae Series Gas Fired Boiler Parts and Technical Support 6 2 3 Display Panel Mark Description 1 Circuit Breaker Air Pressure Switch Fastening Clip Display Panel On Off Switch Pressure Temperature Gauge Panel Sheet Metal Stack Pressure Switch N a AJOJN poe e mm Page 44 ae Series Gas Fired Boiler Parts and Technical Support 6 2 4 C 300 450 Heat Engine Description 3 Gasket Bower to Burner Hood 3 Inside Burner Hood Gasket 4 Outside Bumer Hood Gasket 6 Burner Ferge Win msuaton 8 SealSight ass y yS 9 Sight Glass Holder Page 45 Series Gas Fired Boiler Parts and Technical Support 6 2 5 C 750 900 1050 Heat Engine ARK DESCRIPTION Gasket Blower to Burner Hood Burner Hood Burner Hood Gasket Burner View Glass Assembly Heat Exchanger Sectional Castings Exhaust Pipe Lip Ring Condense Collector Exhaust Manifold Inspection Cover amp Gasket 10 Manifold Gaskets 11 Boiler Outlet Supply Manifold 12 Boiler Inlet Return Manifold 13 Condensate Trap 14 Manifold Mounting Plate lt Oo Ci sl Page 46 rag Series Gas Fired Boiler Parts and Technical Support 6 2 6 C 300 Boiler Gas Train Mark Description Sr NN Blower Swirlplate G
30. Start the boiler and observe proper operating parameters for the system High Fire Setting Set boiler to the Test Mode High as described above to achieve maximum firing rate of the boiler Check combustion readings using a combustion analyzer If combustion readings are not in accordance with Table 3 1 adjust as follows Remove the flat round blue plastic cap from the cover Using a 3mm 7 64 hex wrench turn the adjustment screw counterclockwise to increase or clockwise to decrease gas flow and achieve the desired CO level see Table 3 1 for correct settings There will be a slight time delay between the adjustment and the response of CO j O measuring instrument Adjust the settings in small increments and allow the combustion readings to stabilize before readjusting When desired adjustments are complete reinstall the blue plastic cap on the cover Page 27 Installation Low Fire Settin Set boiler to the Test Mode Low as described above to achieve minimum firing rate of the boiler Check combustion readings using a combustion analyzer If combustion readings are not in accordance with Table 3 1 adjust as follows Remove the cap on the gas regulator using a slotted screwdriver See Fig XX This will expose the offset adjustment screw Using TORX T40 or a 5 mm hex wrench carefully adjust the low fire gas setting to achieve the CO O level prescribed in Table 3 1 Note The rota
31. TACTOR Dry Contacts 24 VAC max 1 amp max DHW Dry Contacts 24 VAC max 1 amp max 16 DAMPER RELAY Combustion Air Damper Dry Contacts 24 VAC max 1 amp max 0 1 2 3 4 Page 37 Series Gas Fired Boiler Parts and Technical Support 6 1 1a Terminal Block Assignments Low Voltage Circuit TB1 Boiler Enable Contact Closure External Limit auto reset Contact Closure HELXAM 0 O Lo 2 0 V ANAL INPUT CONTROL Remote control of firing rate or setpoint 10 VOLT Regulated 10V output E peu COM 1 RS 485 port A 2 RS 485 port B 4 QUTSIDETEMPWFITER Thermistor factory option 39e up cr gp ER o Page 38 Series Gas Fired Boiler Parts and Technical Support 6 1 2 Wiring Series C 300 2 i o 59 e e x o 6851253 e e 25 os 9 L3 Os aces n 88 er 59 48 s EN idu E 85 Je 5 LINE VOLTAGE o ES 7 z s jz LINE VOLTAGE Nu NB al e 5 5 E 3 E g 5 Q PUMP NEUTRAL NE ng Ells 4 5 5 cu mwe 28 8 m oj T
32. agrams The exhaust vent termination must be 14 feet above grade when located adjacent to a public walkway It must also have a minimum 6 foot horizontal and 6 foot vertical clearance above or below any electric meters gas meters regulators or relief equipment Series Gas Fired Boiler WARNING Do not locate intake or exhaust terminations directly above a walkway dripping of conden sation can cause icing of the walking surface Mechanical draft vent terminal Direct vent terminal clearance minimum 12 in Less than 10 ft Mechanical draft vent terminal min Grade Forced air inlet Reference ANSI Z223 1 2002 Sidewall Installations Flue Gas Outlet 10 min J Combustion Air Inlet 4 min mp 4 min above snow line DENN i Rooftop Installations Page 9 3 ft min Installation 3 6 4 Vent Terminations No rain cap or Tee required Outside Plate Cover Plate Centering Fastener Support Plate N Sealant Recommended __ Sealant Termination see text below 12 min ae Vent Termination Details The vent should extend at least three 3 feet above the roof or at least two 2 feet above the highest part of any structure within ten 10 feet of the vent To prevent the possible re circulation of flue gases your vent design
33. all required vents have been installed 4 Water connections are complete and the boiler and system have been filled and purged of air 5 The boiler is connected to a 120 volt power source with a disconnect having adequate overload protection 6 Combustion air openings are not obstructed in any way and have adequate capacity 7 The boiler is placed the proper distance from any combustible walls in accordance with Section 3 3 3 8 Relief valves have been piped to floor drains 9 Condensate piping is properly connected 10 Verify system fluid pH level is within specification 3 11 SAFETY CHECKS The following checks of safety systems must be made before putting the boiler into normal operation Before firing the boiler refer to Sections 4 1 and 4 2 for information on the use of the controls lighting and shut down procedures WARNING Never attempt to operate a boiler that has failed to pass all the safety checks described below Page 18 Installation WARNING After checking controls by manual adjustment make sure they are always reset to their proper settings 3 11 1 Test of Ignition Safety System MACH C300 amp C450 Test the ignition system safety shutdown as follows 1 Loosen the retaining screw and remove the 5 pin connector from one of the two gas safety shut off control valves 2 Cycle the boiler on by generating a heat request The method for this will depend on your boile
34. artment Series Gas Fired Boiler 1 0 INTRODUCTION The P K MACH Q 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 provide maximum efficiency in a minimum amount of space The high quality materials and thoroughly tested design of the boiler should provide years of trouble free service if the instructions in this manual are followed carefully This manual covers installation of P K MACH Series Boilers The model numbers may be followed by a prefix or suffix letter in some cases to indicate special features or different options While details may differ slightly basic operation is the same for all models Boilers may be built to operate with natural gas or liquefied petroleum gas propane 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 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 Patterson Kelley cannot be responsible for the design or operation of s
35. as Leak Test Port Flex Hoses w Gas Valve Adaptors Page 47 Series Gas Fired Boiler Parts and Technical Support 6 2 7 C 450 Boiler Gas Train 2 22 K Description Main Gas Shut off Valve 2 Low Gas Pressure Switch High Gas Pressure Switch Gas Safety Shut off Control Valve Gas Manifold Shut off Valve Air Gas Manifold Swirlplate Blower 9 Gas Leak Test Port Flex Hoses with Gas Valve Adapters Page 48 Series Gas Fired Boiler Parts and Technical Support 6 2 8 C 750 900 1050 Boiler Gas Train man Desorption 1 Main Gas Shut off Valve Low Gas Pressure Switch 3 Hih Gas Pressure Flex Hose with Gas Valve Adapior 8 Premix Combustion Blower 9 Page 49 MACH Series Gas Fired Boiler 7 0 LIMITED WARRANTY 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 will be free from defects in materials and workmanship for a period of five 5 years from date of shipment the Warranty Period For products or parts not manufactured by Patterson Kelley the warranty obligations shall in all respects be limited to one 1 year REMEDY The sole remedy of this warranty is expressly limited to the
36. boiler and the boiler stack The result is improper combustion and premature boiler failure Provisions for combustion and ventilation air must be in accordance with Section 5 3 Air for Combustion and Ventilation of the National Fuel Gas Code ANSI Z223 1 latest edition or applicable provisions of the local building codes In Canada combustion air openings shall comply with CSA B 149 Installation Code The formula is 1 sq in per 1 000 Btu hr of gas input not less than 100 sq in The location shall be neither more than 18 nor less than 6 above the floor level The boiler room shall be provided with two openings to ensure adequate combustion air and proper ventilation One opening should be 6 to 12 inches above the floor and the other 6 to 12 inches below the 120 Volt Electrical Control Junction Box Control Junction B ceiling preferably on opposite walls The size of each opening is determined by whether air is taken Electrical Connections at Rear of Boiler 3 5 COMBUSTION AIR 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 dry wall 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 Comm
37. change of temperature at the boiler Consult your authorized Patterson Kelley boiler representative for application guidance Piping With Air Handling Units The boiler piping system of 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 automatic means to prevent gravity circulation of the boiler water during the cooling cycle Page 15 Installation 3 8 2 Boiler Inlet and Outlet Connections SS Condensate Trap Piped to drain Boiler Inlet and Outlet Connections Make water connections as the application warrants or at a minimum as shown but always in compliance with the local requirements Note The boiler is furnished with 2 grooved connections for Victaulic Style 75 Couplings These coupling must be used with the EPDM Victaulic seals Isolating valves must be installed in both water connections for ease of service The bottom connection to the boiler is the INLET and must be used for the return from the system The top connection to the boiler is the OUTLET and must be connected as the supply to the system Note Condensate Trap must be piped to drain in accordance with all state and local codes Series Gas Fired Boiler 3 8 3 Boiler Water Piping by Installer Strainer To avoid possible contamination of the boiler with dirt rust or sediment from the sy
38. configured for a remote analog input setpoint according to the following table Item Parameter Value Allowable F Range F Maximum Setpoint 4 180 68 185 Minimum Setpoint 5 80 60 140 Boiler Configuration 34 03 The setpoint of the boiler is controlled by an external 0 10 VDC signal A signal of at least 0 5 VDC is required to start the boiler At 0 VDC the setpoint is 32 F at 10 VDC the setpoint is 212 F This setpoint is low and high limited by maximum and minimum setpoint parameters The controlled setpoint voltage range narrows when these limits are used If the above tables values are used the boiler setpoint will be 80 F when the voltage is anything less than approximately 3 VDC It will then increase linearly with voltage until approximately 8 5 VDC when it will be 180 F The setpoint will remain at 180 F even if voltage is increased further Page 24 Installation Analog Input to Control Firing Rate Analog Input Firing Rate Firing Rate Voltage The control must be configured for analog input direct drive by setting parameter 34 to 02 The firing rate of the boiler is controlled by an external 0 to 10 VDC signal At a voltage greater than 0 5 VDC the boiler turns on and runs at low fire until 1 8 VDC is reached The firing rate increases linearly with voltage until high fire is reached at 10 VDC The boiler setpoint Parame
39. d Second Comfort Heat system A temperature If the sensors for these functions are not installed the display will indicate 22 3 12 1 2 Operating Configurations The boiler has several different operating configurations These are Internal Setpoint Domestic Priority Outdoor Air Reset Analog Input Setpoint Analog Input Direct Drive CAUTION Do not modify any parameters other than those specifically mentioned MACH Series Gas Fired Boiler 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 Item Parameter Value Allowable Range Setpoint 4 160 68 185 Low Temp Differential 22 10 0 36 High Temp Differential 23 9 0 36 Low Temp Setpoint 5 68 59 140 The boiler will modulate to try to maintain 160 F If the temperature increases above 169 F which is the setpoint 160 F High Temp Differential 9 F the boiler will shut off Once it shuts off it will not restart until the temperature drops below 150 F which is the setpoint Low Temp Differential The Low Temp Set Point will not permit the operator to adjust the setpoint below 68 F See graph below Internal Setpoint Boiler Turns Off Boiler Tempera
40. d 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 to the regulator 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 Page 3 Safety 2 5 3 Crush Hazards General Warning e Lifting hazards Use properly rated lifting equipment to lift and position the boiler The load is unbalanced Test balance before lifting 3 ft above the floor Do not allow personnel beneath the lifted load Refer to approximate weights in the table below Boiler Size Weight in Pounds 300 000 Btu 354 450 000 Btu 440 750 000 Btu 650 900 000 Btu 700 1 050 000 Btu 750 e Bump hazard from overhead ductwork and piping Install components with adequate vertical clearance 2 5 4 Chemical Hazards General Warning e Chemical hazards from cleaning products Use caution when cleaning the system The use of professional assistance is recommended
41. e falls the setpoint of the boiler is increased The boiler modulates to maintain this setpoint The setpoint is adjusted according to the above parameters The boiler setpoint will be the maximum value 180 F when the outdoor air is at or below a minimum temperature value 20 F The boiler setpoint will be at the minimum value 80 F when outdoor air is at or above a maximum temperature value 70 F The setpoint for in between values of outdoor air temperature is linearly proportional to the above settings Using the values in the table above the boiler setpoint will be 80 F when the outdoor air temperature is 70 F As the outdoor air temperature drops the boiler setpoint will be increased until the outdoor air temperature is 20 F At this point the boiler will reach its maximum setpoint of 180 F If the outdoor air temp drops further the boiler setpoint remains at 180 F The boiler shutoff temperature can be used to turn the boiler off at a given setpoint For example if you wanted to shut the boiler off when the outdoor air temperature was above 65 F you would set the boiler shutoff temp to 90 F since this is the setpoint that is called for at 65 F outside air temp Series Gas Fired Boiler Analog Input to Adjust Setpoint Analog Input Setpoint 150 Boiler Setpoint 100 Non adjustable Curve Boiler Setpoint Voltage The control must be
42. ed Boiler 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 manufactured by Seller the warranty obligations of Seller shall in all respects conform and be limited to one 1 year from the date of shipment Page 51 Limited Warranty SEVERABILITY To the extent that any provision of this warranty would be void or prohibited under applicable law such provisions shall be limited in effect to the minimum extent necessary to render the remaining provisions hereof enforceable NO OTHER WARRANTIES Seller makes no implied warranty of merchantability or fitness for a particular purpose or other warranties with respect to any products or services except as expressly set forth in this limited warranty Series Gas Fired Boiler 8 0 APPENDIX Appendix Date Hi Low Fire Stack Tem Action 52 Sc Sc A j ISIN co o o In o o o lo gagag D DIN o 99935 st LO LO o o LO LO Ke LO oo o SF LO D E
43. em 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 At the time of removal of an existing boiler while the other appliances remaining connected to the common venting system are not in operation the following steps should be followed with each appliance remaining connected to the common venting system placed in operation 1 Sealany unused openings in the common venting system 2 Visually inspect the venting system for proper size and horizontal pitch and determine that there is no blockage or restriction leakage corrosion or other deficiency which could cause an unsafe condition Page 10 Installation 3 Insofar as is practical close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building Turn on clothes dryers and any appliances not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers 4 Place the appliance being inspected in operation Follow the lighting instructions Adjust the thermostat so that the appliance will operate continuously 5 Test for spillage at the draft hood relief opening after 5 minutes of
44. er must take into consideration such things as prevailing winds eddy zones building configurations etc P K can not be responsible for the effects such adverse conditions may have on the operation of the boilers Dimensions listed above or those illustrated are minimum and may or may not be sufficient for conditions at a specific job site A tee must be of approved design and adequate capacity 3 6 5 Venting for Multiple Boilers The venting instructions in this manual apply to a single boiler Venting systems for multiple boilers must be designed by qualified professionals and verified by the stack manufacturer The venting system must prevent backflow of exhaust gas through idle boilers which are not operating Series Gas Fired Boiler 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 through the system is maintained by the fan inside the boiler assembly Vent Installation Details Installation must conform to the vent manufacturer s instructions in all respects including joining clearances fastening fire stopping and other matters Vent ductwork may be run horizontally or vertically if so certified 3 6 7 Removing an Existing Boiler from a common venting syst
45. et and Vent Exhaust Vent ___ P Air Inlet Sidewall venting requires Type of flue i vertical tee termination termination optional Exhaust Vent A Sidewall venting requires Ey ee buned vertical tee termination ___ Sidewall Sidewall Roof Inlet Sidewall Vent Sidewall Inlet and Vent Basic Air Inlet Vent Configurations Page 11 Series Gas Fired Boiler Exhaust Vent 7 Sidewall Venting M Requires Up Elbow Mounted Air inlet Down Elbow Mounted i H Sidewall 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 Required SCFM 1050 245 900 210 750 175 450 105 300 70 The installation of a bird screen on the intake termination is recommended 3 6 10 Sealing the Intake Duct Proper sealing of the intake ductwork is necessary to prevent infiltration of air from conditioned space Joints in PVC or CPVC must be ce
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47. h a InFo sensors blinking dot 1 180 j Standby Mode The display defaults to this mode at startup or reset of the control If no key is pressed for 20 minutes the display will return to this mode The function of the keys may be two fold as shown below ee Key S Duration Function The MACH boiler is equipped with a combination momentary Change to next mode combustion and temperature control This control Reset momentary Reset the control monitors combustion and lighting of the boiler as well Show the comfort heat as maintaining temperature of the supply water The setpoint or max setpoint temperature control portion modulates the boiler to ave momentary maintain the desired outlet temperature based on the Turn the comfort heat system selected operating configuration Pius long anoto Show the domestic hot water CAUTION Minus momentary setpoint Turn the domestic hot water The user should become thoroughly familiar with Minus long system on or off the operation of the boiler and controls before attempting to make any adjustments Note Long duration is greater than 2 seconds When in the Standby Mode the control indicates boiler status with the first digit of the display The remaining digits indicate the boiler s actual temperature or lockout code The following table indicates the meaning of the display digits when i
48. h temperature are all met 5 5 TROUBLESHOOTING The MACH Series boiler will display service codes to indicate some problems with the boiler There are two types of lockouts the control may experience manual reset lockouts requiring an operator to press the reset button and automatic reset lockouts where the control will automatically attempt to restart the boiler A listing of service codes is included at the end of this section Should the unit fail to operate call a qualified service technician to troubleshoot the problem and implement corrective action The Loss of Power In the event of a power failure or when the On Off switch is in the Off position the display panel is not illuminated and the entire system is de energized closing all automatic valves and halting all boiler operations When power is restored the sequence of operation will resume at Step 5 provided that all the limits are satisfied If any manual reset lockout was present when the power is lost the display will flash E 04 when the power is resumed This indicates that the control was in lockout mode but does not indicate which service code was present Series Gas Fired Boiler 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
49. ided that the other limits are satisfied Low Air If the display panel indicates E 08 this indicates insufficient airflow through the burner Check that the burner is clean Cleaning the Burner Section 5 2 and that there are no obstructions to airflow in the intake or exhaust ducts A low air indication does not necessarily mean that the low air switch is defective Air Switch Closed If the display panel indicates B 61 this indicates the air pressure switch did not open when the blower was shut off Check that there is no air flow through the boiler when the fan is off If there is no hidden source of air flow replace the switch Flame Failure In the event of a flame failure during a firing period or a trial for ignition the main fuel valves are de energized and a manual reset lockout occurs After the spark ignition is re energized the 3 second trial for ignition begins again If flame failure occurs during a trail for ignition a safety lockout occurs The display will indicate E 02 If flame failure occurs and an service code is displayed the combustion control must be manually reset E 00 signifies a leaky gas valve In the event of a false flame signal E 00 fault code is indicated This fault code could indicate a gas valve failure or leakage of the gas valve If gas valve leakage is suspected the unit must be isolated by turning off the main gas supply line until the gas valve is replaced Series Gas F
50. ired Boiler Maintenance 5 5 1 Manual Reset Service Codes False flame A flame signal is present when it shouldn t be Flame failure The burner did not light on startup or loss of flame during run E E03 Gas Valve error ______ Valve error Check all gas valves electrical connections all Check all gas valves electrical connections valves electrical connections ESS fees Vale ere MM lockout The power was lost after a lockout The control loses the description of the lockout on power loss One of the external limits has opened High Low Gas Pressure High Temp Low water Note When an Internal Control Failure occurs as identified by E Codes listed above the failure is internal to the MCBA and replacement of the MCBA is required A qualified service technician must be called to replace the MCBA device Page 34 Series Gas Fired Boiler Maintenance 5 5 2 Auto reset Service Codes 019 inlet outlet The inlet water temperature has been more than 18 F above the outlet for more than 75 seconds 625 25 Outlet temp rapid change The outlet water temperature is increasing too fast Indicating low flow condition 26 exhaust back pressure The high exhaust back pressure switch is tripped indicating a blocked stack inlet or condensate system Max delta T The temperature rise across the heat exchanger is greater than maximum allowed indicating insufficient flow
51. lation valve 3 11 2 Test of Low Water Cut out The boiler is furnished with a probe type low water cut out in the outlet nozzle Test as follows Operation of the switch can be checked by first turning the boiler off and then turning the system pump off Isolate the boiler from the system pressure After isolating the system drain the water level below the low water cut out probe Turn the boiler back on It should not operate and a manual reset lockout displaying E 12 on the display panel will occur The LED indicator for Low Water cut out will no longer be illuminated Return the system to normal operation and restart the boiler Refer to Section 4 2 1 3 11 3 Test of High Limit Control Fire the boiler and test the high limit control as follows With the main burner operating turn down the temperature setting on the high limit thermostat until the main burner shuts off A manual reset lockout displaying E 12 on the display panel will occur The high limit switch must be manually reset prior to resetting the boiler at the display panel Readjust the high limit thermostat to the desired setpoint 3 11 4 Test of Gas Pressure Switch Low Gas Pressure Switch The boiler is furnished with a low gas pressure switch The operation of this switch must be checked by slowly closing the main gas cock while the burner is operating The switch should shut down the main Page 19 Installation burner When the gas pressure switch
52. ll fittings Approximate sizing may be based on 1 cubic foot of natural gas per 1 000 Btu per hour input 1 500 000 Btu per hour requires about 500 cubic feet per hour See Typical Boiler Operating Conditions Section 4 3 for more information MACH Series Gas Fired Boiler Pipe Capacity for Natural Gas Installation Nominal Equivalent Pipe Length Maximum Capacity in Cubic Feet of Natural Gas per Hour Iron Pipe Internal Pressure Drop of 0 5 inch Water Column Equivalent Length of Pipe Size Diameter Inches Inches SEI 288 Feet Feet 20 40 60 80 100 150 200 1 2 0 622 1 55 3 1 120 82 66 57 50 40 35 3 4 0 824 2 06 4 12 250 170 138 118 103 84 72 1 1 049 2 62 5 24 465 320 260 220 195 160 135 1 1 4 1 380 3 45 6 9 950 660 530 460 400 325 280 1 1 2 1 610 4 02 8 04 1460 990 810 690 620 500 430 2 2 067 5 17 10 3 2750 1900 1520 1300 1150 950 800 2 1 2 2 469 6 16 12 3 4350 3000 2400 2050 1850 1500 1280 3 3 068 7 67 15 3 7700 5300 4300 3700 3250 2650 2280 4 4 026 10 1 20 2 15800 10900 8800 7500 6700 5500 4600 3 7 1 Gas Supply Piping by Installer The boiler and all gas piping connections should be pressure tested and must be checked for leaks before being placed into service Test with compressed air or inert gas if possible The boiler must be disconnected at the boiler manual shut off valve located at the end of the supplied gas train from the gas supply
53. ller or service agency who has been trained on the Patterson Kelley MACH boiler MACH Series Gas Fired Boiler 5 1 4 Semi Annually every 6 months In addition to the recommended monthly service 1 Clean burner of any accumulated 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 is evident Installation and service must be performed by a qualified installer or service agency who has been trained on the Patterson Kelley MACH boiler The blower motor is permanently lubricated and does not require periodic lubrication 5 1 5 Annually In addition to the recommended monthly service 1 Inspect and clean the inlet screen of any accumulated dust or lint 2 Check burner and clean off any soot or foreign material that may have accumulated See Section 5 2 on Cleaning the Burner Check for corrosion of the burner and its parts If there is evidence of deterioration or corrosion replace immediately 3 Inspect combustion chamber when the burner is removed for inspection Note any signs of deterioration Clean as necessary 4 Inspect and clean heat exchanger Use vacuum to remove accumulations from the heat exchanger pins and surfaces Clean the casting pins by flushing with clean water and air drying Do not use any cleaning agents or solvents A soft nylon brush may be used in accessible areas 5 Drain
54. loor however the boiler must never be installed on carpeting 3 3 2 Placement The boiler must be level to function properly To assist in leveling the boiler the four 4 adjustable leg bolts 1 2 13 NC must be installed The adjustable legs are also necessary to provide adequate floor Series Gas Fired Boiler clearance and prevent distortion of the cabinet twisting etc in addition to leveling Adjustable Leg Bolts 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 provide for the service access clearances even with non combustible surfaces may cause future problems servicing the boiler The boiler must be installed in a space large in comparison to the boiler as described in Section 6 3 of the National Fuel Gas Code ANSI Z223 1 latest edition No pipes ducts etc in C this area Page 6 Installation D D Minimum Clearances from Adjacent Walls Ceiling and Obstructions Type of Surface Dimensions inches A B Ct D Combustible Surfaces 36 24 24 24 Non combustible Surfaces 36 24 24 Do not put pipes ducts etc in this area above the boiler
55. lure resulting from misuse modification not authorized by Seller in writing improper installation or lack of or improper maintenance Equipment furnished by the owner either mounted or unmounted or when contracted for by the owner to be installed or handled Leakage or other malfunction caused by 1 Defective installations in general and specifically any installation which is made a in violation of applicable state or local plumbing housing or building codes b contrary to the written instructions furnished with the unit 2 Adverse local conditions in general and specifically sediment or lime precipitation in the tubes and or headers or corrosive elements in the atmosphere 3 Misuse in general and specifically operation and maintenance contrary to the written instructions furnished with the unit disconnection alteration or addition of components or apparatus not approved by Seller operation with fuels or settings other than those set forth on the rating plate or accidental or exterior damage Production of noise odors discoloration or rusty water Damage to surrounding area or property caused by leakage or malfunction Costs associated with the replacement and or repair of the unit including any freight shipping or delivery charges any removal installation or reinstallation charges any material and or permits required for installation reinstallation or repair Series Gas Fir
56. ly could result in overfiring of other devices supplied from the same source e Fire and explosion hazards Close the main gas shutoff before servicing boiler e 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 e Burn hazard Possible hot surfaces Do not touch gas vent during firing operation Use only factory recommended vent components e 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 MACH Series Gas Fired Boiler 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 correctly and burner hood is securely fastened following any maintenance performed on them These connections cannot be tested after the burner is assembled Gas leak hazard All threaded gas connections must be made using a pipe compound that is resistant to liquefied petroleum 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 an
57. mented For galvanized duct wrap each joint and seam with adhesive aluminum tape 3 6 11 Intake Duct Connection to Boiler Connect the air supply duct to the collar on the back of the boiler Fasten the duct to the collar with sheet metal screws at 90 angles Seal the joint Page 12 Installation 3 6 12 Intake Duct Terminations ___ Round Roof 90 Elbow ___ Sidewall Air Inlet tee mounted horizontally Round No rain cap Unrestricted The roof intake termination must be an unrestrictive type as shown above Centering Support Plate Series Gas Fired Boiler Outside Plate Cover Plate Fastener Sealant Field Provided Inlet Screens i Z Sealant TN Recommended Termination L4 12 Intake Termination Details 3 6 13 Vent Elbows The turn from horizontal to vertical should be made with two 45 ells or with one long radius 90 ell for best operation Do not use short radius ells 3 7 GAS PIPING Before making the gas hook up make sure the boiler is being supplied with the type of fuel shown on the boiler nameplate The boiler shall be installed such that the gas ignition system components are protected from water dripping spraying rain etc during appliance operation and service circulator replacement
58. n the standby level 3 12 1 1 Operation of the Control The boiler is operated through the control display panel The display has 3 modes of standard operating menus The modes are e Standby mode will display Stby EE EEG e Parameter mode will display MST Digi over status e Information mode will display InFo 0 1 Pre purge or post purge At each level the keys and the display have different 2 Ignition functions To ascertain which mode you are in the displayed information will be shown as indicated 3 Burner on in Comfort Heat mode under display 4 Burner on in Domestic Hot Water mode 5 Checking the airflow switch Burner off An internal setpoint has been 6 reached System is still calling for heat 7 Burner off Comfort Heat pump running on Page 20 Series Gas Fired Boiler First Digit Boiler Status delay No system call for heat Burner off Domestic Hot Water pump 8 running on delay No system call for heat Burner off auto reset lockout A code is displayed indicating the reason for the 9 and b lockout See Troubleshooting Section flashing 5 5 A Adjusting the 3 way valve if used H Burner on in manual high fire L Burner on in manual low fire Parameter Mode The parameter mode is used to change the settings of the boiler The parameter mode is accessed by pressing the MODE key several
59. nches for a 450 000 Btu per hour 3 6 FLUE VENTING This boiler requires a special vent system This boiler is not certified for use with Type vent This boiler is Category IV condensing positive pressure as it is defined in ANSI 221 13 4 9 latest edition The vent material must be listed Category IV vent pipe 316L or AL29 4C Stainless Steel and comply with UL 1738 or UL103 In Canada it must comply with ULC 636 The exhaust vent can be run horizontally or vertically Vent installations shall be in accordance with Part 10 Venting of Equipment of the National Fuel Gas Code ANSI Z223 1 or CSA B 149 code or applicable provisions of the local building codes The venting system and the horizontal portions of the venting system shall be supported to prevent sagging The vent must be sized according to the vent manufacturer s recommendations Consult your vent supplier for correct sizing and structural support requirements Design calculations should be based on a maximum of 0 22 W C total frictional resistance in the stack measured at the boiler flue gas discharge with a stack temperature of 210 F gross and a CO level of 9 natural gas or 10 4 propane These values are to be used for vent sizing calculations The installation of a bird screen on the vent termination is recommended Consult your local vent manufacturer for proper sizing 3 6 4 Barometric Damper WARNING Do not use a barometric
60. ntly strong and rigid to support the weight of the boiler all piping and accessories 2 5 1 Electrical Hazards AWARNING Electrical hazard Follow lockout tagout procedure when servicing this boiler e Shock hazard Properly lockout tagout the electrical service and all other energy sources before working on or near the boiler e Shock hazard Do not spray water directly on any electrical components Page 2 Safety 2 5 2 Burn Fire and Explosion Hazards AA General Warning Hot Surface LA WARNING Improper use may result in fire or injury Read instructions safety manual before installing operating or servicing boiler 1998 HCS Inc 800 748 0241 Reorder No 6020 V2WHPK Make sure this union is tight before closing cabinet cover after servicing boiler 01998 HCS Inc 800 748 0241 Reorder No 8032 02NHAK When opening leak test valves always follow instructions in operation and safety manual Q 1998 HCS Inc 800 746 0241 Reorder No 8032 01NHPK e Burn fire and explosion hazards Installation must be in strict conformance to all applicable codes and standards including NFPA 54 ANSI 7223 1 and CAN CGA B 149 Install all required vent lines for gas devices Refer to Section 3 7 1 e Hazard from incorrect fuels Possible fire explosion overheating and damage Do not use any fuels except the design fuels for the unit e Overfire hazards High pressure in gas or propane supp
61. nts of all national state and local codes established by the authorities having jurisdiction or in the absence of such requirements in the U S to the National Fuel Gas Code ANSI Z223 1 NFPA 54 latest edition In Canada the equipment shall be installed in accordance with the current Installation Code for Gas Burning Appliances and Equipment CAN CGA B 149 and applicable Provincial Regulations for the class which should be carefully followed in all cases Authorities having jurisdiction should be consulted before installations are made 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 handle type and c piping of condensate shall conform with the State Plumbing Code 3 3 SETUP The P K MACH Series 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 heat exchanger is constructed and stamped in accordance with ASME Boiler and Pressure Vessel Page 5 3 3 1 Foundation Provide a firm level foundation preferably of concrete Note The boiler may be installed on a combustible f
62. odes for details Page 16 Installation Drain Valve and Piping A drain valve is installed in the inlet system return header connection to the boiler Prior to draining the boiler for maintenance or testing electrical power and gas supply must be turned off to the boiler The boiler must then be isolated from the system at the supply and return connections prior to draining water from the boiler Note This drain valve is installed for draining of the boiler water only not the entire system Draining of the system through the boiler will result in depositing sediment from the system in the boiler which will result in poor heat transfer characteristics of the boiler and early boiler failure Condensate Drain The condensate can be slightly acidic pH between 3 0 and 5 0 This may be corrosive to some building drain systems A condensate neutralization system may be required Disposal of condensate must comply with all state and local codes 3 8 4 Flushing and Filling Water Quality The MACH Series boiler heat exchanger is made of an aluminum alloy The heat exchanger requires special water conditions to retain efficiency and function properly IMPORTANT Chemicals added to the system must be approved by the chemical manufacturer for use in aluminum boilers IMPORTANT Under no circumstances should petroleum based cleaning or sealing compounds be used in the boiler system The boiler is designed to ope
63. on each of the valves equally Example If an increase in the gas flow is required to lower the level turn each of the maximum flow restrictors equivalent amounts i e 4 or turn each and allow the analyzer readings to respond and stabilize before proceeding with additional adjustment Adequate response time must be allowed for combustion readings to stabilize This response time will be longer for low firing rates than for high firing rates High Fire Setting Set boiler to the Test Mode High as described above to achieve maximum firing rate of the boiler Check combustion readings using a combustion analyzer If combustion readings are not in accordance with Table 3 1 adjust as follows Using a slotted screw driver or 2 mm hex wrench set the maximum restrictor high fire screw see the figure below item D on each of the gas safety shut off control valves by turning clockwise or counterclockwise to achieve the desired CO or level see Table 3 1 for correct settings There will be a slight time delay between the adjustment and the response of the CO O measuring instrument Page 26 Clockwise rotation decreases gas flow Counterclockwise rotation increases gas flow Low Fire Settin Set boiler to the Test Mode Low as described above to achieve minimum firing rate of the boiler Check combustion readings using a combustion analyzer If combustion readings are not in accordance with Table 3 1
64. on chemicals which must be avoided are fluorocarbons and other halogenated compounds most commonly present as refrigerants or solvents such as freon trichlorethylene perchlorethylene chlorine etc These chemicals Page 7 from inside or outside the building In Canada ventilation air openings shall be at least 10 of the Cross sectional area required for combustion air but not less than 10 square inches It is to be located at the highest practical point communicating with outdoors WARNING Under no circumstances shall the boiler room ever be under a negative pressure Particular care should be taken when exhaust fans compressors air handling units or other equipment may rob air from the boiler 3 5 1 Air Inlet Requirements If air is taken directly from outside the building each opening minimum of two should have a net free area of 1 square inch for each 4 000 Btu per hour of total boiler input For instance 112 5 square inches are required for 450 000 Btu per hour input When air is taken from the outdoors through a vertical duct 1 square inch per 4 000 Btu per hour is required If a horizontal duct is used 1 square inch per 2 000 Btu per hour is required 1 225 square inches for 450 000 Btu per hour input Series Gas Fired Boiler If air is taken from another interior space each opening should have a net free area of 1 square inch for each 1 000 Btu per hour of boiler input 450 square i
65. opens a manual reset lockout displaying E 12 on the display panel will occur Upon re opening the main gas cock the E 12 indicator will remain on until the display panel is manually reset High Gas Pressure Switch C450 units equipped with a high pressure switch must be checked by closing the downstream gas cock while the burner is operating The switch should shut down the main burner When the gas pressure switch opens a manual reset lockout displaying E 12 on the display panel will occur Upon re opening the gas cock the E 12 indicator will remain on until the display panel is manually reset C750 C900 and C1050 units equipped with a high pressure switch must be checked by closing the downstream gas cock with the boiler off When the boiler is starte it should enter its normal starting cycle and fail on high gas pressure when the gas safety valves open The high gas pressure switch actuation is evident when a manual reset lockout displaying E 12 on the display panel occurs Upon re opening the gas cock the E 12 indicator will remain on until the display panel is manually reset Series Gas Fired Boiler Installation 3 12 INITIAL ADJUSTMENTS Mode Description Display Example Standby Normal display 1st digit 3 12 1 Operating Temperature Controller Stby mode without a dot 0180 Parameter Parameter 1st digit with PArA settings a dot 1 125 Information display boiler 1st digit wit
66. ore or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance Table of Contents 6 1 3 Wiring Series 450 40 6 1 4 Wiring Series 750 900 1050 41 6 2 Boiler Parts 56 42 6 2 1 Main 42 6 2 2 Control 43 6 2 3 Display Panel 44 6 2 4 C 300 450 Heat Engine 45 6 2 5 C 750 900 1050 Heat Engine 46 6 2 6 C 300 Boiler Gas Train 47 6 2 7 C 450 Boiler Gas Train 48 6 2 8 C 750 900 1050 Boiler Gas Train 49 7 0 LIMITED WARRANTY 50 8 0 APPENDIX eene 52 WARNING Chemicals fuels or other potentially hazardous or toxic materials must not be stored in the same room as the boiler WARNING Installation and service must be performed by a qualified installer or service agency who has been trained on the Patterson Kelley MACH Boiler What to do if you smell gas e 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 e If you cannot reach your gas supplier call the fire dep
67. ps or less 750 750 000 728 712 500 300 712 500 8 amps or less 900 900 000 873 846 000 360 846 000 8 amps or less 1050 1 050 000 1019 987 000 420 987 000 8 amps or less Note The heat exchanger is constructed and stamped for 50 psig maximum operating pressure and or 200 F maximum temperature Page 29 Series Gas Fired Boiler 5 0 MAINTENANCE 5 1 MAINTENANCE AND INSPECTION SCHEDULE 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 when servicing boiler in order to prevent the accumulation of gas in or around the combustion chamber WARNING General lockout tagout procedure must be employed when servicing this unit WARNING Determine the cause of the lockout before resetting the boiler If able to determine cause of lockout then appropriate corrective action should be taken If not able to determine cause of the problem call a qualified service technician Verify proper operation after servicing 5 1 1 Daily Observe operating temperature and general conditions Make sure that the flow of combustion and ventilating air to the boiler is not obstructed Determine the cause of any service codes or lockouts on the display panel Observe any unusual noises or operating conditions
68. r configuration See Section 3 12 1 2 3 The boiler should run through the normal startup sequence checking all of the limits and switches as in a normal start up See Sequence of Operation Section 5 4 4 When the boiler reaches the ignition period a 2 will display as the first digit in the display the spark terminal will energize and one of the gas safety shut off control valves will open One open gas valve should not provide sufficient fuel to light the burner 5 After3 seconds the combustion control should lock out and the display will flash E 02 indicating a flame failure After completing this test turn off the boiler and reconnect the 5 pin connector to the gas safety shut off control valves retightening the retaining screw MACH C750 C900 amp C1050 Test the ignition system safety shutdown as follows 1 Cycle the boiler on by generating a heat request The method for this will depend on your boiler configuration See Section 3 12 1 2 2 Place the boiler in operation at the high fire setting See section 3 12 4 Gas Valve Setup and Adjustment Test Mode High Series Gas Fired Boiler 3 Smoothly close the downstream manual isolation valve to reduce the gas flow and cause flame failure 4 display will flash E 02 indicating a flame failure The 02 lockout will remain until reset on the display After completing this test turn off the boiler and open the downstream manual iso
69. rate in a closed loop system As such the system should be tight and not require make up water A high percentage of Series Gas Fired Boiler 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 scale thickness of 1 16 will result in a 12 546 loss of efficiency Water pH The pH of the hydronic system fluid must be between 6 0 and 8 5 A periodic check of the system pH should be conducted to ensure these pH levels are maintained IMPORTANT Glycol and other additives must be approved by the chemical manufacturer for use in aluminum boilers and must meet the required pH levels listed above to prevent damaging the boiler The water quality should be within the guidelines established by the American Boiler Manufacturers Association as follows Total 4 22222 1 150 ppm The amount of oils fats grease and other organic matter should be limited to 10 ppm Consult your water conditioning or chemical treatment supplier for analysis and recommendations Flushing the System Before filling the boiler flush the system to remove any debris from construction or maintenance Clean and flush old piping thoroughly before installing the boiler IMPORTANT Under no circumstances should the hydronic system be flushed while the boiler is attached to the system since the deb
70. repair or replacement of any part found to be defective under conditions of normal use within the Warranty Period Installation is not included WARRANTY The owner must notify the original installer of the Product and Seller Attention Patterson Kelley Co P O Box 458 East Stroudsburg PA 18301 in writing within the Warranty Period providing a detailed description of all claimed defects Transportation to the factory or other designated facility for repairs of any products or items alleged defective shall in all events be the responsibility and at the cost of the owner EXCLUSIONS Seller shall have no liability for and this warranty does not cover A Incidental special or consequential damages such as loss of the use of products facilities or production inconvenience loss of time or labor expense involved in repairing or replacing the alleged defective Product B The performance of any Product under conditions varying materially from those under which such Product is usually tested under industry standards at of the time of shipment Page 50 Limited Warranty Any damage to the Product due to abrasion erosion corrosion deterioration abnormal temperatures or the influence of foreign matter or energy The design or operation of owner s plant or equipment or of any facility or system of which any Product may be made a part The suitability of any Product for any particular application Any fai
71. ris or corrosion products could accumulate in the boiler and plug the boiler heat exchanger Page 17 Installation IMPORTANT If the piping system attached to this unit will be chemically cleaned the boiler must be disconnected from the system and a bypass installed so that the chemical cleaning solution does not circulate through the boiler Following chemical cleaning the system should be thoroughly rinsed to remove cleaning agents prior to reconnecting the boiler to the system Filling To be sure that the boiler is not air bound open the pressure relief valve located at the rear of the boiler Leave the relief valve open until a steady flow of water is observed Close the valve and finish filling the system 3 9 BURNER AND IGNITION SYSTEM 3 9 1 Inspection Inspect the unit to be sure nothing was damaged or knocked loose during shipment Since some damage may be hidden remove the top cover and inspect the boiler Inspect the gas train blower ignition electrode and boiler in general to be sure there was no damage during shipment or installation Series Gas Fired Boiler 3 10 PRE START CHECK LIST 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 connection has been made pressure tested for leakage and the line purged of air Make sure
72. se and locations of the controls the operation of the boiler adjustment of its various mechanisms and all applicable safety precautions If any of the provisions of this manual are not fully and completely understood contact the Patterson Kelley Sales Department toll free at 877 728 5351 for assistance 2 3 SAFETY FEATURES It is the responsibility of the customer to maintain the safety features such as guards safety labels safety controls interlocks lockout devices etc in place and operable Series Gas Fired Boiler 2 4 SAFETY LABELS When opening leak test valves always follow instructions in operation and safety manual 1998 HCS Inc 800 748 0241 Reorder No 6032 01NHPK Improper use may result in fire or injury Read instructions safety manual before installing operating or servicing boiler 01998 HCS Inc 800 748 0241 Reorder No 6020 V2WHPK A WARNING Electrical hazard Follow lockout tagout procedure when servicing this boiler The safety labels shown above are affixed to your boiler Although the labels are of high quality they may become dislodged or unreadable over time Contact Patterson Kelley toll free at 877 728 5351 for replacement labels 2 5 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 sufficie
73. stem a strainer near the boiler inlet is strongly recommended Even new systems may contain sufficient foreign material to eventually reduce the performance of the heat exchanger Adequate circulation of good clean water is essential to maximum efficiency and long life of the boiler Relief Valve and Piping Each boiler is supplied with a pressure relief valve sized in accordance with ASME requirements The relief valve should be piped to a suitable floor drain Reducing couplings or other restrictions are not permitted in the discharge line Low Water Cut off The boiler is furnished with a probe type low water cut off no field piping is required If the water level in the boiler drops below the probe the boiler will shut down and a flashing E 12 service code will be displayed on the control panel The low water cutoff circuit will automatically reset when the low water condition clears however the boiler controls will retain the lockout condition until the reset button on the display is depressed IMPORTANT The low water cutout probe only prevents boiler operation when the water level in the boiler is insufficient It does not detect low water conditions in other parts of the system Installation of high point vents or additional low water safety devices to protect the system should be considered Installation of external limit controls may be required by certain codes or in certain installations Review applicable local c
74. ter 4 remains active to shut down the boiler when the temperature in the boiler exceeds this value plus the high temp differential These voltage levels as explained above are all non adjustable 3 12 2 Gas Pressure Adjustment Note Adjustments shall only be performed by service representative specifically trained and certified to perform maintenance on the Patterson Kelley MACH Series boiler See rating plate for the minimum and maximum gas pressure of the boiler Each boiler is furnished with a manual shut off valve which has an integrated test port Series Gas Fired Boiler This port is located on the upstream side of the valve body for measuring supply pressure See figure below Gas Pressure Test Port 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 propane 3 12 3 Air Flow Adjustments The air flow is pre set at the factory prior to shipment In unusual situations the air gas ratio may have to be adjusted to obtain proper combustion readings for specific local conditions Combustion measurement instrumentation must be used to adjust the boiler for local conditions See instructions below Adjust the carbon dioxide CO or oxygen O2 reading to achieve conditions as listed in the following Table 3 1 3 12 4 Gas Valve Setup and Adjustment Note Verify gas pressure at inlet
75. the and buttons for three seconds MACH C300 amp C450 Required Tools 2 mm hex wrench Slotted screwdriver Combustion analyzer The MACH C300 and C450 boilers are equipped with two combined gas air control and gas safety shut off control valves The valves function in parallel with the variable speed combustion blower to supply the correct gas air ratio for optimum performance and efficiency The combustion blower speed is controlled automatically and determines the amount of negative pressure felt at the gas safety shut off control valves The gas valve servo regulators adjust gas flow for each valve to maintain zero pressure at the outlet nozzle of the associated valves Series Gas Fired Boiler Installation Table 3 1 Combustion Reading For Setting Gas Safety Shut Off Control Valves Nominal High Fire Setting Low Fire Setting Fuel Gas Pressure CO2 O2 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 Adjustment There must be sufficient load to operate the boiler at high fire to perform the following adjustments Start the boiler and observe proper operating parameters for the system Note The MACH C300 and C450 boilers are each equipped with two gas safety shut off control valves that operate in parallel When making any adjustment to the valves the adjustment must be performed
76. the ignition speed 7 After the 15 second prepurge the gas pressure switch circuit is checked to ensure the gas pressure is within design parameters 8 Ifthere are no lockouts then when the blower speed is within 200 rpm of the ignition fan speed a trial for ignition period of 3 seconds is initiated The internal spark generator and the gas safety shut off control valves are energized 9 The internal spark generator is de energized 3 seconds before the end of the trial for ignition period After the trial for ignition period if a flame signal is detected by the flame rectification system the control initiates a flame stabilization period of 5 seconds at the ignition rpm of the fan The fan is driven to low fire for 1 minute before the boiler is released to modulation Page 32 Maintenance 10 The unit modulates between the low fire setting and the high fire setting to maintain the desired outlet water temp set point 11 When the load is below the low fire rating of the boiler the boiler will continue firing and the outlet water temperature will rise until it reaches the set point temperature differential At this point the burner is turned off and the fan continues to run to post purge the boiler for 15 seconds 12 When the water temperature is reduced by the load on the system a heat request is again generated The operating sequence will recycle to step 6 provided the limits on water level gas pressure and hig
77. tion of the Low Fire adjustment is opposite of the High Fire as follows Clockwise rotation increases gas flow counterclockwise rotation decreases gas flow Adjustments to the offset pressure regulators should not exceed turn at a time before allowing the readings to respond and stabilize After proper low fire offset adjustment is made reinstall the slotted cap on the regulator Following all gas valve adjustments check for proper light off and verify correct fuel air mix and combustion quality throughout the entire firing range from lowest to highest fan speed High fire adjustment Low fire adjustment C750 900 10500 Adjusting Low and High Series Gas Fired Boiler 4 0 OPERATION 4 1 GENERAL 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 performance criteria were met with the gas manifold and control assembly provided on this boiler when the boiler underwent tests specified in ANSI Z21 13 CSA 4 9 latest edition See Factory Firetest label 4 2 NORMAL LIGHTING AND SHUT DOWN PROCEDURES If a fault is indicated please refer to Troubleshooting Section 5 5 to determine the cause of the fault prior to start up WARNING Do not use this boiler if any part has been
78. to Step 5 provided that the other limits are satisfied Low Gas Pressure The low gas pressure switch opens when there is or has been insufficient gas pressure available for proper operation of the boiler E 12 is shown on the display and burner operation is interrupted If a gas supply shut off valve is closed for any reason a low gas condition will result When gas pressure is restored E 12 will remain on the display panel and the boiler will remain locked out until the front panel reset button is pressed Once the control is reset the sequence returns to Step 5 provided that the other limits are satisfied High Gas Pressure The high gas pressure switch opens when there is or has been excessive gas pressure for the proper operation of the boiler An E 12 service code is displayed and the burner operation is interrupted When proper gas pressure is restored E 12 remains on the display with the boiler locked out until the front display panel reset button is pressed High Water Temperature When the boiler water has exceeded both the operating and high limit temperature the high limit switch opens and E 12 is shown on the display When the water temperature falls below the high limit temperature the boiler will remain locked out until the switch is Page 33 Maintenance manually reset and the front panel reset button is pressed Once the switch and the front panel are reset the sequence returns to Step 5 prov
79. ture Boiler Temperature Boiler Set Point Boiler Turns On 145 Time Domestic Priority If an indirect domestic hot water DHW tank is connected the DHW function of the boiler will activate when the DHW temperature controller supplied by others closes Terminal 5 to 8 TB 1 refer to Section 6 1 1 indicating a call for heat from the DHW system The parameters should be set as follows Page 22 Installation Item Parameter Value DHW Setpoint 1 140 DHW Setpoint Addition 33 30 DHW Status 2 1 DHW High Temp Differential 25 6 DHW Low Temp Differential 24 DHW Options 35 13 In the above example the boiler temperature will be set to the DHW Setpoint the DHW Setpoint Addition 140 F 30 F 170 F when the DHW temperature controller indicates a call for heat from the DHW system When the DHW system calls for heat the Central heat pump output Terminal 10 TB2 de energizes and the DHW pump output Terminal 11 TB2 energizes providing 120 VAC power is provided to energize a relay coil for the DHW pump The DHW status should be set to 1 DHW system ON Series Gas Fired Boiler OUTDOOR TEMP W FILTER HEAT REQUEST HEAT REQUEST INTERLOCK JUMPER CIRC PUMP PWM SIGNAL INTERLOCK JUMPER DHW TEMP SENSOR DUTOODR TEMP SENSOR DHW AQUASTAT TB Mo 115y C PMP CNTA 115VAC SW OUTPUT TER
80. uch systems and a qualified engineer or contractor must be consulted 2 0 SAFETY 2 1 GENERAL Safety 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 e Operated and serviced by qualified properly trained personnel in accordance with all applicable codes laws and regulations Note Each safety device must be maintained and checked per the recommended schedule refer to Section 5 1 of this manual 2 2 TRAINING The MACH Series gas fired boiler must be e Installed operated and serviced in accordance with instructions contained in this manual e Installed by qualified personnel in accordance with designs prepared by qualified facility engineers including structural mechanical electrical and other applicable disciplines Page 1 AA WARNING Improper use may result in fire or injury Read instructions safety manual before inst h operating 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 property damage serious injury or death Proper training is the best protection against accidents Operating and service personnel must be thoroughly familiar with the basic construction of the MACH Series boiler the u
81. z RMCI MODULE ama 2 8 2 Ps 4 115 NEUTRAL minor T 5 5 115 NEUTRAL z B8 2 1 28 1 m 6 GROUND s 25 26 E 7 GROUND 0 23 GND gt Ground a zu n a 5 ma 115 sw OUTPUT F 75 X 2 okt B To tac ewe cun Sio x 8 pke ns g kE 15 e TM Ti5wc DHW PMP 1 115 MASTER ALARM RY ng t ke 2 rx 2 2k e Hg MASTER ALARM RLY qH r SE z K3 l WAY VALVE RELAY Lc x 55 Ka 1 frg k3 2 55 n M 3 WAY VALVE RELAY Ima z og Te 1_ DAMPER RELAY gt ee __ 2 DAMPER RELAY E t 9 LR AS Page 41 Series Gas Fired Boiler 6 2 BOILER PARTS LIST Parts and Technical Support 6 2 1 Main Assembly MACH Series 750 900 1050 Mark Description Blower and Gas Train 1 Heat Engine Manifold System Return Boiler Outlet Boiler Gas Train Cabinet Control Panel Manifold System Supply Boiler Inlet High Temperature Aquastat AJU m Page 42 Series Gas Fired Boiler Parts and Technical Support 6 2 2 Control Panel Description AM 3 Relay Module Boiler Control MACH Series MCBA Transformer Low Water

Patterson-Kelley MACH-05 User's Manual

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