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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
Boilers
Installation Date:
_______________________
100 Burson Street, P.O. Box 458,
East Stroudsburg, PA 18301
Telephone: (877) 728-5351, Facsimile: (570) 476-7247
www.pkboilers.com
MACH-05
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Related Manuals for Patterson-Kelley MACH-05
Summary of Contents for Patterson-Kelley MACH-05
- Page 1 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 Boilers Installation Date: _______________________ 100 Burson Street, P.O.
- Page 2 MACH® Series Gas-Fired Boiler...
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Page 3: Table Of Contents
3.6.8 Intake/Exhaust Layout ...10 3.6.9 Intake Duct Materials and Sizes: ...12 3.6.10 Sealing the Intake Duct...12 3.6.11 Intake Duct Connection to Boiler ... 12 3.6.12 Intake Duct Terminations ... 12 3.6.13 Vent Elbows ... 13 3.7 Gas Piping ... 13 3.7.1 Gas Supply Piping by Installer ... - Page 4 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: • Do not try to light any appliance.
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Page 5: Introduction
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 such systems and a qualified engineer or contractor must be consulted. -
Page 6: Safety Labels
Reorder No. 5025-V1WHPK 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 S AFETY... -
Page 7: Crush Hazards
• 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. 2.5.3 Crush Hazards •... -
Page 8: Pressure Hazards
1998 HCS, Inc. 800-748-0241 • Pressure hazard! Hot fluids. Install isolation valves on boiler water inlet and outlet. Make sure isolation valves are closed before servicing boiler. • Pressure hazard! Hot fluids. Annually test safety relief valve for proper operation. Do not operate boiler with faulty relief valve. -
Page 9: Installation
Claims for hidden damages must be filed with your carrier within 7 days. The boiler carton is equipped with a “Tip (N) Tell”. If "Tip (N) Tell” arrow point is blue, that indicates that the package has been on its side or tipped over in transit. -
Page 10: Clearances
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. -
Page 11: Combustion Air
These chemicals, when burned, form acids which quickly attack the 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... -
Page 12: Flue Venting
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 inches for a 450,000 Btu per hour.) 3.6 F ENTING This boiler requires a special vent system. -
Page 13: Vent Terminations
MACH® 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. Direct vent terminal clearance minimum 12 in. 4 ft. min. 4 ft. min. -
Page 14: Sealed Combustion Air/Venting System
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... - Page 15 MACH® Series Gas-Fired Boiler Roof Sidewall Inlet, Roof Vent Exhaust Vent (Sidewall venting requires vertical tee termination.) Air Inlet (Tee mounted horizontal.) Sidewall Inlet and Vent Exhaust Vent (type of (Type of flue termination flue termination optional when roof venting.) optional when roof venting.)
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Page 16: Intake Duct Materials And Sizes
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 90º angles. Seal the joint. 3.6.12 Intake Duct Terminations... -
Page 17: Vent Elbows
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, control replacement, etc.) -
Page 18: Gas Supply Piping By Installer
7.67 4.026 10.1 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... -
Page 19: Boiler Inlet And Outlet Connections
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... -
Page 20: Boiler Water Piping By Installer
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. -
Page 21: Burner And Ignition 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. -
Page 22: Pre-Start Check List
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. -
Page 23: Test Of Low Water Cut-Out
The display will flash E-02 indicating a flame failure. The E-02 lockout will remain until reset on the display. After completing this test, turn off the boiler and open the downstream manual isolation 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. -
Page 24: Initial 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 in the standby level. - Page 25 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 times until the display shows PArA. The parameters are selected with the STEP key, and changed with the plus “+”...
- Page 26 169° 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 –...
- Page 27 Boiler Shutoff Temp. Outdoor Air Offset Boiler Configuration The set point of the boiler is controlled by an outdoor temperature sensor. As the outdoor temperature falls the setpoint of the boiler is increased. The boiler modulates to maintain this setpoint.
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Page 28: Gas Pressure Adjustment
0 to 10 VDC signal. At a voltage greater °F Range °F than 0.5 VDC the boiler turns on and runs at low fire 68-185 until 1.8 VDC is reached. The firing rate increases linearly with voltage until high fire is reached at 10 60-140 VDC. -
Page 29: Air Flow Adjustments
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 “+”... - Page 30 Fuel Natural Gas Propane 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.
- Page 31 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.
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Page 32: Operation
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 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 33: Emergency Shut-Off
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. ONDITIONS LP Gas **(2500 Btu/cu. ft.) -
Page 34: Maintenance
Notify responsible individuals for required corrective action or repair. WARNING! Check daily to be sure that the boiler area is free and clear of any combustible materials, including CHEDULE flammable vapors and liquids. 5.1.2 Weekly Observe the conditions of the main flame. -
Page 35: Semi-Annually (Every 6 Months)
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. -
Page 36: Sequence Of Operation
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. - Page 37 Loss of Water Level The low water switch opens when there is insufficient water level in the boiler. E 12 is shown on the display, and burner operation is interrupted. When the correct water level is re-established, pushing the reset button will return the sequence to Step 5, provided that the other limits are satisfied.
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Page 38: Manual Reset Service Codes
Call for service. Call for service. Call for service. The air pressure switch failed to close to indicate sufficient air flow to start the boiler. Call for service. One of the external limits has opened. (High/Low Gas Pressure, High Temp, Low water). -
Page 39: Auto-Reset Service Codes
If any “Manual Reset” limit device trips, reset without determining and correcting the cause. The air pressure switch failed to close to indicate sufficient air flow to start the boiler. The outlet water temperature has exceeded the internal high limit temperature setting. -
Page 40: Parts/Technical Support
Parts and Technical Support 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. -
Page 41: Wiring Diagrams
MASTER ALARM RELAY THREE WAY VALVE RELAY THREE WAY VALVE RELAY DAMPER RELAY DAMPER RELAY Label Boiler Supply Power, 115 VAC, 60 HZ, 1 ph, 8 amp Aux. Switched Output Boiler Circ. Pump DHW Circ. Pump Boiler Supply Ground Aux .Ground Aux. -
Page 42: Terminal Block Assignments - Low Voltage Circuit (Tb1)
MACH® Series Gas-Fired Boiler 6.1.1a Terminal Block Assignments – Low Voltage Circuit (TB1) Terminal Number HEAT REQUEST HEAT REQUEST INTERLOCK JUMPER INTERLOCK JUMPER DHW TEMP. SENSOR OUTDOOR TEMP SENSOR CIRC. PMP PWM SIGNAL COMMON COMMON O-10 V ANAL. INPUT CONTROL Remote control of firing rate or setpoint. -
Page 43: Wiring Series C-300
MACH® Series Gas-Fired Boiler Parts and Technical Support 6.1.2 Wiring Series C-300 Page 39... -
Page 44: Wiring Series C-450
MACH® Series Gas-Fired Boiler Parts and Technical Support 6.1.3 Wiring Series C-450 Page 40... -
Page 45: Wiring Series C-750/900/1050
MACH® Series Gas-Fired Boiler Parts and Technical Support 6.1.4 Wiring Series C-750/900/1050 Page 41... -
Page 46: Boiler Parts List
6.2 B OILER ARTS 6.2.1 Main Assembly MACH Series 300/450 Mark Description Blower and Gas Train Manifold, System Return, Boiler Outlet Manifold, System Supply, Boiler Inlet Cabinet High Temperature - Aquastat MACH Series 750/900/1050 Mark Description Heat Engine Boiler Gas Train... -
Page 47: Control Panel
MACH® Series Gas-Fired Boiler 6.2.2 Control Panel Mark Description AM-3 Relay Module Boiler Control MACH Series - MCBA Transformer Low Water Cutoff Control Mounting Plate Page 43 Parts and Technical Support... -
Page 48: Display Panel
MACH® Series Gas-Fired Boiler 6.2.3 Display Panel Mark Description Circuit Breaker Air Pressure Switch Fastening Clip Display Panel On/Off Switch Pressure Temperature Gauge Panel Sheet Metal Stack Pressure Switch Page 44 Parts and Technical Support... -
Page 49: C-300/450 Heat Engine
Sight Glass Holder Exhaust Pipe Lip Ring Exhaust Manifold Inspection Cover Gasket Inspection Cover Gasket (Header Gasket) Boiler Outlet / Supply Manifold Boiler Inlet / Return Manifold Condensate Trap Manifold Mounting Plate Thermistor (Temperature Sensor) Page 45 Parts and Technical Support... -
Page 50: C-750/900/1050 Heat Engine
Heat Exchanger Sectional Castings Exhaust Pipe Lip Ring Condense Collector / Exhaust Manifold Inspection Cover & Gasket Manifold Gaskets Boiler Outlet / Supply Manifold Boiler Inlet / Return Manifold Condensate Trap Manifold Mounting Plate Page 46 Parts and Technical Support... -
Page 51: C-300 Boiler Gas Train
MACH® Series Gas-Fired Boiler 6.2.6 C-300 Boiler Gas Train Mark Description Main Gas Shut-off Valve Low Gas Pressure Switch Gas Safety Shut-off/Control Valve Air/Gas Manifold Swirlplate Blower Gas Leak Test Port Flex Hoses w/ Gas Valve Adaptors Page 47 Parts and Technical Support... -
Page 52: Boiler Gas Train
MACH® Series Gas-Fired Boiler 6.2.7 C-450 Boiler Gas Train Mark Description Main Gas Shut-off Valve Low Gas Pressure Switch High Gas Pressure Switch Gas Safety Shut-off/Control Valve Gas Manifold Shut-off Valve Air/Gas Manifold Swirlplate Blower Gas Leak Test Port Flex Hoses with Gas Valve Adapters... -
Page 53: C-750/900/1050 Boiler Gas Train
MACH® Series Gas-Fired Boiler 6.2.8 C-750/900/1050 Boiler Gas Train Mark Description Main Gas Shut-off Valve Low Gas Pressure Switch High Gas Pressure Switch Gas Safety Shut-off/Control Valve Gas Manifold Shut-off Valve Flex Hose with Gas Valve Adaptor Venturi Premix Combustion Blower... -
Page 54: 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... - Page 55 MACH® Series Gas-Fired 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,...
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Page 56: Appendix
MACH® Series Gas-Fired Boiler Appendix 8.0 APPENDIX Date Hi/Low-Fire Stack Temp Action Page 52...