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PATTERSON-KELLEY
MACH C1500/C2000
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
LMACH- 07
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Related Manuals for Patterson-Kelley MACH C1500
Summary of Contents for Patterson-Kelley MACH C1500
- Page 1 LMACH- 07 PATTERSON-KELLEY MACH C1500/C2000 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...
- Page 2 MACH® Series Gas-Fired Boiler Table of Contents...
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Page 3: Table Of Contents
MACH® Series Gas-Fired Boiler Table of Contents 1.0 INTRODUCTION ........1 3.6.12 Removing an Existing Boiler ....12 3.7 Gas Piping ............13 2.0 SAFETY............1 3.7.1 Gas Supply Piping by Installer ....15 2.1 General ..............1 3.8 Boiler Water Piping..........15 2.2 Training..............1 3.8.1 Piping Design .........15 2.3 Safety Features ..........2 3.8.2 Boiler Inlet and Outlet Connections .. - Page 4 The same features which permit this boiler to achieve trained on the Patterson-Kelley MACH Boiler. high-efficiency performance make it unlike most other boilers of this general size, so it is important to understand how this boiler operates.
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Page 5: Introduction
Proper training is the best protection against accidents. Operating and service personnel must be 2.0 SAFETY thoroughly familiar with the basic construction of the P-K MACH C1500/C2000 boiler, the use and 2.1 G ENERAL locations of the controls, the operation of the boiler,... -
Page 6: Safety Features
Although the labels are of high quality, they When opening leak test valves, always follow instructions in may become dislodged or unreadable over time. operation and safety manual. Contact Patterson-Kelley toll-free at (877) 728-5351 1998 HCS, Inc. 800-748-0241 Reorder No. 8032-01NHPK for replacement labels. •... -
Page 7: Crush Hazards
MACH® Series Gas-Fired Boiler Installation • • Fire and explosion hazards! Do not store or use Overfire and underfire hazards! Possible fire, gasoline or other flammable vapors or liquids in explosion, overheating, and component failure. the vicinity of this or any other gas fired appliance. Do not attempt to adjust firing rate of the boiler. -
Page 8: Chemical Hazards
MACH® Series Gas-Fired Boiler Installation 2.5.4 Chemical Hazards 2.5.6 Slip, Fall Hazards General Warning General Warning • Tripping hazard! Do not install piping on floor • Chemical hazards from cleaning products. Use surfaces. Maintain clear path around boiler. caution when cleaning the system. The use of •... -
Page 9: Installation
3.2 C OMPLIANCE WITH ODES The P-K MACH C1500/C2000 Boiler with standard Lifting the front of the boiler slightly will allow the components and options complies with American boiler to be rolled off the shipping skid onto the National Standard/CSA Standard ANSI Z21.13/CSA... -
Page 10: Clearances
MACH® Series Gas-Fired Boiler Installation bolts may be removed allowing the wheels to recess up Minimum Clearances from Adjacent Walls, into the boiler. The base will sit flat on the provided Ceiling, and Obstructions (shown above &below) foundation. If the boiler is to be pulled out for maintenance, the wheels may be left attached. -
Page 11: Combustion Air
MACH® Series Gas-Fired Boiler Installation requires less than 15 amps. Before starting the boiler, compounds, most commonly present as refrigerants check to ensure that the proper electrical service is or solvents, such as freon, trichlorethylene, connected to the boiler. perchlorethylene, chlorine, etc. These chemicals, when burned, form acids which quickly attack the An external electrical disconnect (not supplied with boiler and the boiler stack. -
Page 12: Flue Venting
MACH® Series Gas-Fired Boiler Installation • 3. Motorized louvers shall be interlocked with the When rooms are on different floors, each opening appliance so that they are proven open prior to shall have an area equal to 2 square inches for main burner ignition and operation. -
Page 13: Barometric Damper
MACH® Series Gas-Fired Boiler Installation Vent design calculations should be based on a This boiler should not be connected into any portion maximum of 0.44" W.C. combined frictional of another mechanical draft system without resistance across the air inlet duct and the stack, with a consulting your venting manufacturer. -
Page 14: Vertical Vent Systems
To prevent the possible re-circulation of flue gases, the vent designer must take into consideration such things as prevailing winds, eddy zones, building configurations, etc. Patterson-Kelley Co. 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. -
Page 15: Direct Vent (Sealed Combustion) Systems
(1.22 m) horizontally from any electric of gas meter, regulator or relief equipment. 3.6.7 Sidewall Venting with Sealed Combustion The MACH C1500/C2000 Boilers are certified for direct sidewall venting with a sidewall air inlet only. Both the air inlet and the exhaust vent must terminate Vent Installation Details... -
Page 16: Intake Duct Materials And Sizes
MACH® Series Gas-Fired Boiler Installation 3.6.8 Intake Duct Materials and Sizes: At the time of removal of an existing boiler, while the other appliances remaining connected to the common Material: PVC, CPVC, single wall galvanized steel, or venting system are not in operation, the following other suitable materials. -
Page 17: Gas Piping
MACH® Series Gas-Fired Boiler Installation 3.7 G IPING RECOMMENDED GAS PIPING INSTALLATION Before making the gas hook-up, make sure the boiler is being supplied with the type of fuel shown on the Remote Gas boiler nameplate. Supply Shutoff The boiler shall be installed such that the gas ignition system components are protected from water (dripping, spraying, rain, etc.) during appliance Drip Leg... -
Page 18: Gas Supply Piping By Installer
MACH® Series Gas-Fired Boiler Installation Pipe Capacity for Natural Gas 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 (in feet) Size Diameter 90º... -
Page 19: Boiler Inlet And Outlet Connections
Victaulic Style Couplings. These temperature at the boiler. Consult your authorized coupling must be used with the EPDM Victaulic Patterson-Kelley boiler representative for application seals. Adapters from Victaulic to NPT are guidance. available from the factory. Isolating valves must be installed in both water connections for ease of service. -
Page 20: Boiler Water Piping By Installer
Water Quality down and a flashing E 12 service code will be The MACH C1500/C2000 boiler heat exchanger is displayed on the control panel. The low water cutoff made of an aluminum alloy. The heat exchanger... -
Page 21: Burner And Ignition System
MACH® Series Gas-Fired Boiler Installation untreated make-up water may cause premature failure IMPORTANT! due to buildup of scale; such failure is not covered by warranty. If the piping system attached to this unit will be chemically cleaned, the boiler must be Scale can also reduce efficiency. -
Page 22: Safety Checks
3.11.1 Test of Ignition Safety System resetting the boiler at the display panel. Readjust the MACH C1500/C2000 high-limit thermostat to the desired setpoint. Test the ignition system safety shutdown as follows: 3.11.4 Test of Gas Pressure Switch 1. -
Page 23: Initial Adjustments
MACH® Series Gas-Fired Boiler Installation High Gas Pressure Switch The MACH® C1500/C2000 boiler is equipped with a The boiler is furnished with a high pressure switch that combination combustion and temperature control. must be checked by closing the downstream gas cock This control monitors combustion and lighting of the with the boiler off. - Page 24 MACH® Series Gas-Fired Boiler Installation Standby Mode: Parameter Mode: The display defaults to this mode at startup or reset of The parameter mode is used to change the settings of the control. If no key is pressed for 20 minutes the the boiler.
- Page 25 MACH® Series Gas-Fired Boiler Installation The boiler will modulate to try to maintain 160° F. If Step Value the temperature increases above 169° F which is the Outlet water temp setpoint 160° F + High Temp Differential 9°F the Inlet water temp boiler will shut off.
- Page 26 MACH® Series Gas-Fired Boiler Installation Outdoor Air Reset (optional): TB2) energizes providing 120 VAC power is provided to energize a relay coil for the DHW pump. The OU TD OO R A IR vs B OILER SETP O IN T DHW status should be set to 1 (DHW system ON).
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Page 27: Burner Setup
MACH® Series Gas-Fired Boiler Installation above settings. Using the values in the table above, tables values are used the boiler setpoint will be 80° F the boiler setpoint will be 80° F when the outdoor air when the voltage is anything less than approximately 3 temperature is 70°... -
Page 28: Gas Pressure Adjustment
MACH® Series Gas-Fired Boiler Installation adjusted to obtain proper combustion readings for specific local conditions. 3.12.3 Gas Pressure Adjustment Combustion measurement instrumentation must be Note: Adjustments shall only be performed by used to adjust the boiler for local conditions (See qualified and knowledgeable installer or service instructions below). - Page 29 MACH® Series Gas-Fired Boiler Installation Low Fire Setting Adjustment: Set boiler to the “Test Mode Low”, as described There must be sufficient load to operate the boiler at above, to achieve minimum firing rate of the boiler. high fire to perform the following adjustments. Check combustion readings using the combustion analyzer.
- Page 30 MACH® Series Gas-Fired Boiler Installation C1500/C2000 Adjusting Low and High Analyzer probe in boiler exhaust High fire adjustment Low fire adjustment Table 3-1 Combustion Reading For Setting Gas Safety Shut Off / Control Valves Nominal High Fire Setting Low Fire Setting Fuel Gas Pressure % CO...
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Page 31: Operation
MACH® Series Gas-Fired Boiler Operation 4.0 OPERATION 4.2.1 Lighting Procedures 1. Close main gas valve. 4.1 G ENERAL 2. Turn On-Off switch to "OFF" position. 3. Wait 5 minutes. 4.1.1 Control Panel Front 4. Open main gas valve. 5. Turn On-Off switch to "ON" position. 6. - Page 32 MACH® Series Gas-Fired Boiler Operation 4.3 T YPICAL OILER PERATING ONDITIONS Model Input Total Natural Gas Number Rating Amperage (1030 Btu/cu. ft.*) (BTU/Hr) Gas Rate Output Capacity (CFH) (Btu/hr) C1500 1,500,000 Less than 15 1456* 1,440,000 C2000 2,000,000 Less than 15 1942* 1,920,000 Note: The heat exchanger is constructed and stamped...
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Page 33: Maintenance
Installation and service must be performed by a qualified and knowledgeable installer or service Observe operating temperature and general conditions. agency who has been trained on the Patterson-Kelley Make sure that the flow of combustion and ventilating MACH boilers. air to the boiler is not obstructed. Determine the cause of any service codes or lockouts on the display panel. -
Page 34: Semi-Annually (Required For Boilers Operated Year Round)
This procedure is qualified installer or service agency who has been available on request from the PK Factory. trained on the Patterson-Kelley MACH boiler. Installation and service must be performed by a The blower motor is permanently lubricated and does qualified installer or service agency who has been not require periodic lubrication. -
Page 35: After All Repairs Or Maintenance
MACH® Series Gas-Fired Boiler Maintenance 5.3 A FTER EPAIRS OR AINTENANCE 9. When the load is below the minimum firing rate of 1. Follow "Pre-Start Check List" (Section 3.10) and the boiler, the boiler will continue firing and the all "Safety Checks" (Section 3.11). outlet water temperature will rise until it reaches the set point + temperature differential. -
Page 36: Troubleshooting
MACH® Series Gas-Fired Boiler Maintenance 5.5 T ROUBLESHOOTING WARNING If any “Manual Reset” limit device trips, DO NOT reset without determining and correcting the cause. (Manual Reset Limits include: Flame safeguard, high or low gas pressure, high temperature limit) Loss of Water Level The MACH®... - Page 37 MACH® Series Gas-Fired Boiler Maintenance High Water Temperature When the boiler water has exceeded the high water temperature limit setting, the high limit switch opens Air Switch Closed and locks out. The control shows E 02 on the display. If the display panel indicates b 61, the air pressure When the water temperature falls below the high-limit switch did not open when the blower was shut off.
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Page 38: Manual Reset Service Codes
MACH® Series Gas-Fired Boiler Maintenance 5.5.1 Manual Reset Service Codes Code Lockout Description E 00 False flame. A flame signal is present when it shouldn’t be. E 02 Flame failure. The burner did not light on startup, or loss of flame during run or high temp limit tripped. E 03 Gas Valve Relay Board error. -
Page 39: Auto-Reset Service Codes
MACH® Series Gas-Fired Boiler Maintenance 5.5.2 Auto-reset Service Codes Code Lockout Description b 08 Air pressure switch open. The air pressure switch failed to close to indicate sufficient air flow to start the boiler. b 24 Switched inlet / outlet. The inlet water temperature has been more than 18°... -
Page 40: Parts/Technical Support
Spare parts and replacement parts can be ordered from 6.1 S CHEMATIC IAGRAMS Patterson-Kelley by calling toll free (877) 728-5351. The fax number is (570) 476-7247. Refer to the parts list shown on the assembly drawing provided in this Typical schematic drawings are shown on the manual. -
Page 41: Wiring Diagrams
MACH® Series Gas-Fired Boiler Parts and Technical Support 6.2 W IRING IAGRAMS 6.2.1a Terminal Block Assignments – High Voltage Circuit (TB2) Terminal Number Label Description 115 VAC LINE Boiler Supply Power, 115 VAC, 60 HZ, 1 ph, 8 amp 115 VAC NEUTRAL 115 VAC NEUTRAL Aux. -
Page 42: Terminal Block Assignments - Low Voltage Circuit (Tb1)
MACH® Series Gas-Fired Boiler Parts and Technical Support 6.2.1b Terminal Block Assignments – Low Voltage Circuit (TB1) Terminal Number Label Description HEAT REQUEST Boiler Enable, Contact Closure. DO NOT ENERGIZE. HEAT REQUEST INTERLOCK JUMPER External Limit (auto reset), Contact Closure. DO NOT ENERGIZE. -
Page 43: Wiring Diagram For Series C-1500/C-200042
MACH® Series Gas-Fired Boiler Parts and Technical Support 6.2.2 Wiring Diagram for Series C-1500/C-2000 Page 39... -
Page 44: Boiler Parts List
MACH® Series Gas-Fired Boiler Parts and Technical Support 6.3 B OILER ARTS 6.3.1 Main Assembly Mark Description Cabinet Top Boiler Outlet Boiler Inlet Blower/Burner Assembly Front Control Panel Cabinet Page 40... -
Page 45: Control Panel
MACH® Series Gas-Fired Boiler Parts and Technical Support 6.3.2 Control Panel Gas Valve Relay Board (GVRB) Mark Description Terminal Block 1 (TB1) 120V 120V/24V Transformer High Temperature Limit Low Water Cut Off (LWCO) Terminal Block 2 (TB2) Low V AM3 Relay Board Air Switch (on back) 10 Amp Circuit Breaker High Exhaust Back Pressure Switch... -
Page 46: C1500/C2000 Heat Engine
MACH® Series Gas-Fired Boiler Parts and Technical Support 6.3.3 C1500/C2000 Heat Engine MARK DESCRIPTION Blower Outlet Gasket Blower Outlet Transition Burner Gasket Burner Ignition Sight Glass Window Outlet Water Manifold Heat Exchanger Sectional Castings Relief Vavle Inlet Water Connection Boiler Drain Valve Condensate Collector w/Rear Drain Inlet Flow Pipes Page 42... -
Page 47: C1500/C2000 Gas Train
MACH® Series Gas-Fired Boiler Parts and Technical Support 6.3.4 C1500/C2000 Gas Train Mark Description Burner Burner Gasket Blower Outlet Transition Piece Blower Outlet Gasket Blower Automatic Gas Valve Main Gas Shutoff Valve High & Low Gas Pressure Switches Secondary Manual Shutoff Vavle Gas Valve Sensing Line Venturi Page 43... -
Page 48: Limited Warranty
LIMITED WARRANTY with the unit Subject to the terms and conditions herein, Patterson-Kelley Co., 2. Adverse local conditions in general and, specifically, Seller, warrants to the original owner at the original installation site sediment or lime precipitation in the tubes and/or headers that products manufactured by Seller will be free from defects in or corrosive elements in the atmosphere. - Page 49 MACH® Series Gas-Fired Boiler Limited Warranty Page 45...
- Page 50 MACH® Series Gas-Fired Boiler Appendix Page 46...
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Page 51: Appendix
MACH® Series Gas-Fired Boiler Appendix 8.0 APPENDIX Date Hi/Low Stack Action Fire Temp Page 47...