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P-K MACH 'n' Roll
CONDENSING INDIRECT DOMESTIC &
POOL WATER HEATING SYSTEM
Model Number:
Serial Number:
Start-Up Date:
Patterson-Kelley
155 Burson Street
East Stroudsburg, PA 18301
Telephone: 570.476.7261
Toll Free: 877.728.5351
Fax: 570.476.7247
www.pattersonkelley.com
The information in this manual is the property of Patterson-Kelley. The descriptions and specifications contained in this manual were in effect at the time this
manual was approved for publication. While Patterson-Kelley will continue to support earlier model boilers to within a reasonable time limit, we reserve the
right to discontinue models and replacement parts at any time or change specifications or design without notice and without incurring any obligation.
with NURO
™
MnR300-MnR399-MnR500
MnR750-MnR1050 for Indirect
Domestic Water Heating
&
MnRP300-MnRP399-MnRP500
MnRP750-MnRP1050 for
Indirect Pool Water Heating
Part # 1004905989
Revised: January 3, 2020
INSTALLATION
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INSTALLATION
INSTALLATION
INSTALLATION
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INSTALLATION
INSTALLATION
INSTALLATION
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& O W N E R'S
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Related Manuals for Patterson-Kelley MACH ‘n’ Roll with NURO Series
Summary of Contents for Patterson-Kelley MACH ‘n’ Roll with NURO Series
- Page 1 MANUAL The information in this manual is the property of Patterson-Kelley. The descriptions and specifications contained in this manual were in effect at the time this manual was approved for publication. While Patterson-Kelley will continue to support earlier model boilers to within a reasonable time limit, we reserve the...
- Page 2 ® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 NOTE: & THIS MANUAL IS A SUPPLEMENT TO THE APPLICABLE BOILER INSTALLATION & OWNER’S MANUAL PRIOR TO INSTALLATION, REFER TO THE ® MACH CM300-C1050 NURO INSTALLATION AND OPERATION MANUAL (2019) MnR300 & MnRP300 CM300 MnR399 &...
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Page 3: Table Of Contents
® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 Table of Contents ..INTRODUCTION ..........................VII ..SAFETY ..............................1 ........................1 ENERAL ........................2 RAINING ....................... 2 AFETY EATURES ......................2 AFETY ABELS ....................3 AFETY RECAUTIONS 2.5.1 Electrical Hazards ....................3 2.5.2 Burn, Fire, and Explosion Hazards................ -
Page 4: Oll ™ Recovery Performance
® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 3.9.2 Test of High Temperature Limit Aquastat ...............26 3.9.3 Test of Domestic Water Temperature Sensor ............26 3.9.4 Test of Operating Aquastat ..................26 ..NURO CONTROL SYSTEM SETUP ....................27 NURO C ................27 ONTROL YSTEM... -
Page 5: Introduction
® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 1 Introduction This manual describes the installation and operation ™ of the P-K MACH ‘n’ Roll If the information in this manual condensing indirect is not followed, fire or explosion domestic hot water and pool heating systems for use ®... -
Page 6: Safety
® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 2 Safety Installation and service must be 2.1 General performed by a qualified ™ The P-K MACH ‘n’ Roll MnR & MnRP models with installer, service agency, or gas sizes 300/399/500/750/1050 must be: supplier. -
Page 7: Training
If any of the provisions of this manual are not fully and completely understood, contact Patterson-Kelley Technical Service at 570.476.7261 or toll free at 877.728.5351. -
Page 8: Safety Precautions
® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 2.5 Safety Precautions Provide a suitable location for the P-K MACH ‘n’ Roll ™ system, away from normal personnel traffic, with adequate working space, adequate clearances, proper ventilation and lighting, with a structure sufficiently strong and rigid to support the weight of the boiler, P-K MACH ‘n’... -
Page 9: Chemical Hazards
® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 2.5.4 Chemical Hazards • Chemical hazards from cleaning products. Use caution when cleaning the system. The use of professional assistance is recommended. Use safe procedures for the disposal of all cleaning solutions. General Warning 2.5.5 Pressure Hazards •... -
Page 10: Compliance With Codes
150 psig. Therefore, the domestic side pressure must never exceed 150 psig. Patterson-Kelley recommends a pressure-only relief valve constructed and stamped in accordance with ASME Boiler and Pressure Vessel Code, Section VIII with a maximum 150 psig set pressure. Most MACH ‘n’... -
Page 11: Clearances (Mnr & Mnrp Sizes 300,399, & 500)
® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 NOTICE! The P-K MACH ‘n’ Roll ™ system may be installed on a combustible floor; however, it must never be installed on carpeting. 3.3.2 Clearances (MnR & MnRP sizes 300,399, & 500) Since the P-K MACH ‘n’... -
Page 12: Clearances (Mnr & Mnrp Sizes 750 & 1050)
36** * CSA minimum. Actual clearance depends upon venting requirements. ** Left-Side Service access (“D” Dimension) is helpful for routine maintenance access. Patterson-Kelley recommends equal clearance between each appliance when there is insufficient access at the rear to allow for service and adjustment ... -
Page 13: Expansion Tank & Fill System
® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 3.3.4 Expansion Tank & Fill System ™ Before making any mechanical connections to the P-K MACH ‘n’ Roll ® system or to the P-K MACH appliance, it is imperative that the expansion tank / fill system be checked for a suitable fill pressure. The expansion tank ships with a 12 psig precharge, but it is possible that air pressure may reduce during shipment. -
Page 14: Connecting To The Domestic Hot Water System (Mnr Indirect Domestic Water Heating Models)
® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 Connecting to the Domestic Hot Water System (MnR Indirect Domestic Water Heating Models) ™ The P-K MACH ‘n’ Roll ® is designed to occupy the space underneath the applicable P-K MACH appliance at the factory, but the 2”... -
Page 15: Domestic Hot Water Piping Connections (Mnr750-Mnr1050)
® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 3.4.2 Domestic Hot Water Piping Connections (MnR750-MnR1050) On the MnR750 & MnR1050, the domestic hot water piping connections (2” type L copper) are located at the left rear side of the unit as shown below: DHW SUPPLY (OUT) DHW RETURN (IN) ™... -
Page 16: Example Domestic Hot Water System Installation (Single Unit)
® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 3.4.3 Example Domestic Hot Water System Installation (Single Unit) It is important to note that the MACH ‘n’ Roll ™ is designed to operate in conjunction with a domestic ® water storage tank. From the initial call for heat, it takes approximately two minutes until the P-K MACH appliance operates at maximum power, so the storage tank needs to be sized appropriately for the application. -
Page 17: Example Domestic Hot Water System Installation (Multiple Units)
® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 sufficient to achieve an accurate tank temperature reading. If using a thermowell, thermal paste is recommended. 3.4.4 Example Domestic Hot Water System Installation (Multiple Units) The image below shows a sample piping arrangement for a typical domestic hot water system with two P-K MACH ‘n’... -
Page 18: Domestic Hot Water Piping Considerations
® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 3.4.5 Domestic Hot Water Piping Considerations ™ It is recommended to install the P-K MACH ‘n’ Roll system as close as possible to the domestic water storage tank in order to minimize the overall length of piping. The P-K MACH ‘n’ Roll ™... -
Page 19: Flushing The Domestic Water
® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 3.4.6 Flushing the Domestic Water ™ The P-K MACH ‘n’ Roll system features an expansion tank/fill valve assembly that provides water to the ® P-K MACH appliance and its piping. A dual-check valve ensures that the water in the appliance loop cannot re-enter the domestic loop. - Page 20 ® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 • STEP 6 – Open the stem of the appliance’s safety relief valve. • STEP 7 – If available, open the manual isolation valves in the domestic piping. This will fill the domestic side of the heat exchanger with water.
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Page 21: Connecting To The Pool Water System (Mnrp Indirect Pool Heating Models)
® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 Connecting to the Pool Water System (MnRP Indirect Pool Heating Models) 3.5.1 Pool Hot Water Piping Connections (MnRP300, 399, & 500) POOL SUPPLY (OUT) POOL RETURN (IN) Patterson Kelley 2020 Revised: January 3, 2020 1004905989 MnR &... -
Page 22: Pool Hot Water Piping Connections (Mnrp750 &1050)
® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 3.5.2 Pool Hot Water Piping Connections (MnRP750 &1050) POOL SUPPLY (OUT) POOL RETURN (IN) Patterson Kelley 2020 Revised: January 3, 2020 1004905989 MnR & MnRP 300-399-500-750- All Rights Reserved. Released: January 3, 2020 1050 NURO Rev C (Jan-2020).docx Page 17... -
Page 23: Example Pool Heating System (Single Unit)
® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 3.5.3 Example Pool Heating System (Single Unit) Patterson Kelley 2020 Revised: January 3, 2020 1004905989 MnR & MnRP 300-399-500-750- All Rights Reserved. Released: January 3, 2020 1050 NURO Rev C (Jan-2020).docx Page 18... -
Page 24: Example Pool Heating System (Multiple Units With Duration)
® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 3.5.4 Example Pool Heating System (Multiple Units with Duration) Patterson Kelley 2020 Revised: January 3, 2020 1004905989 MnR & MnRP 300-399-500-750- All Rights Reserved. Released: January 3, 2020 1050 NURO Rev C (Jan-2020).docx Page 19... -
Page 25: Pool Water Piping Considerations
® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 3.5.5 Pool Water Piping Considerations It is recommended the installer take into consideration the distance that the unit will be placed away from the pool. Since the intention of the pool package is to have the heat exchanger operate through the pool circulation pump loop, no additional MACH circulation pump is installed. -
Page 26: Filling Pool Water Side Of System
® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 3.5.7 Filling Pool Water Side of System Before filling the system, ensure all the mechanical connections are complete. Also, refer to the P-K ® MACH CM300 through C1050 NURO installation and operation manual to ensure the appliance’s pressure relief valve is installed correctly. - Page 27 ® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 ™ The P-K MACH ‘n’ Roll system requires 20 Amp, 120 VAC, single phase, 60 hertz electrical service. For added convenience, a 4”x4” electrical junction box is provided with “pigtails” for the hot, neutral, and ground leads.
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Page 28: Control Panel For The Circulating Pumps
® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 3.6.1 Control Panel for the Circulating Pumps Remove the lower front sheet metal panel of the MnR750-MnR1050 to reveal the pump control panel. On the MnR300-MnR399-MnR1050, the pump control panel is located on the left hand side of the lower frame. -
Page 29: High Voltage (Tb2) Terminal Block
® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 3.6.2 High Voltage (TB2) Terminal Block ® For P-K MACH appliances, the high voltage (TB2) terminal block has inputs for line voltage (120VAC) connections, all other connections are for pilot duty output use only. •... -
Page 30: Pre-Start Check List
® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 3.8 Pre-Start Check List Before attempting to start the P-K MACH ‘n’ Roll ™ ® system and P-K MACH appliance, ensure the following items have been completed. ® 1. Refer to the P-K MACH CM300 through C1050 NURO installation and operation manual to verify the gas piping is installed correctly. -
Page 31: Test Of High Temperature Limit Aquastat
® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 3.9.2 Test of High Temperature Limit Aquastat Ensure that a normally-closed high temperature limit aquastat is installed either in the domestic hot water, pool water supply piping or the domestic water storage tank. The normally-closed terminals MUST be wired to the appliance’s START INTERLOCK #1 terminals (TB2-7 &... -
Page 32: Nuro Control System Setup
® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 NURO CONTROL SYSTEM SETUP NURO Control System Overview ® ® The P-K MACH appliance is equipped with the NURO control which consists of 2 main components; the combustion and ® temperature controllers. The NURO is an intelligent control system with advanced features including a 7”... -
Page 33: Domestic Hotw
® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 4.2 Domestic Hot Water Setup Wizard From the Home Screen, press <SETTINGS> in the lower right corner to load the “Main Menu” screen shown to the right. Touch <Setup Wizard> to launch the “Setup Wizard”... -
Page 34: Domestic Hot Water Control (Aquastat In Storage Tank)
® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 4.2.1 Domestic Hot Water Control (Aquastat in Storage Tank) The next screen of the Setup Wizard allows the user to choose how the MACH ‘n’ Roll ™ system is controlled for Domestic Hot Water (DHW) operation. If the installation features a normally-closed (break ®... -
Page 35: Domestic Hot Water Control (Temperature Sensor In Storage Tank) - Preferred
® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 After the “DHW Boiler Setpoint Temperature”, “DHW Boiler Max Setpoint Temperature” and “Max DHW Boiler Temperature” values have been programmed, press <NEXT> to continue. The final screen of the Setup Wizard asks the user to adjust the “on differential”... -
Page 36: Sensor As An Aquastat
® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 Press <NEXT> to proceed to the next Setup Wizard screen, and refer to either Section 4.2.2.1 4.2.2.2. For Pool Heater models, program the NURO as Domestic Hot Water being the pool water values. 4.2.2.1 Sensor as an Aquastat If “Sensor as an Aquastat”... -
Page 37: On/Off Differentials
® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 4.2.2.2 Sensor for Remote Modulation If “Sensor for Remote Modulation” is selected, the next screen allows the user to adjust two settings: • DHW Tank Setpoint Temperature o This is the desired domestic hot water setpoint temperature to maintain in the storage tank. -
Page 38: Maintenance
® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 Maintenance 5.1 Maintenance and Inspection Schedule ™ This schedule applies when the MACH ‘n’ Roll is in use. Verify proper operation after servicing. Proper lockout/ tag out procedure must be employed when servicing this unit. -
Page 39: Annually
® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 • If applicable, verify the operating aquastat is functioning properly. 5.1.4 Annually • The brazed plate heat exchanger can scale up with calcium and other minerals present in the domestic water. This will inhibit heat transfer and it may be necessary to clean or replace the brazed plate heat exchanger. - Page 40 ® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 5.3 Troubleshooting Circulation Pump Deadhead Deadheading occurs when the circulation pump is unable to deliver any flow. Ensure that any isolation valves installed in the system are OPEN. It may be necessary to slightly restrict isolation valves on the pump discharge to achieve the desired flow rate, but they should never be completely closed unless the unit is turned off and being serviced.
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Page 41: Parts/Technical Support
Technical Service 1.877.728.5351 6 Parts/Technical Support Spare parts and replacement parts can be ordered from 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 manual. Technical information is also available at the above number and at the -Kelley website www.pattersonkelley.com. -
Page 42: Peration
® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 ™ NOTE: The power distribution on the P-K MACH ‘n’ Roll system provides power to the circulation ® pumps as well as to the P-K MACH appliance. This allows the user to bring a single code-compliant disconnect to the 4”x4”... - Page 43 ® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 Patterson Kelley 2020 Revised: January 3, 2020 1004905989 MnR & MnRP 300-399-500-750- All Rights Reserved. Released: January 3, 2020 1050 NURO Rev C (Jan-2020).docx Page 38...
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Page 44: M N R300, 399, & 500 C
® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 6.3 MnR300, 399, & 500 Components Description Electrical Assembly / Pump Control Panel • 10-0510-0878 Appliance Return Coupling (1-1/2” Victaulic #72) • 26-5000-0101 Expansion Tank • 86-8560-0100 Appliance Supply Coupling (1-1/2” Victaulic #72) •... -
Page 45: M N R750 & 1050 C
® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 6.4 MnR750 & 1050 Components – Appliance Side Mark Description Automatic Air Vent (1/2” NPT-M) • 10-0490-7147 Appliance Supply Coupling (2” Victaulic #72) • 10-0490-7730 90° Elbow (2” Victaulic) – QTY 4 •... -
Page 46: Recovery Performance Data
® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 7 RECOVERY PERFORMANCE DATA ™ 7.1 P-K MACH ‘n’ Roll Recovery Performance Data at 40F MACH 'n' Roll Recovery Rates from 40°F MnR1050 3000 2957 MnR750 MnR500 2500 MnR399 MnR300 1978 2000 1474 1500... -
Page 47: R P Data 50F
® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 7.2 P-K MACH ‘n’ Roll ™ Recovery Performance Data at 50F MACH 'n' Roll Recovery Rates from 50°F MnR1050 4000 3944 MnR750 3500 MnR500 MnR399 3000 MnR300 2374 2500 2000 1685 1500 1276 1121... -
Page 48: R P Data 60F
® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 7.3 P-K MACH ‘n’ Roll ™ Recovery Performance Data at 60F MACH 'n' Roll Recovery Rates from 60°F MnR1050 4000 3950 MnR750 3500 MnR500 MnR399 2968 3000 MnR300 2500 1967 2000 1436 1500 1144... -
Page 49: Data At 70F
® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 7.4 P-K MACH ‘n’ Roll ™ Recovery Performance Data at 70F MACH 'n' Roll Recovery Rates from 70°F MnR1050 4000 3937 MnR750 3500 MnR500 MnR399 3000 MnR300 2500 2335 2000 1641 1500 1271 1094... -
Page 50: Data At 80F
® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 7.5 P-K MACH ‘n’ Roll ™ Recovery Performance Data at 80F MACH 'n' Roll Recovery Rates from 80°F MnR1050 4000 3925 MnR750 3500 MnR500 MnR399 2951 3000 MnR300 2500 1915 2000 1430 1500 1153... -
Page 51: P P D
® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 ™ 7.6 P-K MACH ‘n’ Roll Pool Performance Data Pool Size with Respect to Equipment Size 20°F Rise 25°F Rise Correction Factor Correction Factor 12.5 4.25 Heat Time (Hours) Heat Time (Hours) Pool Size (thousands of gallons) Pool Size (thousands of gallons) 1050... -
Page 52: (Mach & Roll) Specific Limited Warranty
(MACH & ROLL) SPECIFIC LIMITED WARRANTY Subject to the terms and conditions herein and the Terms and Conditions of Sale (as defined herein), Patterson-Kelley (“Seller”) warrants to the purchaser of the product (“Buyer”) that the heat exchanger and burner are free of defects in material and workmanship, when operated... - Page 53 ® P-K MACH Gas Fired Appliance Technical Service 1.877.728.5351 (iii) 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 heating media, fuels or settings other than those set forth on the rating plate or accidental or exterior damage;...
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