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Harsco Industrial MACH C1500GG Installation & Owner's Manual

Gas-fired dual fuel boiler natural gas or propane
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MACH® GAS-FIRED BOILER
C1500GG & C2000GG
Dual Fuel Boiler
Natural Gas or Propane
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 Harsco Industrial, Patterson-Kelley
C.S.A Design-Certified
Complies with ANSI Z21.13/CSA 4.9
Gas-Fired Low Pressure Steam and Hot Water
Boilers
Model #: ______
Start-up Date:
_______________________
Harsco Industrial, Patterson-Kelley
100 Burson Street,
East Stroudsburg, PA 18301
Telephone: (570) 476-7261
Facsimile: (570) 476-7247
www.harscopk.com
©2011 Harsco Industrial, Patterson-Kelley
Printed : 4/28/2011
Serial #: ______________________
MACH® C1500GG-C2000GG
Rev. 1.01 (4/28/11)

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  • Page 1 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 Harsco Industrial, Patterson-Kelley C.S.A Design-Certified Complies with ANSI Z21.13/CSA 4.9 Gas-Fired Low Pressure Steam and Hot Water Boilers Model #: ______...

  • Page 2: Table Of Contents

    MACH® Gas-Fired Boiler INTRODUCTION ....................4 SAFETY ......................4 General.......................... 4 Training ......................... 4 Safety Features ......................5 Safety Labels ........................ 5 Safety Precautions ......................6 INSTALLATION ....................8 Receiving and Storage ....................8 Compliance with Codes ....................8 Setup ..........................9 Electrical Connections....................
  • Page 3 MACH® Gas-Fired Boiler 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 If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

  • Page 4: Introduction

    Harsco Industrial, Patterson-Kelley cannot be responsible for the design or operation of such systems and a qualified engineer or contractor must be consulted.

  • Page 5: Safety Features

    1998 HCS, Inc. 800-748-0241 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 Harsco Industrial, Patterson-Kelley toll-free at (877) 728-5351 for replacement labels.

  • Page 6: Safety Precautions

    MACH® Gas-Fired Boiler AFETY RECAUTIONS 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 sufficiently strong and rigid to support the weight of the boiler, all piping, and accessories.
  • Page 7 General Warning must be in accordance with all applicable regulations. A condensate neutralization kit is available. Please contact your local Harsco Industrial, Patterson-Kelley representative. 2.5.5 Pressure Hazards Pressure hazard! Hot fluids. Install isolation valves on boiler water inlet and outlet.

  • Page 8: Installation

    MACH® Gas-Fired Boiler 3.0 INSTALLATION Installation and service must be performed by a qualified installer, service agency, or gas supplier. ECEIVING AND TORAGE 3.1.1 Initial Inspection Upon receiving the boiler, inspect it for signs of shipping damage. Since some damage may be hidden, we recommend unpacking the boiler, removing the top, front, and side covers and inspect the boiler.

  • Page 9: Setup

    MACH® Gas-Fired Boiler ETUP 3.3.1 Foundation Provide a firm, level foundation, preferably of concrete. NOTICE! The boiler may be installed on a combustible floor, however the boiler must never be installed on carpeting. 3.3.2 Placement The wheels provided with this boiler are for positioning purposes only. When positioning this boiler, maintain positive control of it at all times.

  • Page 10: Electrical Connections

    MACH® Gas-Fired Boiler † "C" Space required for pipes, ducts, etc. in this area above Type of Surface Dimensions (inches) the boiler. C† * Clearance depends upon exhaust vent configuration. ** Service access is required on left side of boiler to facilitate Combustible Surfaces boiler maintenance.
  • Page 11 The outdoor air sensor and programming help are available from the local Harsco Industrial, Patterson-Kelley Representative. This circuit is energized by the boiler with a 5V potential. The temperature sensor must be a NTC having 12k@25°C.

  • Page 12: Inlet Air And Exhaust Venting

    MACH® Gas-Fired Boiler NLET IR AND XHAUST ENTING 3.5.1 Applicable Codes & Standards CODES United States: NFPA 54/ANSI Z223.1 National Fuel Gas Code NFPA/ANSI 211 Chimneys, Fireplaces, Vents and Solid Fuel Burning Appliances Canada CAN/CSA B149.1 Installation Codes for Gas Burning Equipment STANDARDS UL 1738 Venting Systems for Gas-Burning Appliances, Categories II, III, and IV...
  • Page 13 MACH® Gas-Fired Boiler Category IV An appliance that operates with a positive vent static pressure and with a vent temperature that may cause excessive condensate production in the vent. Direct Vent An appliance that is constructed and installed so that all air for combustion is derived directly from outdoors and all flue gases are discharged to the outdoors.
  • Page 14 MACH® Gas-Fired Boiler Air Inlet Requirements – United States (NFPA 54/ANSI Z223.1 & NFPA/ANSI 211) 3.5.2.1 When air is supplied from inside the building, the total required volume shall be the sum of the required volume for all the appliances located in the mechanical room. Adjacent rooms furnished with fixed openings communicating directly with the mechanical room are considered part of the required volume.
  • Page 15 MACH® Gas-Fired Boiler Air Inlet Requirements – Canada (CAN/CSA B149.1) 3.5.2.2 A. Ventilation of the space occupied by fuel burning appliance(s) or equipment shall be supplied by a ventilation opening at the highest practicable point communicating with the outdoors. The total cross sectional area of the ventilation opening must be either 10% of the net free area required for combustion air or 10 sq.
  • Page 16 MACH® Gas-Fired Boiler 3.5.3 Flue Venting This boiler is not certified for use with Type "B" vent nor with PVC/CPVC venting. All boiler venting systems should be designed by a qualified venting professional experienced in venting system design. The information contained herein should This boiler be used as a guide only and is not intended to be used in lieu of qualified technical expertise.
  • Page 17 MACH® Gas-Fired Boiler Table of Required Stainless Steel Vent Adapters and Category II Motorized Dampers Stainless Vent Normally-Closed Nominal Boiler Size Adapter Motorized Damper Stack Size C1500GG - 10” 10” 13” 3.38” 10" 2630000226 1004906945 C2000GG The normally-closed motorized damper operates on 120 VAC and features an end limit switch wired into the boiler’s external interlock circuit.
  • Page 18 MACH® Gas-Fired Boiler 3.5.3.3 CATEGORY IV INSTALLATIONS If the vent installation is designed for Category IV conditions only (condensing – positive pressure) as it is defined in ANSI Z21.13/CSA 4.9, latest edition. The vent material must be as listed in Table in section 3.5.1.2 and can be run horizontally or vertically.
  • Page 19 MACH® Gas-Fired Boiler Through the wall terminations shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators, relief valves or other equipment. Direct Vent (Sealed Combustion) Systems Clearances The vent terminal shall be located at least 12 in.
  • Page 20 MACH® Gas-Fired Boiler 3.5.3.5 Flue Connection The boiler vent should not be connected into any portion of another mechanical draft system without consulting the vent manufacturer. The boiler shall not be connected to any part of a vent system serving a Category I or II appliance, nor shall a Category I or II appliance be connected to any part of the vent system serving this appliance.
  • Page 21 Harsco Industrial, Patterson-Kelley can not be responsible for the effects such adverse conditions may have on the operation of the boilers. Dimensions listed above are minimums and may not be sufficient for conditions at a specific job site.
  • Page 22 MACH® Gas-Fired Boiler 3.5.5.1 Intake Duct Materials and Sizes Air Requirements – SCFM The air intake duct can be fabricated from PVC, CPVC, single wall Boiler Size Required SCFM galvanized steel, or other suitable materials. The duct must be C1500GG rigid enough to maintain the full required cross sectional area under all operating conditions.

  • Page 23: Gas Piping

    MACH® Gas-Fired Boiler 3.5.6 Removing an Existing Boiler (from a common venting system) 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:...
  • Page 24 MACH® Gas-Fired Boiler Remote Gas Supply Shutoff Drip Leg Boiler Main Gas Valve Meter Union Field Gas Piping Install a sediment trap (drip leg) and a union connection upstream of the primary manual shutoff valve on the boiler. Gas piping should be installed in accordance with National Fuel Gas Code, ANSI Z223.1, latest edition, and any other local codes which may apply.

  • Page 25: Boiler Water Piping

    MACH® Gas-Fired Boiler 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.
  • Page 26 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 change of temperature at the boiler. Consult your authorized Harsco Industrial, Patterson-Kelley boiler representative for application guidance.
  • Page 27 Each boiler is supplied with a pressure-relief valve sized in accordance with ASME requirements. Lower pressure relief valves are available, contact your Harsco Industrial, Patterson-Kelley representative. The relief valve should be piped to a suitable floor drain. Reducing couplings or other restrictions are not permitted in the discharge line.
  • Page 28 The condensate is acidic (pH between 3.0 and 5.0) and may be corrosive to some building drain systems. A condensate neutralization system may be required and is available from Harsco Industrial, Patterson-Kelley. Disposal of condensate must comply with all state and local codes.

  • Page 29: Pre-Start Check List

    MACH® Gas-Fired Boiler TART HECK Before attempting to start the boiler, make sure the following items have been completed. 1. Inspect the gas train, blower, ignition electrode and boiler in general to be sure there was no damage during shipment or installation. 2.
  • Page 30 MACH® Gas-Fired Boiler 3.9.2 Test of Low Water Cut-off The boiler is furnished with a probe-type low water cut-off in the outlet nozzle. Test as follows: Push and hold the red “Push to test” button for at least 5 seconds. A manual lockout reset error displaying LOCKOUT LOW WATER LEVEL on the display panel should occur.

  • Page 31: Initial Adjustments

    MACH® Gas-Fired Boiler 3.10 I NITIAL DJUSTMENTS 3.10.1 Operating Temperature Controller ® The MACH boilers C1500GG-2000GG are equipped with ENVI™ Control; an intelligent control system with advanced features such as text-based display, communication capabilities, and boiler sequencing. Errors are date and time stamped providing built-in history of boiler status and performance.
  • Page 32 MACH® Gas-Fired Boiler 3.10.2 Boiler Setpoint The factory default setpoint is 180 °F. If a different setpoint is desired, push the menu button and then select PROGRAM PARAMETERS from the menu. A screen opens that allows the user to view and change operating parameters (see screenshot below.) Parameters Parameters...
  • Page 33 MACH® Gas-Fired Boiler Additional CH Parameters are available and used for the various CH Modes other than mode 0, the standard Setpoint & (Thermo)Stat control mode. These modes are further described in the ENVI™ Control Advanced User’s Guide. 3.10.4 Other Parameters Other parameters include the settings for DHW (Domestic Hot Water), Boiler Settings and OEM Settings.

  • Page 34: Burner Adjustment

    URNER DJUSTMENT NOTICE! Adjustments shall only be performed by service representative specifically trained and certified ® to perform maintenance on the Harsco Industrial, Patterson-Kelley MACH boiler. Verify proper operation after servicing. See rating plate for the minimum and maximum inlet gas pressure of the boiler.
  • Page 35 MACH® Gas-Fired Boiler 3.11.1 Combustion Setup and Adjustment Boiler Test Mode for High and Low fire: Set the combustion using the Service Menu BNR ON TEST HI & BNR ON TEST LOW modes. These test modes should be used when checking and setting the gas safety shut off / control valves on the MACH® boiler. In this mode a heat request is required.
  • Page 36 MACH® Gas-Fired Boiler High Fire Setting Set boiler to the “BNR ON TEST HI”, 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 of Combustion Exhaust Settings, adjust as follows: Remove the flat, round, plastic cap from the gas valve.

  • Page 37: Operation

    MACH® boiler C1500GG-2000GG boilers. 4.1.2 Tests All Harsco Industrial, Patterson-Kelley boilers are fire tested at the factory prior to shipment. This procedure includes testing of the limits and adjustment of combustion parameters. This testing and setup information is recorded on the “Factory Firetest”...

  • Page 38: Typical Boiler Utility Requirements

    MACH® Gas-Fired Boiler 4.2.3 Normal Shut Down Procedures 1. Turn the on/off switch to the off position. Close all manual gas valves. (if shutdown for extended period.) 4.2.4 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.

  • Page 39: Maintenance

    MACH® Gas-Fired Boiler 5.0 MAINTENANCE AINTENANCE AND NSPECTION CHEDULE This schedule applies when the boiler is in use. Verify proper operation after servicing. Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Use care when reassembling main gas line to assure all connections are tight.
  • Page 40 6. Check the condensate drain system. Clean and flush as necessary. Installation and service must be performed by a qualified and knowledgeable installer or service agency who has been trained on the Harsco Industrial, Patterson-Kelley MACH® boilers. 5.1.4 Semi-Annually (required for boilers operated year round) In addition to the recommended monthly service: 1.

  • Page 41: Cleaning The Burner

    MACH® Gas-Fired Boiler 9. Perform combustion analysis and readjust as necessary according to section 3.11. It is recommended that a copy of this report is filed for future reference. 10. 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 that has been trained on the ®...

  • Page 42: Sequence Of Operation

    MACH® Gas-Fired Boiler EQUENCE OF PERATION 1. When the Boiler On/Off switch is turned on, power is provided through a circuit breaker to the boiler control and the combustion blower. 2. If the high gas, low gas or low water level control is open, the boiler control locks out and displays an error. 3.

  • Page 43: Troubleshooting

    MACH® Gas-Fired Boiler ROUBLESHOOTING 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, stack temperature, low water level.) The ENVI™ boiler control will display text based error descriptions to indicate any 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 that will self reset when the error condition clears.
  • Page 44 MACH® Gas-Fired Boiler 5.5.6 Low Air If the display panel indicates Locking AIR SWITCH NOT OPEN or Locking AIR SWITCH NOT CLOSED this indicates improper airflow through the boiler. Check the hoses leading to the air switches. Verify proper blower operation. An air switch error does not necessarily mean that the air switch is defective.
  • Page 45 MACH® Gas-Fired Boiler 5.5.10 Manual Reset Error Codes – A## Code ENVI™ Control Display Lockout Description Unassigned No Error Description, Call For Service Ignition Failure During an attempt to light, no flame was detected IGNITION FAILURE Flame Failure During run, the flame was lost FLAME FAILURE The temperature in the boiler exceeded the setting on High Limit...
  • Page 46 MACH® Gas-Fired Boiler 5.5.11 Auto-reset Error Codes – E## Code ENVI™ Control Display Lockout Description Outlet Temperature Sensor Open Boiler outlet water temperature sensor open circuit OUT TEMP SENS OPEN Inlet Temperature Sensor Open Boiler inlet water sensor temperature open circuit IN TEMP SENS OPEN Flue Temperature Sensor Open Boiler flue gas temperature sensor open circuit...

  • Page 47: Parts/Technical Support

    MACH® Gas-Fired Boiler 6.0 PARTS/TECHNICAL SUPPORT Spare parts and replacement parts can be ordered from Harsco Industrial, Patterson-Kelley by calling toll free (877) 728-5351. The fax number is (570) 476-7247. Technical information is also available at the above number and at the Harsco Industrial, Patterson-Kelly website www.harscopk.com.
  • Page 48 MACH® Gas-Fired Boiler 6.1.2 Terminal Block Assignments – Low Voltage Circuit (TB1) Terminal Number Label Description ENABLE / DISABLE Boiler Enable, Contact Closure. DO NOT ENERGIZE. ENABLE / DISABLE EXTERNAL INTERLOCK External Limit, Contact Closure. DO NOT ENERGIZE. EXTERNAL INTERLOCK OUTDOOR TEMP Outdoor temperature sensor SENSOR...
  • Page 49 MACH® Gas-Fired Boiler 6.1.3 MACH® Boiler C1500GG/C2000GG Wiring Diagram Page 49...
  • Page 50 MACH® Gas-Fired Boiler ® 6.1.4 Dual Fuel Control Wiring MACH C1500GG/C2000GG Page 50...

  • Page 51: Boiler Parts List

    MACH® Gas-Fired Boiler OILER ARTS 6.2.1 Main Assembly Mark Description Cabinet Top Boiler Outlet Boiler Inlet Blower/Burner Assembly Front Control Panel Cabinet Page 51...
  • Page 52 MACH® Gas-Fired Boiler 6.2.2 Control Panel 5 Amp Circuit Breaker Mark Description Terminal Block 2 (TB2) 120V 10 Amp Circuit Breaker High Temperature Limit ENVI™ Control Main Board ENVI™ Control Interface Board Terminal Block 1 (TB1) Low V Air Switch (on back) Low Water Cut-Off Board High Exhaust Back Pressure Switch (HEBPS) on back...
  • Page 53 MACH® Gas-Fired Boiler 6.2.3 MACH® Boiler 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 54 MACH® Gas-Fired Boiler ® 6.2.4 Gas Train Assembly Drawing MACH C-1500GG/C-2000GG Mark Description Natural Gas Inlet Valve (1 1/2”) Natural Gas Automatic Valve Natural Gas Low Pressure Switch Propane Gas Inlet Valve (1 1/4”) Propane Gas Automatic Valve Propane Gas Low Pressure Switch Automatic Gas Valve Sensing Line High Gas Pressure Switch Secondary Manual Gas Shutoff Valve...

  • Page 55: Limited Warranty

    7.0 LIMITED WARRANTY Subject to the terms and conditions herein, Harsco Industrial, Patterson-Kelley, Seller warrants to the original owner at the original installation site that products manufactured by Seller will be free from defects in materials and workmanship for a period of one (1) years from date of start up (the "Warranty Period"), provided that startup is completed within six months from the date of shipment.

  • Page 56: Supplemental Information

    8. Sytem Water pH level 9. Comments: Performed by: (Print Name) Please return a copy to Harsco Industrial, Patterson-Kelley, ATTN: Boiler Technical Service Harsco Industrial, Patterson-Kelley • 100 Burson Street • E. Stroudsburg, PA 18301 Phone: (570) 476-7261 • Fax: (570) 476-7247 • www.harscopk.com...

  • Page 57: Mach® Boiler Fire Test Report - Liquid Propane

    8. Sytem Water pH level 9. Comments: Performed by: (Print Name) Please return a copy to Harsco Industrial, Patterson-Kelley, ATTN: Boiler Technical Service Harsco Industrial, Patterson-Kelley • 100 Burson Street • E. Stroudsburg, PA 18301 Phone: (570) 476-7261 • Fax: (570) 476-7247 • www.harscopk.com...

  • Page 58: Maintenance Log

    MACH® Gas-Fired Boiler AINTENANCE Date Hi/Low Stack Action Fire Temp...

  • Page 59: Mach ® Boiler Altitude Derate Schedule

    MACH® Gas-Fired Boiler ® OILER LTITUDE ERATE CHEDULE For installations over 2000 ft elevations, a derate schedule is applied. The boiler input rating must be reduced by 4% per 1000 ft. This is illustrated using the following graph. 4% Derate Schedule 2000 3000 4000...

  • Page 60: Mach® Water Chemistry

    MACH® Gas-Fired Boiler MACH® W ATER HEMISTRY ® The MACH boiler uses an aluminum alloy that will withstand the acidic condensate (pH ~ 3.0 to 5.0) formed when firing natural or LP gas under conditions which cause the flue gas to condense on the fire side of the heat exchanger.
  • Page 61 MACH® Gas-Fired Boiler Before commissioning, a sample of the system water and the make-up water should be analyzed to assure the proper mixture of water, chemical treatment and (if applicable) glycol. This analysis can be made by your local water treatment firm, or by one of the manufacturers listed below. The water chemistry should be adjusted as recommended in the analysis results.

This manual is also suitable for:

Mach c2000ggMach c1500Mach c2000

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