1. Manuals
  2. Brands
  3. Harsco Manuals
  4. Boiler
  5. Patterson-Kelley MACH Series
  6. Installation & owner's manual

Harsco Patterson-Kelley MACH Series Installation & Owner's Manual

Gas-fired boiler
Hide thumbs
Table of Contents

Advertisement

Quick Links

PATTERSON-KELLEY
MACH
C2500
®
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
Model #:_______
Start-Up Date:
_______________________
100 Burson Street, P.O. Box 458,
East Stroudsburg, PA 18301
Telephone: (877) 728-5351,
Facsimile: (570) 476-7247
www.pkboilers.com
Serial #______________________
©2009 Patterson-Kelley, A Harsco Company
XLMACH- 09

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Patterson-Kelley MACH Series and is the answer not in the manual?

Questions and answers

Marvin Dickerson
February 18, 2025

need help with parts ID, low water cutoff probe for c2500

0

Summary of Contents for Harsco Patterson-Kelley MACH Series

  • Page 1 Complies with ANSI Z21.13/CSA 4.9 Gas-Fired Low Pressure Steam and Hot Water Boilers Model #:_______ Serial #______________________ Start-Up Date: _______________________ 100 Burson Street, P.O. Box 458, East Stroudsburg, PA 18301 Telephone: (877) 728-5351, Facsimile: (570) 476-7247 www.pkboilers.com ©2009 Patterson-Kelley, A Harsco Company...

  • Page 2: Table Of Contents

    MACH® Series Gas-Fired Boiler ..INTRODUCTION ...........................4 ..SAFETY..............................4 2.1 General .............................4 2.2 Training.............................4 2.3 Safety Features ..........................5 2.4 Safety Labels ............................5 2.5 Safety Precautions ...........................6 ..INSTALLATION.............................8 3.1 Receiving and Storage ........................8 3.2 Compliance with Codes........................8 3.3 Setup ..............................9 3.4 Electrical Connections ........................10 3.5 Inlet Air and Exhaust Venting ......................10 3.6 Gas Piping ............................20...
  • Page 3 MACH® Series 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

    MACH® Series Gas-Fired Boiler Installation INTRODUCTION ® The P-K MACH C2500 Gas-Fired Boiler is 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.

  • Page 5: Safety Features

    MACH® Series Gas-Fired Boiler Installation ® Operating and service personnel must be thoroughly familiar with the basic construction of the P-K MACH C2500 boiler, the use and locations of the controls, the operation of the boiler, adjustment of its various mechanisms, and all applicable safety precautions.

  • Page 6: Safety Precautions

    MACH® Series Gas-Fired Boiler Installation 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 MACH® Series Gas-Fired Boiler Installation Gas may lose its odor. Proper gas sensing equipment and procedures should be used for leak checks. 2.5.3 Crush Hazards • Lifting hazards! Use properly rated lifting equipment to lift and position the boiler. The load is unbalanced.

  • Page 8: Installation

    MACH® Series Gas-Fired Boiler Installation 3 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, unpack the boiler, open the front, and side doors and inspect the boiler.

  • Page 9: Setup

    MACH® Series Gas-Fired Boiler Installation ETUP 3.3.1 Foundation and Placement Provide a firm, level foundation, preferably of concrete. The wheels provided with this boiler are for positioning purposes only. When positioning this boiler, maintain positive control of it at all times. Do not attempt to move the boiler on surfaces that are not level.

  • Page 10: Electrical Connections

    MACH® Series Gas-Fired Boiler Installation Type of Surface Dimensions (inches) C† Combustible Surfaces Minimum Clearances Recommended Clearances 18** for Service Access † "C" Space required for pipes, ducts, etc. in this area above the boiler. * “B” Clearance depends upon exhaust vent configuration. ** Do not put pipes, ducts, vents, etc in this space.
  • Page 11 MACH® Series Gas-Fired Boiler Installation 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 ULC S636-95 Standard for Type BH Venting Systems Sheet Metal and Thermoplastic Duct Construction Manual Air Conditioning Contractors National Association (SMACNA) These codes and standards contain information for the venting of gas fired appliances, including, but not limited to...
  • Page 12 MACH® Series Gas-Fired Boiler Installation 3.5.1.2 Venting Materials for Flue/Exhaust Systems ® MACH Series boilers are Category IV appliances, which vent with a positive exhaust pressure and with a ® temperature that is likely to cause condensation in the vent. Therefore, any venting system used with the MACH Series boiler must comply with the requirements for Category IV venting systems as specified in the latest edition of NFPA 54/ANSI Z223.1 in the US or the latest edition of CAN/CSA B-149.1 in Canada.
  • Page 13 MACH® Series Gas-Fired Boiler Installation Openings used to connect indoor spaces to obtain the required minimum volume shall be sized as follows: • When rooms are on the same floor, each opening shall have an area equal to 1 square inch for each 1000 Btu/hr (2200 mm / kW) of installed appliance input capacity, but not less than 100 square inches.
  • Page 14 MACH® Series Gas-Fired Boiler Installation When combustion air is supplied for a forced draft burner by natural airflow from the outdoors and there is no draft regulator or draft hood in the same space, there shall be a permanent opening with a cross sectional area not less than 1 sq.
  • Page 15 MACH® Series Gas-Fired Boiler Installation The air inlet and vent must be sized so that the total pressure drop across the boiler is less than 0.44” w.c. This pressure drop includes both the inlet and vent ducts friction loss. For example, if the inlet air duct loss is 0.2” w.c., the vent duct loss cannot exceed 0.24 “w.c.
  • Page 16 MACH® Series Gas-Fired Boiler Installation Conventional Vent Systems The following termination clearance requirements are for conventional, non-direct vent installations. • The vent system shall terminate at least 3 ft above a forced air inlet within 10 feet horizontally. • The vent system shall terminate at least 4 ft below, 4 ft horizontally from or 1 ft above any door, operable window or gravity inlet into any building.
  • Page 17 MACH® Series Gas-Fired Boiler Installation The condensate formed from combustion NOTICE! flue gases is acidic. The condensate shall be drained in accordance with local code requirements. A condensate neutralizer may be required by local code. 3.5.3.4 Vent Terminations Vertical vents are allowed to be terminated with a variety of ends, including stub stock, exit cone, vent tee or unrestrictive cap, as shown below.
  • Page 18 MACH® Series Gas-Fired Boiler Installation 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 can not be responsible for the effects such adverse conditions 36”...
  • Page 19 MACH® Series Gas-Fired Boiler Installation Both the air inlet and the exhaust vent must terminate on the same wall of the building and must utilize the same type of termination fitting with the same orientation. Allowable termination fittings are: 90° elbows, tees, or straight vents. Do not install this boiler with sidewall vent and room air inlet! NOTICE! The figure above shows the sidewall penetration requirements.

  • Page 20: Gas Piping

    MACH® Series Gas-Fired Boiler Installation 6. After it 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 to the National Fuel Gas Code, ANSI Z223.1 and CSA B149 Installation Code.

  • Page 21: Boiler Water Piping

    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 22 MACH® Series Gas-Fired Boiler Installation C2500 Pressure Drop C2500 Variable Pumping Firing Rate (%) Flow (GPM) 3.7.1.1 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 change of temperature at the boiler.
  • Page 23 MACH® Series Gas-Fired Boiler Installation Piping must be installed such that no piping stresses are transmitted to the boiler. The boiler shall not be used as a pipe anchor. Condensate Trap must be piped to drain in accordance with all national, state and local codes. If NOTICE! installed outdoors, it must be field heat traced.

  • Page 24: Pre-Start Check List

    MACH® Series Gas-Fired Boiler Installation Under no circumstances should the hydronic system be flushed while the boiler is attached to the NOTICE! system since the debris or corrosion products could accumulate in the boiler and plug the boiler heat exchanger. Chemicals added to the system must be approved by the chemical manufacturer for use in aluminum NOTICE! boilers.
  • Page 25 MACH® Series Gas-Fired Boiler Installation Never attempt to operate a boiler that has failed to pass all the safety checks described below. After checking controls by manual adjustment, make sure they are always reset to their proper settings. If the expected error code(s) do not appear, call for qualified service. NOTICE! 3.9.1 Test of Ignition Safety System...

  • Page 26: Initial Adjustments

    MACH® Series Gas-Fired Boiler Installation 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 burner. When the gas LOCKING LOW GAS PRESSURE pressure switch opens, a manual reset lockout displaying on the display panel...
  • Page 27 MACH® Series Gas-Fired Boiler Changing parameters requires an understanding of the parameters and the functionality of the boiler. The boiler may not function properly if parameters are changed from the factory values. 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 PARAMETERS from the menu.

  • Page 28: Additional Menu Items

    MACH® Series Gas-Fired Boiler 3.10.3 Other CH Parameters Other settings include the following items: Description Value Units CH Setpoint °F BLR OP (Off = 0, On = 1, Off/Pump On = 2, and On/Pump On = 3) CH Mode Hysteres On (On Differential) °F Hysteres Off (Off Differential) °F...
  • Page 29 MACH® Series Gas-Fired Boiler The second test mode checks the fan rate with the burner off at high speed or at low speed. These test modes will automatically terminate after 15 minutes of inactivity or can be terminated from the control/display panel by pressing the cancel/reset button 3.11.2 Fuel/Air Adjustment ®...
  • Page 30 MACH® Series Gas-Fired Boiler To adjust high fire: Required Tools: Flat head screwdriver and Combustion analyzer Start the boiler and observe proper operating parameters for the system. Set boiler to the “BNR ON TEST HI”, as described above, to achieve maximum firing rate of the boiler.

  • Page 31: Operation

    MACH® Series Gas-Fired Boiler 4 OPERATION ENERAL 4.1.1 Control Panel Front Become familiar with the basic operation of the boiler. The interior of the front door shows the boiler Operating Instructions. 4.1.2 Factory Tests Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on this boiler when the boiler underwent factory tests specified in ANSI...

  • Page 32: Emergency Shut-Off

    MACH® Series Gas-Fired Boiler MERGENCY If overheating occurs or the gas supply fails to shut off, Main Shutoff do not turn off or disconnect Gas Valve the electrical supply to the pump. Instead, shut off the gas supply at a location external to the boiler.

  • Page 33: Maintenance

    MACH® Series Gas-Fired Boiler 5 MAINTENANCE AINTENANCE AND NSPECTION CHEDULE This schedule applies when the boiler is in use. Verify proper operation after servicing. Proper lockout/ tagout procedure must be employed when servicing this unit. Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.
  • Page 34 MACH® Series Gas-Fired Boiler 4. Test the low water level cut-out. Refer to Section 3.9.2. 5. Test low gas pressure switch. Refer to Section 3.9.4. 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 that has been ®...

  • Page 35: Cleaning The Burner

    MACH® Series Gas-Fired Boiler 9. Perform combustion analysis and readjust as necessary according to table 3-1 and section 3.10.4. 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. 11.

  • Page 36: Troubleshooting

    MACH® Series Gas-Fired Boiler 8. The control modulates the firing rate between low and high fire to maintain the desired outlet water temperature. 9. The burner will continue firing until the outlet water temperature reaches set point plus hysteresis (Off Differential). At this temperature the fuel supply is shut off and the combustion air fan continues to run for a 30 second post- purge.
  • Page 37 MACH® Series Gas-Fired Boiler 5.6.2 Loss of Water Level The low water switch opens when there is insufficient water level in the boiler. Lockout LOW WATER LEVEL is shown on the display, the burner operation is interrupted, and the boiler locks out. When the correct water level is re- established, and the control reset button is pressed, the boiler will reset and will start the sequence at Step 4.

  • Page 38: Manual Reset Error Codes - A

    MACH® Series Gas-Fired Boiler These errors signify flame error. This may be caused by a failed or leaky gas valve or a flame detector malfunction. If gas valve leakage is suspected, the unit must be isolated by turning off the main gas supply line. Qualified and knowledgeable service personnel must be called to evaluate and repair/replace the failed parts.

  • Page 39: Auto-Reset Error Codes - E

    ® MACH Series Gas-Fired Boiler Appendix Code ENVI Display Lockout Description Maximum temperature differential across the Max Delta Temp Exceeded MAX DT EXCEEDED boiler has been exceeded Rapid Rise Inlet Error Inlet temperature is rising too rapidly RAPID RISE INLET TMP Rapid Rise Outlet Error Outlet temperature is rising too rapidly RAPID RISE OUT TEMP...

  • Page 40: Parts/Technical Support

    ® MACH Series Gas-Fired Boiler Appendix Internal Error 36 Call for service. INTERAL ERROR 36 Internal Error 37 Call for service. INTERAL ERROR 37 Rapid Rise Heat Exchanger Temperature across heat exchanger is rising faster RAPID RISE HX ERROR Temperature than allowed Temperature of the Outlet water is rising faster than Rapid Rise Outlet Temp...
  • Page 41 ® MACH Series Gas-Fired Boiler Appendix 120V DHW PUMP OUTPUT 120V AC output when boiler is in DHW Mode (pilot duty only) 120V CIRC PUMP OUTPUT 120V AC output when boiler is in CH Mode (pilot duty only) 120V DAMPER OUTPUT 120V AC output when boiler is enabled (pilot duty only) MASTER ALARM RELAY...
  • Page 42 ® MACH Series Gas-Fired Boiler Appendix ® 6.1.3 Wiring Diagram for MACH C-2500...

  • Page 43: Boiler Parts List

    ® MACH Series Gas-Fired Boiler Appendix OILER ARTS 6.2.1 Main Assembly Mark Description Cabinet Top Boiler Outlet Boiler Inlet Blower/Burner Assembly Front Control Panel Cabinet...
  • Page 44 ® MACH Series Gas-Fired Boiler Appendix 6.2.2 Control Panel User Interface/Display Screen Mark Description Terminal Block 1 (TB1) ENVI IF Board Terminal Block 2 (TB2) 120 V Low Water Cut Off (LWCO) High Temperature Limit ENVI Main Board Air Switch 10 Amp Circuit Breaker High Exhaust Back Pressure Switch 5 Amp Circuit Breaker...
  • Page 45 ® MACH Series Gas-Fired Boiler Appendix 6.2.3 C2500 Heat Engine MARK DESCRIPTION Outlet Water Connection Burner Transition Burner Gasket Burner Ignition Sight Glass Window Outlet Water Manifold Heat Exchanger Sectional Castings Relief Valve Inlet Water Connection Boiler Drain Valve Condensate Collector w/Rear Drain Inlet Water Manifold Inspection Cover...
  • Page 46 ® MACH Series Gas-Fired Boiler Appendix 6.2.4 C2500 Gas Train Mark Description Burner Burner Transition Piece Blower Transition Piece Blower Venturi Secondary Manual Shutoff Valve Automatic Gas Valve Main Gas Shutoff Valve High Gas Pressure Switch Low Gas Pressure Switch High Exhaust Backpressure Switch...

  • Page 47: Limited Warranty

    ® MACH Series Gas-Fired Boiler Appendix LIMITED WARRANTY ® P-K MACH Series Boiler LIMITED WARRANTY LIMITED WARRANTY Subject to the terms and conditions herein, Patterson-Kelley Co., 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) year from date of start up (the "Warranty Period"), provided that start up is completed within six months from the date of shipment.

  • Page 48: Appendix A Maintenance Log

    ® MACH Series Gas-Fired Boiler Appendix APPENDIX A MAINTENANCE LOG Date Hi/Low Stack Action Fire Temp...
  • Page 49 ® MACH Series Gas-Fired Boiler Appendix...

  • Page 50: Appendix 2 Mach Water Chemistry

    ® MACH Series Gas-Fired Boiler Appendix ® APPENDIX 2 MACH WATER CHEMISTRY ® The MACH boiler uses a special aluminum alloy to operate properly during full condensing service. This special alloy can withstand the acidic combustion condensate. This condensate has a pH of ~3.0 to 5.0. Having a chemical resistance to acidic environments does not guarantee a widespread chemical resistance across the whole pH range or resistance to all types of chemicals.
  • Page 51 ® MACH Series Gas-Fired Boiler Appendix NOTICE! Under no circumstances should the hydronic system be flushed while the boiler is attached to the system. Debris or corrosion products may accumulate in the boiler and plug the heat exchanger. The boiler must be disconnected from the system and a bypass installed so that the chemical cleaning solution does not circulate through the boiler.

This manual is also suitable for:

Patterson-kelley mach c2500

Table of Contents

Save PDF