Patterson-Kelley MACH C-1500H Installation & Owner's Manual

Gas fired boilers w/ nuro control system
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P-K MACH
w/ NURO
®
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
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
GAS FIRED BOILERS
®
CONTROL SYSTEM
Natural Gas or Propane Gas
C-1500H/C-2000H
C-2500/C-3000/C-4000
Dual Fuel
C1500GG, C2000GG
C2500GG, C3000GG,
C4000GG
Part # 1004905981
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
www.pattersonkelley.com
Revised: January 3, 2020
 Patterson-Kelley 2020: All Rights Reserved.
obligation.
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Summary of Contents for Patterson-Kelley MACH C-1500H

  • Page 1  Patterson-Kelley 2020: All Rights Reserved. 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.
  • Page 2 ® P-K MACH Gas Fired Boiler Technical Service 1.877.728.5351...
  • Page 3 ® P-K MACH Gas Fired Boiler Technical Service 1.877.728.5351 Safety OTICE Each safety device must be & maintained and checked per the General recommended schedule. Refer to ® P-K MACH C-1500H, C-2000H, C-2500, C-3000, C-4000 Section for more information. ® All P-K MACH C-1500H, C-2000H, C-2500, C-3000, C-4000 Gas- AFETY...
  • Page 4 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. Hazard Warnings...
  • Page 5 Collection and disposal must be in accordance with all applicable regulations. A condensate neutralization kit is available. Please contact your local Patterson-Kelley representative for more information. Burn, Fire and Explosion Hazards Burn, fire, and explosion hazards! Installation must be in strict conformance to all applicable codes and standards including NFPA 54, ANSI Z223.1 and CAN/CSA B.149.
  • Page 6: Table Of Contents

    3.5.5 Inlet Duct Connection to Boiler ..................34 3.5.6 Intake Duct Materials and Sizes ..................34 3.5.7 Category II Installations ....................35 3.5.8 Category IV Installations ....................36  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved.
  • Page 7 ..............60 ORMAL IGHTING AND DOWN ROCEDURES 5.2.1 Normal Lighting Procedures ..................... 60  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx Page 2...
  • Page 8 6.1.4 Semi-Annually ........................62 6.1.5 Annually ........................... 62 & C ..............63 LEANING THE URNER OMBUSTION HAMBER 6.2.1 MACH C-1500H & C-2000H ..................... 63 6.2.2 MACH C-2500, C-3000 & C-4000 ..................65 ................66 AINTENANCE AND NSPECTION CHEDULE ..................66 FTER...
  • Page 9 BOILERS IN MULTI-METAL SYSTEMS ................... 116 APPENDIX D – BEST PRACTICES FOR NEW & RETROFIT SYSTEMS ........117 APPENDIX E – INSTALLATION AND QUICK REFERENCE ............119  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved.
  • Page 10: Introduction

    Patterson-Kelley cannot be responsible for the design or performance can be misused operation of such systems and a qualified engineer or contractor which could result in personal must be consulted.
  • Page 11: Purpose Of This Document

    Patterson-Kelley manufactures quality products. The primary concern of all Patterson-Kelley equipment installation procedures is Safety. Safety instructions and considerations are presented and repeated throughout the document as needed. At any time during the installation if you have any questions on the information contained within, or do not fully and completely understand the content, please contact Patterson-Kelley Technical Service at 570.476.7261 or toll free at 877.728.5351.
  • Page 12: Site Preparation

    Insufficient clearance can restrict the service access, increasing the possibility of injury.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx...
  • Page 13: Compliance With Codes

    (b) field installed gas cocks must be “T” handle type, (c) piping of condensate shall conform to the State Plumbing Code, and (d) refer to the Massachusetts Supplement for further details.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved.
  • Page 14: Location Setup

    NOTICE! This appliance is certified for INDOOR use only! The boiler must be level within 0.25° in order to function properly. Failure to heed this warning could result in personal injury or death.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved.
  • Page 15: Clearances

    Note: Failure to provide recommended service clearances may make it difficult to perform service on the boiler(s).  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved.
  • Page 16: Inlet Air And Exhaust Venting Considerations

    Faulty vent installation can allow toxic fumes to be released into living areas. This may cause property damage, injury, or death.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx...
  • Page 17: Category Ii/Iv Flue Gas Exhaust Vent Planning

    (Exhaust Only) 220 °F (gross) 9.2% 10.4% C-3000, C-4000 +0.01” to +0.4” W.C.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx Page 12...
  • Page 18: Venting Materials For Flue/Exhaust Systems

    NOTE 2: When this material is used for venting, it must be listed to either UL- 1738 or ULC-S636 (depending on the local requirements). Consult the local boiler codes for more information.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved.
  • Page 19: Required Clearances

    Improper interconnection of venting systems may result in leakage of flue gases into occupied spaces.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx...
  • Page 20 Section 3.5. The appliance connector should incorporate provisions to drain condensate formed in the vent system. The connector should include an appropriate drain section (not provided).  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved.
  • Page 21: Gas Piping Considerations

    The P-K MACH proper water conditions to remain efficient and function properly. For more information, refer to Patterson-Kelley’s Water Quality Standards for Hydronic Boilers in Multi-Metal Systems in Appendix C – Water Quality Standards Quality Standards for Hydronic Boilers in Multi-Metal Systems as this applies to the warranty of your heat exchanger.
  • Page 22: Appliance Connections (C-1500H & C-2000H)

    Gas Fired Boiler Technical Service 1.877.728.5351 3.2.1 Appliance Connections (C-1500H & C-2000H) All connections must be in compliance with national, state, and local code requirements.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved.
  • Page 23: Appliance Connections (C-2500 & C-3000)

    Gas Fired Boiler Technical Service 1.877.728.5351 3.2.2 Appliance Connections (C-2500 & C-3000) All connections must be in compliance with national, state, and local code requirements.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved.
  • Page 24: Appliance Connections (C-4000)

    Gas Fired Boiler Technical Service 1.877.728.5351 3.2.3 Appliance Connections (C-4000) All connections must be in compliance with national, state, and local code requirements.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx...
  • Page 25: Electrical Connections

    10AWG wire. Do not over-tighten the terminal screws. Maximum tightening torque = 6 in-lbs!  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx...
  • Page 26: Power Requirements (C-3000 & C-4000)

    208 VAC main voltage. Refer to Section 7.1, for proper wiring and configuration of the internal control transformer.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx...
  • Page 27 12 AWG wire. The ground terminal can accommodate Main Power Connection maximum 8 AWG wire.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx...
  • Page 28: High Voltage (Tb2) Terminal Block

    (DHW) Pump, Air Damper, System 240VAC and maximum current capacity of 1/2 Amp. Pump, etc.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved.
  • Page 29: Low Voltage (Tb1) Terminal Block

    Ground – TB1-17 provides an equipment (frame) ground connection for input, output, or communication connections. For independently powered control devices, it may be necessary to create a common ground.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved.
  • Page 30 The wireless receiver should be installed at or near the boiler, and the wireless temperature sensor should be installed on the North face of the building and shielded from direct sunlight exposure.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved.
  • Page 31: Air Inlet Requirements - United States

    2. Screens shall be not smaller than 1/4 inch. 3. Motorized louvers shall be interlocked with the appliance so that they are proven open prior to main burner ignition and operation.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved.
  • Page 32: Air Inlet Requirements - Canada

    F. When all combustion air is supplied through a make-up air heater, and the appliance is interlocked to the heater, the requirements of Paragraphs A through E do not apply.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved.
  • Page 33: P-K Mach

    For example, joints in PVC or CPVC piping must be cemented. For galvanized duct, wrap each joint and seam with adhesive aluminum tape or other sealant. Patterson-Kelley recommends installing a 1” x 1” or larger bird screen on the exterior termination. Ensure that the screen does not become blocked with snow, ice, insects etc.
  • Page 34: Motorized Combustion Air Dampers

    If the combustion air intake ductwork and the exhaust vent terminate on the same wall of NOTE: the building, they must utilize the same type of termination fitting. Patterson-Kelley recommends including a motorized combustion air damper in each NOTE: appliance’s air intake ductwork. Refer to Section 3.4.5...
  • Page 35  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx...
  • Page 36: Flue Gas / Exhaust Venting

    Vertical vents are allowed to be terminated with a variety of ends, including plain straight pipe, elbow, or vent tee. Horizontal vents must be terminated with an elbow or vent tee. Similarly, a bird screen with 1” x 1” openings is recommended for termination. Patterson-Kelley does not recommend using a vent rain cap of any type.
  • Page 37: Vent Termination

    This is illustrated in the following diagram. Additionally, the boiler vent shall terminate at least 3 ft. above a forced air inlet located within 10 ft.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved.
  • Page 38: Venting For Multiple Boilers

    Patterson-Kelley recommends that common venting systems be designed for a maximum continuous exhaust pressure of -0.04” W.C. when measured in the common vent. Locking inline dampers are recommended on the exhaust connection of each individual appliance in order to control the exhaust back pressure within the appliance and upstream of this damper.
  • Page 39: Sealed Combustion/Direct Vent Systems

    The installation of a 1” x 1” birdscreen on the intake termination is recommended. Ensure that the screen does not become blocked with snow, ice, insects, etc.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved.
  • Page 40: Category Ii Installations

    Category IV vent installations. 120VAC motorized dampers with end limit switches are available for purchase from Patterson-Kelley. Other damper motor voltages are acceptable, provided they do not exceed 240VAC. The Air Damper Interlock circuit for the end limit switch is always 120VAC which is sourced from the boiler itself.
  • Page 41: Category Iv Installations

    CPVC Support Spacing (Feet) Vent Size Sch. 40 Sch. 80 4-1/2 4-1/2 5-1/2 5-1/2 6-1/2  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx Page 36...
  • Page 42: Removing An Existing Boiler

    3,000 cubic feet per 11 of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or hour. CAN/CSA B149.1 Natural Gas and Propane Installation Code.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved.
  • Page 43: Piping

    1,500,000 1500 2,000,000 2000 2,500,000 2500 1000 3,000,000 3000 1200 4,000,000 4000 1600  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx Page 38...
  • Page 44: Natural Gas Piping

    If using soap and water or a similar leak test method, make sure to clean off all moisture from the gas pipe fittings prior to placing the appliance into service.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved.
  • Page 45: Boiler Water Piping

    All water connections should be in compliance with national, state, and local code requirements. Adapters from Victaulic to NPT are available from Patterson-Kelley. The bottom rear connection to the boiler is the INLET and must be used for the return from the system. The top rear connection to the boiler is the OUTLET and must be connected as the supply to the system.
  • Page 46 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 Patterson-Kelley. If the condensate drainage system is exposed to freezing temperatures, it must be field heat traced. The boiler could generate up to one gallon of condensate per 100,000 BTU input.
  • Page 47: Water Quality

    “water quality”. For information, can be found on our website www.pattersonkelley.com please refer to Patterson-Kelley Multi-Metal Systems Water Quality Standards as it appears in Appendix C – Water Quality Standards Quality Standards for Hydronic Boilers in Multi-Metal Systems as this applies to the warranty of your heat exchanger.
  • Page 48: Safety Checks

    The manual reset high temperature limit is located inside the boiler’s front door, toward the top of the control panel and is identified with a yellow label.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved.
  • Page 49: Gas Pressure Switch Tests

    “Reset Control”. NOTE Make sure to re-open the downstream gas cock (inside the boiler) after a successful test.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved.
  • Page 50: Fuel/Air Adjustments

    A combustion analyzer must be used. Combustion must be set in accordance with the Recommended Combustion Settings for P-K MACH Boilers in Section 3.11.2.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved.
  • Page 51: Manual Control Mode For High And Low Fire Adjustment

    NOTICE! For high altitude adjustments (greater than 2,000 feet above sea level), see Appendix B – Boiler Altitude Derate Schedule at the end of this manual.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved.
  • Page 52: Adjusting High Fire

    (units = V) as measured by the ignition electrode/ionization probe. When the boiler is in standby, prepurge, or postpurge the flame signal should read 0V. During main flame, a strong flame signal should read between 20-50V.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved.
  • Page 53: Initial Nuro Control Setup And Adjustment

    When the boiler or water heater is powered on, the NURO touchscreen will display an initial Startup Screen then the Local Representative screen. This shows the name, address and phone number of the local Patterson-Kelley representative.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved.
  • Page 54: Home Screen

    NOTE For more information on any value, please refer to the NURO Boiler Controller: Advanced User’s Guide, Part Number is 1004905979.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx...
  • Page 55: Setup Wizard

    Less than 20 3689 1600 3,800,000 C-4000 4,000,000 440-480 Three Less than 20  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx Page 50...
  • Page 56: Dual Fuel Boiler Operation

    4.4.3 for model-specific information on the location of the gas trains, the fuel selector switch and the dual fuel wiring diagrams.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx...
  • Page 57: P-K Mach C1500Gg & C2000Gg

    If operating with Natural Gas, ensure the Propane Gas valve/cock is CLOSED. If operating with Propane Gas, ensure the Natural Gas valve/cock is CLOSED. Failure to do so could result in equipment damage, injury, and/or death.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved.
  • Page 58: Fuel Selector Switch Location

    If operating with Natural Gas, ensure the Propane Gas valve/cock is CLOSED. If operating with Propane Gas, ensure the Natural Gas valve/cock is CLOSED. Failure to do so could result in equipment damage, injury, and/or death.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved.
  • Page 59: P-K Mach C2500Gg, C3000Gg & C4000Gg

    If operating with Natural Gas, ensure the Propane Gas valve/cock is CLOSED. If operating with Propane Gas, ensure the Natural Gas valve/cock is CLOSED. Failure to do so could result in equipment damage, injury, and/or death.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved.
  • Page 60: Natural Gas Train And Propane Gas Train Locations (C4000Gg)

    If operating with Natural Gas, ensure the Propane Gas valve/cock is CLOSED. If operating with Propane Gas, ensure the Natural Gas valve/cock is CLOSED. Failure to do so could result in equipment damage, injury, and/or death.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved.
  • Page 61: Fuel Selector Switch Location

    If operating with Natural Gas, ensure the Propane Gas valve/cock is CLOSED. If operating with Propane Gas, ensure the Natural Gas valve/cock is CLOSED. Failure to do so could result in equipment damage, injury, and/or death.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved.
  • Page 62: P-K Mach C1500T & C2000T

    Natural Gas The boiler must be level within 0.25° in order to function properly. Failure to heed this warning could result in personal injury or death.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved.
  • Page 63: High Turndown C1500T & C2000T

    Gas Fired Boiler Technical Service 1.877.728.5351 4.5.2 High Turndown C1500T & C2000T Must be level for appliance to function correctly  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx...
  • Page 64: Operations

    A clear plastic cover protects the touch screen which can be opened by pinching the clasp and swinging open to the left.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved.
  • Page 65: Factory Tests

    See illustration on the right for valve locations. The upper shut off valve is for Propane Gas and the lower valve for Natural Gas.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved.
  • Page 66: Maintenance

    NOTICE! Proper maintenance schedule and record this unit. Failure to do so could keeping is critical for optimum performance and to result in electrocution, injury, or maintain the Patterson-Kelley warranty. death. NOTE: The combustion blower motor is permanently lubricated and does not require periodic lubrication.
  • Page 67: Monthly Preventative Maintenance

    4. Replace the ignition electrode and gasket. 5. Drain and flush the water side of the heat exchanger as required (separate from system flush) using clean water only.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved.
  • Page 68: Cleaning The Burner & Combustion Chamber

    11. Perform a leak test of the gas valves in accordance with the manufacturer's instructions. Cleaning the Burner & Combustion Chamber Patterson-Kelley recommends cleaning burner and combustion chamber once annually: 6.2.1 MACH C-1500H & C-2000H 1. Lockout/tagout gas supply to the boiler.
  • Page 69 Reseal the inspection cover and continue washing through the burner hole. 21. If the accumulation of debris on the fireside of the heat exchanger requires additional cleaning, use a serrated cleaning tool which is available from Patterson-Kelley. 22. Reconnect the condensate tubing to the condensate neutralization tank.
  • Page 70: Mach C-2500, C-3000 & C-4000

    18. Move to the right hand side of the boiler, and remove one of the rectangular fireside inspection covers in the middle of the boiler by loosening the six M6 nuts.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved.
  • Page 71: Maintenance And Inspection Schedule

    Reseal the inspection cover and continue washing through the burner hole. 20. If the accumulation of debris on the fireside of the heat exchanger requires additional cleaning, serrated cleaning tool which is available from Patterson-Kelley. 21. Reconnect the condensate tubing to the condensate neutralization tank.
  • Page 72: Sequence Of Operations

    9. When the outlet water temperature is reduced by the load on the system, a heat request is generated. The operating sequence will recycle to Step 3.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved.
  • Page 73: Troubleshooting

    Switch ON”, this indicates improper airflow through the boiler. First, verify proper standby blower operation – when the boiler is in “Standby”, the blower should also be in standby.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved.
  • Page 74: Flame Failure

    When the blockage is removed, the boiler will automatically restart. If no blockage is found, it may be necessary to replace the high exhaust back pressure switch.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved.
  • Page 75: Parts/Technical Support

    Gas Fired Boiler Technical Service 1.877.728.5351 7 Parts/Technical Support Spare parts and replacement parts can be ordered from Patterson-Kelley by calling toll free (877) 728-5351. Reach Use of Non-Factory Authorized us by fax at (570) 476-7247. replacement parts are not...
  • Page 76 ® P-K MACH Gas Fired Boiler Technical Service 1.877.728.5351 Figure 7.1.1a Power Box Wiring Diagram (240V Configuration Shown)  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx...
  • Page 77 ® P-K MACH Gas Fired Boiler Technical Service 1.877.728.5351 Figure 7.1.1b Power Box Wiring Diagram (480V Configuration Shown)  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx...
  • Page 78: Terminal Block Assignments - Low Voltage (Tb1) Terminal Block

    Configurable for Setpoint or Firing Rate Control ENABLE / DISABLE Contact Closure Enables Comfort Heat Operation Open Circuit Disables Comfort Heat Operation ENABLE / DISABLE  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx...
  • Page 79: Terminal Block Assignments - High Voltage (Tb2) Terminal Block

    NEUTRAL N1 Unused Unused Unused L1 for 110-120VAC, Single phase, 60Hz HOT L1 Unused  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx Page 74...
  • Page 80: Wiring Diagrams

    Gas Fired Boiler Technical Service 1.877.728.5351 Wiring Diagrams 7.2.1 C-1500H & C-2000H Wiring Diagram Patterson Kelley, LLC  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx...
  • Page 81 ® P-K MACH Gas Fired Boiler Technical Service 1.877.728.5351 Patterson Kelley, LLC  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx Page 76...
  • Page 82: C-1500Gg & C-2000Gg Dual Fuel Wiring Diagram

    P-K MACH Gas Fired Boiler Technical Service 1.877.728.5351 7.2.2 C-1500GG & C-2000GG Dual Fuel Wiring Diagram Patterson Kelley, LLC  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx...
  • Page 83 ® P-K MACH Gas Fired Boiler Technical Service 1.877.728.5351 Patterson Kelley, LLC  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx Page 78...
  • Page 84: C1500T & C2000T Wiring Diagram

    P-K MACH Gas Fired Boiler Technical Service 1.877.728.5351 7.2.3 C1500T & C2000T Wiring Diagram Patterson Kelley, LLC  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx...
  • Page 85 ® P-K MACH Gas Fired Boiler Technical Service 1.877.728.5351 Patterson Kelley, LLC  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx Page 80...
  • Page 86: C2500 Wiring Diagram

    P-K MACH Gas Fired Boiler Technical Service 1.877.728.5351 7.2.4 C2500 Wiring Diagram Patterson Kelley, LLC  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx...
  • Page 87 ® P-K MACH Gas Fired Boiler Technical Service 1.877.728.5351 Patterson Kelley, LLC  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx Page 82...
  • Page 88: C-2500 Dual Fuel Wiring Diagram

    P-K MACH Gas Fired Boiler Technical Service 1.877.728.5351 7.2.5 C-2500 Dual Fuel Wiring Diagram Patterson Kelley, LLC  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx...
  • Page 89 ® P-K MACH Gas Fired Boiler Technical Service 1.877.728.5351 Patterson Kelley, LLC  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx Page 84...
  • Page 90 ® P-K MACH Gas Fired Boiler Technical Service 1.877.728.5351 Patterson Kelley, LLC  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx Page 85...
  • Page 91: Control Transformer - Power Box (C-3000 & C-4000 Only)

    Improper configuration of the control transformer could result in serious injury or death. Figure 7.2.4a C-3000 & C-4000: 208 VAC, three phase, 60 hertz:  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved.
  • Page 92 Technical Service 1.877.728.5351 Figure 7.2.4b C-3000 & C-4000: 220-240 VAC, Three Phase, 60 hertz: Figure 7.2.4c C-3000 & C-4000: 440-480 VAC, Three Phase, 60 hertz:  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved.
  • Page 93: C-3000 & C-4000 240V Wiring Diagram

    P-K MACH Gas Fired Boiler Technical Service 1.877.728.5351 7.2.7 C-3000 & C-4000 240V Wiring Diagram Patterson Kelley, LLC  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx...
  • Page 94 ® P-K MACH Gas Fired Boiler Technical Service 1.877.728.5351 Patterson Kelley, LLC  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx Page 89...
  • Page 95: C-3000 & C-4000 240V Dual Fuel Wiring Diagram

    P-K MACH Gas Fired Boiler Technical Service 1.877.728.5351 7.2.8 C-3000 & C-4000 240V Dual Fuel Wiring Diagram Patterson Kelley, LLC  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx...
  • Page 96 ® P-K MACH Gas Fired Boiler Technical Service 1.877.728.5351 Patterson Kelley, LLC  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx Page 91...
  • Page 97 ® P-K MACH Gas Fired Boiler Technical Service 1.877.728.5351 Patterson Kelley, LLC  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx Page 92...
  • Page 98: C-3000 & C-4000 480V Wiring Diagram

    P-K MACH Gas Fired Boiler Technical Service 1.877.728.5351 7.2.9 C-3000 & C-4000 480V Wiring Diagram Patterson Kelley, LLC  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx...
  • Page 99 ® P-K MACH Gas Fired Boiler Technical Service 1.877.728.5351 Patterson Kelley, LLC  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx Page 94...
  • Page 100: C3000Gg & C4000Gg 480V Dual Fuel Wiring Diagram

    P-K MACH Gas Fired Boiler Technical Service 1.877.728.5351 7.2.10 C3000GG & C4000GG 480V Dual Fuel Wiring Diagram Patterson Kelley, LLC  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx...
  • Page 101 ® P-K MACH Gas Fired Boiler Technical Service 1.877.728.5351 Patterson Kelley, LLC  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx Page 96...
  • Page 102 ® P-K MACH Gas Fired Boiler Technical Service 1.877.728.5351 Patterson Kelley, LLC  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx Page 97...
  • Page 103: Boiler Parts Identification (C-1500H & C-2000H)

    Burner/Blower Assembly Front Door / NURO Touchscreen Cabinet Base Sheet Metal Cabinet Natural Gas Train  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx...
  • Page 104: Nuro Control Panel (C-1500H & C-2000H)

    NURO Touchscreen Assembly Transformer XFMR1 (20VA) High Exhaust Back Pressure Switch Push to Test LWCO Button Air Pressure Switch  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx...
  • Page 105: Heat Exchanger Assembly (C-1500H & C-2000H)

    Return Manifold/Header Burner Studs Inlet Coupling (2-1/2” Victaulic) Ignition Electrode Manual Drain Valve Supply Temperature Sensor  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx...
  • Page 106: Natural Gas Train, Burner & Blower Assembly (C-1500H & C-2000H)

    Low Gas Pressure Switch Ignition Electrode & Gasket Internal (Downstream) Gas Cock Blower Gasket Air Intake Box & Transition Piece  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx...
  • Page 107: Natural Gas Train, Burner & Blower Assembly High Turndown (C1500T & C2000T)

    Main Gas Shutoff/Control Valve Combustion Blower / Fan Low Gas Pressure Switch Burner Transition Piece Air/Gas Venturi  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx...
  • Page 108: Propane Gas Train, Burner & Blower Assembly (C-1500H & C-2000H)

    Gas Piping & Supports Main Gas Shutoff/Control Valve Low Gas Pressure Switch Internal (Downstream) Gas Cock High Gas Pressure Switch  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx...
  • Page 109: Boiler Parts Identification C-2500, C-3000 & C-4000)

    NURO Control Panel Natural Gas Train Front Door / NURO Touchscreen Cabinet Base Sheet Metal Cabinet  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx...
  • Page 110: Nuro Control Panel (C-2500, C-3000 & C-4000)

    LWCO Circuit Board Transformer XFMR2 (40VA) Low Voltage (TB1) Terminal Block Transformer XFMR1 (20VA) NURO Touchscreen Assembly  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx...
  • Page 111: Main Power Box (C-3000 & C-4000 Only)

    Grounding Terminal Blower Motor Relay 20A Three Phase Breaker (Incoming Three Phase Power) Fuse Holder  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx...
  • Page 112: Heat Exchanger Assembly (C-2500, C-3000 & C-4000)

    Return Manifold/Header Burner Studs Inlet Coupling (3”/4” Victaulic) Ignition Electrode Manual Drain Valve Supply Temperature Sensor  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx...
  • Page 113: Natural Gas / Propane Gas Train, Burner & Blower Assembly (C-2500 & C-3000)

    Auxiliary High Exhaust Back Pressure (“Dirty Burner”) Combustion Blower / Fan Switch Burner Hood Casting High Gas Pressure Switch  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx...
  • Page 114: Natural Gas / Propane Gas Train, Burner & Blower Assembly (C-4000)

    Stainless Steel Mesh Burner Combustion Blower / Fan Low Gas Pressure Switch Auxiliary High Exhaust Back Pressure (“Dirty Burner”) Switch  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx...
  • Page 115 Last Update 12/12/2016 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...
  • Page 116 No sales representative, agent, or employee of Seller or any reseller in the chain of sale of the product is authorized to make any modification, extension, or addition to this Specific Limited Warranty, unless agreed to in writing by Seller.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved.
  • Page 117: Boiler Fire-Test Report

    ® P-K MACH Gas Fired Boiler Technical Service 1.877.728.5351 8 Boiler Fire-Test Report  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx Page 112...
  • Page 118 ® P-K MACH Gas Fired Boiler Technical Service 1.877.728.5351 Dual Fuel Addendum  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx Page 113...
  • Page 119: Appendix A - Maintenance Log

    Appendix A – Maintenance Log Hi Fire / Stack Date Action Low Fire Temp  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx Page 114...
  • Page 120: Appendix B - Boiler Altitude Derate Schedule

    Although the appliance’s capacity is reduced due to the lower air density, the combustion tuning should follow the standard combustion guidelines of Section 3.11.2. Tune the combustion for the same O levels as discussed in Section 3.11.2.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved.
  • Page 121: Appendix C - Water Quality Standards Quality Standards For Hydronic Boilers In Multi-Metal Systems

    Gas Fired Boiler Technical Service 1.877.728.5351 Appendix C – Water Quality Standards Quality Standards for Hydronic Boilers in Multi-Metal Systems Patterson-Kelley boilers are designed to be incorporated into any multi-metal hydronic heating system. All multi- metal hydronic systems require that attention be paid to water treatment.
  • Page 122: Appendix D - Best Practices For New & Retrofit Systems

    NOTE: This strainer is not intended to remove fine particulate matter from the boiler system which will be discussed later in this appendix. 4. Patterson-Kelley recommends installing a water meter on the cold water fill piping. The intention of this device is to periodically monitor the amount of fresh water introduced into the system piping.
  • Page 123 (blended) sample. 11. Within the first three months after startup, Patterson-Kelley recommends collecting a follow-up water sample from the hydronic system. This should be compared to the initial startup sample in order to determine any changes in pH, Alkalinity, conductivity, etc.
  • Page 124: Appendix E - Installation And Quick Reference

    Maximum Inlet Pressure = 14.0” W.C. Maximum Inlet Pressure = 14.0” W.C. NOTE Patterson-Kelley recommends installing an individual lock-up type gas regulator in the gas supply piping to each boiler. For installations where one master lock-up type gas pressure regulator will service multiple...
  • Page 125 ® P-K MACH Gas Fired Boiler Technical Service 1.877.728.5351 Appliance Connections (MACH C-1500H & C-2000H) All connections should be in compliance with national, state, and local code requirements. OTICE The appliance is furnished with a 3/4” manual drain (ball) valve which allows the user to completely drain the heat exchanger.
  • Page 126 The chart below represents the pressure drop (Ft of Head) versus the water flow rate (GPM) for the MACH C-1500H & C-2000H. This information is useful to help size an appropriate circulation pump. Keep in mind this pressure drop represents the boiler only, additional consideration is needed for any connected piping, valves, strainers, couplings, flanges, etc.
  • Page 127 The appliance is furnished with 3/4” drain tubing which is used to drain built-up condensation inside the appliance’s combustion chamber. Connect this 3/4” drain tubing to the condensate neutralization system.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved.
  • Page 128 The appliance is furnished with 3/4” drain tubing which is used to drain built-up condensation inside the appliance’s combustion chamber. Connect this 3/4” drain tubing to the condensate neutralization system.  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved.
  • Page 129 Minimum Flow Ignition 95 GPM 40°F Minimum Flow Low Fire 76 GPM 20°F  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx Page 124...
  • Page 130 27.8 ft 425.6 GPM 19.7 ft 324.7 GPM 30.7 ft 447.2 GPM 21.7 ft  Patterson-Kelley 2020 Revised: January 3, 2020 1004905981 P-K MACH C1500H-C4000 Installation and All Rights Reserved. Released: January 3, 2020 Owners Manual (Rev F Jan-2020).docx Page 125...

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