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C.S.A Design-Certified
Complies with ANSI Z21.13/CSA 4.9
Gas-Fired Low Pressure Steam and Hot Water
Boilers
ASME Code, Section IV
Certified by Patterson-Kelley
C.S.A Design-Certified
Complies with ANSI Z21.13/CSA 4.9
Gas-Fired Low Pressure Steam and Hot Water
Boilers
Installation Date:
_______________________
100 Burson Street, P.O. Box 458,
East Stroudsburg, PA 18301
Telephone: (877) 728-5351, Facsimile: (570) 476-7247
www.pkboilers.com
MACH-04
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Related Manuals for Patterson-Kelley MACH Series
Summary of Contents for Patterson-Kelley MACH Series
- Page 1 MACH-04 C.S.A Design-Certified Complies with ANSI Z21.13/CSA 4.9 Gas-Fired Low Pressure Steam and Hot Water Boilers ASME Code, Section IV Certified by Patterson-Kelley C.S.A Design-Certified Complies with ANSI Z21.13/CSA 4.9 Gas-Fired Low Pressure Steam and Hot Water Boilers Installation Date: _______________________ 100 Burson Street, P.O.
- Page 2 MACH® Series Gas-Fired Boiler...
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Page 3: Table Of Contents
MACH® Series Gas-Fired Boiler Table of Contents 1.0 INTRODUCTION ........1 3.6.11 Intake Duct Connection to Boiler ..12 3.6.12 Intake Duct Terminations ..... 12 2.0 SAFETY ............ 1 3.6.13 Vent Elbows ......... 13 2.1 General ..............1 3.7 Gas Piping ............13 2.2 Training..............1 3.7.1 Gas Supply Piping by Installer .... - Page 4 Failure to trained on the Patterson-Kelley MACH® Boiler. do so could result in fire or explosion and serious injury, death, and/or property damage.
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Page 5: Introduction
Patterson-Kelley cannot be responsible Proper training is the best protection against accidents. for the design or operation of such systems and a Operating and service personnel must be thoroughly qualified engineer or contractor must be consulted. -
Page 6: Safety Labels
Although the labels are of high quality, they NOTE may become dislodged or unreadable over time. When opening leak test valves, Contact Patterson-Kelley toll-free at (877) 728-5351 always follow instructions in operation and safety manual. for replacement labels. 1998 HCS, Inc. 800-748-0241 Reorder No. -
Page 7: Crush Hazards
MACH® Series Gas-Fired Boiler Safety • 2.5.3 Crush Hazards Burn hazard! Possible hot surfaces. Do not touch gas vent during firing operation. Use only factory recommended vent components. • Burn hazard! Pipes, vents, and boiler components could be hot. Do not touch piping or stack surfaces during operation or immediately after shutdown of the boiler. -
Page 8: Pressure Hazards
MACH® Series Gas-Fired Boiler Safety 2.5.5 Pressure Hazards 2.5.6 Slip, Fall Hazards WARNING WARNING Improper use may Improper use may result in fire or injury. result in fire or injury. Read instructions/safety Read instructions/safety manual before installing, manual before installing, operating or servicing boiler. -
Page 9: Installation
MACH® Series Gas-Fired Boiler Installation 3.0 INSTALLATION Code, Section IV for 50 psig maximum operating pressure and/or 200º F maximum temperature. Other codes or approvals which apply will be labeled 3.1 R ECEIVING AND TORAGE on the boiler. Installation of the boiler must conform to all the requirements of all national, state and local codes 3.1.1 Initial Inspection established by the authorities having jurisdiction or,... -
Page 10: Clearances
MACH® Series Gas-Fired Boiler Installation clearance and prevent distortion of the cabinet, (twisting, etc.) in addition to leveling. Adjustable Leg Bolts Minimum Clearances from Adjacent Walls, Ceiling, and Obstructions Type of Surface Dimensions (inches) Adjustable Legs for Leveling and Floor Clearance C†... -
Page 11: Combustion Air
MACH® Series Gas-Fired Boiler Installation An external electrical disconnect (not supplied with when burned, form acids which quickly attack the the boiler) with adequate overload protection is boiler and the boiler stack. The result is improper required. The boiler must be grounded in accordance combustion and premature boiler failure. -
Page 12: Flue Venting
MACH® Series Gas-Fired Boiler Installation If air is taken from another interior space, each 3.6.2 Flue Connection opening should have a net free area of 1 square inch The connection from the boiler to the vent should be for each 1,000 Btu per hour of boiler input (450 square as direct as possible and the upward slope of any inches for a 450,000 Btu per hour.) horizontal breaching should be at least 1/4 inch per... -
Page 13: Vent Terminations
MACH® Series Gas-Fired Boiler Installation 3.6.4 Vent Terminations WARNING! Do not locate intake or exhaust terminations directly above a walkway; dripping of conden- sation can cause icing of the walking surface. No rain cap or Tee. required, Mechanical draft vent terminal Direct vent terminal Outside Plate... -
Page 14: Sealed Combustion Air/Venting System
MACH® Series Gas-Fired Boiler Installation 3.6.6 Sealed Combustion Air/Venting System 3. Insofar as is practical, close all building doors and windows and all doors between the space in The MACH® Series Boilers are also certified for which the appliances remaining connected to the operation with a sealed combustion air and pressurized common venting system are located and other venting system. - Page 15 MACH® Series Gas-Fired Boiler Installation Exhaust Vent Exhaust Vent (type of (Type of flue termination flue termination optional when roof venting.) optional when roof venting.) Air Inlet (tee mounted horizontally.) Roof Air Inlet (Type of flue Roof termination optional.) Sidewall Sidewall Inlet, Roof Vent Roof Inlet and Vent Air Inlet...
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Page 16: Intake Duct Materials And Sizes
MACH® Series Gas-Fired Boiler Installation 3.6.9 Intake Duct Materials and Sizes: Material: PVC, CPVC (Schedule 40), single wall Sidewall galvanized steel, or other suitable materials. Air Inlet The intake duct must be sized for a maximum pressure (tee mounted drop of 0.22 inches W.C., at 100 SCFM (MACH® horizontally) 450) or 70 SCFM (MACH®... -
Page 17: Vent Elbows
MACH® Series Gas-Fired Boiler Installation Remote Gas Shutoff 3.6.13 Vent Elbows (not supplied) The turn from horizontal to vertical should be made Natural Gas with two 45º ells or with one long radius 90º ell for Supply By Installer best operation. Do not use "short radius" ells. Union Drip Leg 3.7 G... -
Page 18: Gas Supply Piping By Installer
MACH® Series Gas-Fired Boiler Installation Pipe Capacity for Natural Gas Nominal Equivalent Pipe Length Maximum Capacity in Cubic Feet of Natural Gas per Hour Iron Pipe Internal Pressure Drop of 0.5 inch Water Column/Equivalent Length of Pipe (in feet) Size Diameter 90º... -
Page 19: Boiler Inlet And Outlet Connections
Strainer Valve configured so as to limit the time rate of change of temperature at the boiler. Consult your authorized Patterson-Kelley boiler representative for application Boiler Inlet and Outlet Connections guidance. Make water connections as the application warrants, or at a minimum as shown, but always in compliance Piping With Air Handling Units with the local requirements. -
Page 20: Boiler Water Piping By Installer
MACH® Series Gas-Fired Boiler Installation 3.8.3 Boiler Water Piping by Installer Drain Valve and Piping A drain valve is installed in the inlet (system return) Strainer header connection to the boiler. Prior to draining the To avoid possible contamination of the boiler with boiler for maintenance or testing, electrical power and dirt, rust or sediment from the system, a strainer near gas supply must be turned off to the boiler. -
Page 21: Burner And Ignition System
MACH® Series Gas-Fired Boiler Installation untreated make-up water will cause premature failure IMPORTANT! due to buildup of scale; such failure is not covered by If the piping system attached to this unit will be warranty. chemically cleaned, the boiler must be Scale can also reduce efficiency. -
Page 22: Pre-Start Check List
MACH® Series Gas-Fired Boiler Installation 3.10 P TART HECK WARNING! Before attempting to start the boiler, make sure the following items have been completed. After checking controls by manual adjustment, make sure they are always reset to their proper 1. Section 3.9.1 Inspection. settings. -
Page 23: Test Of High-Limit Control
MACH® Series Gas-Fired Boiler Installation will occur. The LED indicator for Low Water cut-out 3.12 I NITIAL DJUSTMENTS will no longer be illuminated. Return the system to normal operation and restart the 3.12.1 Operating Temperature Controller for boiler. Refer to Section 4.2.1. MACH®... - Page 24 Turn the comfort heat system Parameters higher than 4 are only accessible by Plus long* on or off authorized service personnel trained on the P-K Show the domestic hot water MACH Series Boiler. Minus momentary setpoint Turn the domestic hot water Upper Minus...
- Page 25 MACH® Series Gas-Fired Boiler Installation High Temp. Differential 0-36 Step Value Low Temp. Setpoint 59-140 Outlet water temp Inlet water temp Domestic Hot Water temp * The boiler will modulate to try to maintain 160° F. If the temperature increases above 169° F which is the Outdoor air temp * setpoint 160°...
- Page 26 MACH® Series Gas-Fired Boiler Installation temperature controller indicates a call for heat from Outdoor Air Reset (optional): the DHW system. When the DHW system calls for heat, the Central heat pump output (Terminal 10 TB2) OU TD OO R A IR vs B OILER SETP O IN T deenergizes and the DHW pump output (Terminal 11 TB2) energizes providing 120 VAC power is provided to energize a relay coil for the DHW pump.
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Page 27: Gas Pressure Adjustment
0-10 VDC signal. A signal of at least 0.5 VDC is Patterson-Kelley MACH® Series boiler. required to start the boiler. At 0 VDC the setpoint is 32° F; at 10 VDC the setpoint is 212° F. This setpoint... -
Page 28: Air Flow Adjustments
MACH® Series Gas-Fired Boiler Installation Note: valve body for measuring supply pressure. (See figure Verify gas pressure at inlet to boiler is in below.) accordance with Table 3-1 below. Gas flow is dependent primarily on fan speed not upstream gas pressure. - Page 29 MACH® Series Gas-Fired Boiler Installation Table 3-1 Combustion Reading For Setting Gas Safety Shut Off / Control Valves Nominal High Fire Setting Low Fire Setting Model Fuel Gas Pressure % CO % CO Natural Gas 7" W.C. 4.9+ 0.2 9.1+ 0.2 5.1+ 0.2 8.9+ 0.2 7"...
- Page 30 MACH® Series Gas-Fired Boiler Installation Low Fire Setting "R" Set boiler to the “Test Mode Low”, as described above, to achieve minimum firing rate of the boiler. Check combustion readings using a combustion analyzer. If combustion readings are not in accordance with Table 3-1 adjust as follows: •...
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Page 31: Operation
MACH® Series Gas-Fired Boiler Operation 4.0 OPERATION 4.2.1 Lighting Procedures 1. Close main gas valve. 4.1 G ENERAL 2. Turn On-Off switch to "OFF" position. 3. Wait 5 minutes. 4.1.1 Control Panel Front 4. Open main gas valve. 5. Turn On-Off switch to "ON" position. 6. -
Page 32: Typical Boiler Operating Conditions
MACH® Series Gas-Fired Boiler Operation WARNING! If overheating occurs or the gas supply fails to shut off, do not turn off or disconnect the electrical supply to the pump. Instead, shut off the gas supply at a location external to the boiler. 4.3 T YPICAL OILER... -
Page 33: Maintenance
5.1.1 Daily qualified installer or service agency who has been Observe operating temperature and general conditions. trained on the Patterson-Kelley MACH® boiler. Make sure that the flow of combustion and ventilating air to the boiler is not obstructed. Determine the cause of any service codes or lockouts on the display panel. -
Page 34: Annually
Installation and service must be performed by a with the manufacturer's instructions. qualified installer or service agency who has been trained on the Patterson-Kelley MACH® boiler. Installation and service must be performed by a The blower motor is permanently lubricated and does qualified installer or service agency who has been not require periodic lubrication. -
Page 35: Sequence Of Operation
MACH® Series Gas-Fired Boiler Maintenance 5.4 S 10. The unit modulates between the low fire setting EQUENCE OF PERATION and the high fire setting to maintain the desired outlet water temp set point. 1. When the On/Off (Main power) switch is turned on, power is provided through a circuit breaker to 11. - Page 36 MACH® Series Gas-Fired Boiler Maintenance Loss of Water Level High Water Temperature The low water switch opens when there is insufficient When the boiler water has exceeded both the operating water level in the boiler. E 12 is shown on the display, and high-limit temperature the high limit switch opens, and E 12 is shown on the display.
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Page 37: Manual Reset Service Codes
MACH® Series Gas-Fired Boiler Maintenance 5.5.1 Manual Reset Service Codes Code Lockout Description E 00 False flame. A flame signal is present when it shouldn’t be. E 02 Flame failure. The burner did not light on startup, or loss of flame during run. E 03 Gas Valve error. -
Page 38: Auto-Reset Service Codes
MACH® Series Gas-Fired Boiler Maintenance 5.5.2 Auto-reset Service Codes Code Lockout Description b 08 Air pressure switch open. The air pressure switch failed to close to indicate sufficient air flow to start the boiler. b 18 Outlet high limit temp. The outlet water temperature has exceeded the internal high limit temperature setting. -
Page 39: Parts/Technical Support
6.0 PARTS/TECHNICAL SUPPORT Spare parts and replacement parts can be ordered from Technical information is also available at the above Patterson-Kelley by calling toll free (877) 728-5351. number. Ask for the Heat Transfer Department. The fax When ordering replacement parts please have the number is (570) 476-7247. -
Page 40: Wiring Diagrams
MACH® Series Gas-Fired Boiler Parts and Technical Support 6.1 W IRING IAGRAMS 6.1.1 Terminal Block Assignments – High Voltage Circuit (TB2) Terminal Number Label Description 115 VAC LINE Boiler Supply Power, 115 VAC, 60 HZ, 1 ph, 8 amp 115 VAC NEUTRAL 115 VAC NEUTRAL Aux. -
Page 41: Terminal Block Assignments - Low Voltage Circuit (Tb1)
MACH® Series Gas-Fired Boiler Parts and Technical Support 6.1.1a Terminal Block Assignments – Low Voltage Circuit (TB1) Terminal Number Label Description HEAT REQUEST Boiler Enable, Contact Closure. DO NOT ENERGIZE. HEAT REQUEST INTERLOCK JUMPER External Limit (auto reset), Contact Closure. DO NOT ENERGIZE. -
Page 42: Wiring Series C-300
MACH® Series Gas-Fired Boiler Parts and Technical Support 6.1.2 Wiring Series C-300 Page 38... -
Page 43: Wiring Series C-450
MACH® Series Gas-Fired Boiler Parts and Technical Support 6.1.2 Wiring Series C-450 Page 39... -
Page 44: Boiler Parts List
MACH® Series Gas-Fired Boiler Parts and Technical Support 6.2 B OILER ARTS 6.2.1 Main Assembly MACH Series 300 MACH Series 450 Mark Description Blower and Gas Train Manifold, System Return, Boiler Outlet Manifold, System Supply, Boiler Inlet Cabinet High Temperature - Aquastat... -
Page 45: Control Panel
MACH® Series Gas-Fired Boiler Parts and Technical Support 6.2.2 Control Panel Mark Description AM-3 Relay Module Boiler Control MACH Series - MCBA Transformer Low Water Cutoff Control Mounting Plate Page 41... -
Page 46: Display Panel
MACH® Series Gas-Fired Boiler Parts and Technical Support 6.2.3 Display Panel Mark Description Circuit Breaker Air Pressure Switch Fastening Clip Display Panel On/Off Switch Pressure Temperature Gauge Panel Sheet Metal Stack Pressure Switch Page 42... -
Page 47: Heat Engine
MACH® Series Gas-Fired Boiler Parts and Technical Support 6.2.4 Heat Engine Refer to next page for parts listing. Page 43... - Page 48 MACH® Series Gas-Fired Boiler Parts and Technical Support Mark Description Gasket Blower to Burner Hood Burner Hood Inside Burner Hood Gasket Outside Burner Hood Gasket Burner Burner Flange With Insulation Sight Glass Seal Sight Glass Sight Glass Holder Exhaust Pipe Lip Ring Exhaust Manifold Inspection Cover Gasket Inspection Cover...
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Page 49: Series C-300 Boiler Gas Train
MACH® Series Gas-Fired Boiler Parts and Technical Support 6.2.5 Series C-300 Boiler Gas Train Mark Description Main Gas Shut-off Valve Low Pressure Gas Switch Gas Safety Shut-off/Control Valve Air/Gas Manifold Swirlplate Blower Gas Leak Test Port Flex Hoses w/ Gas Valve Adaptors Page 45... -
Page 50: Series C-450 Boiler Gas Train
MACH® Series Gas-Fired Boiler Parts and Technical Support 6.2.6 Series C-450 Boiler Gas Train Mark Description Main Gas Shut-off Valve Low Pressure Gas Switch High Pressure Gas Switch Gas Safety Shut-off/Control Valve Gas Manifold Shut-off Valve Air/Gas Manifold Swirlplate Blower Gas Leak Test Port Flex Hoses with Gas Valve Adapters Page 46... -
Page 51: Limited Warranty
D. The design or operation of owner's plant or manufactured by Patterson-Kelley Co., Seller warrants equipment or of any facility or system of which to the original owner at the original installation site any Product may be made a part. - Page 52 MACH® Series Gas-Fired Boiler Limited Warranty charges to return the boiler and or components. SEVERABILITY Seller's liability under this warranty shall not in To the extent that any provision of this warranty would any case exceed the amount paid for the Product be void or prohibited under applicable law, such found to be defective.
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Page 53: Appendix
MACH® Series Gas-Fired Boiler Appendix 8.0 APPENDIX Date Hi/Low-Fire Stack Temp Action Page 49... - Page 54 MACH® Series Gas-Fired Boiler Appendix Parameter Settings for MCBA 14C 10XX Controls No. Description Lower Limit Upper Limit MACH MACH Installed 300 PK 450 PK MCBA Factory Factory Parameter Setting Setting Settings MCBA MCBA 14C1028 14C1036 End User Settings Setvalue for DHW Water Storage Tank: 68 F Water Storage Tank: 158 F 140 140 140 140...
- Page 55 MACH® Series Gas-Fired Boiler Appendix No. Description Lower Limit Upper Limit MACH MACH Installed 300 PK 450 PK MCBA Factory Factory Parameter Setting Setting Settings MCBA MCBA 14C1028 14C1036 26 DHW detection hysteresis On -9 F 54 F 27 DHW detection hysteresis Off -36 F 54 F 28 Restart delay CH (*10.2 seconds)
- Page 56 MACH® Series Gas-Fired Boiler Appendix No. Description Lower Limit Upper Limit MACH MACH Installed 300 PK 450 PK MCBA Factory Factory Parameter Setting Setting Settings MCBA MCBA 14C1028 14C1036 exchanger X9 = External heat request (by RMCI ) DHW 3 Way Vlv or Pmp (1st digit) 0X = 3 way valve normally open 1X = Hot water pump 2X = 3 way valve normally closed...
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