Patterson-Kelley Harsco Industrial MACH CM300 Installation & Owner's Manual

Gas-fired boiler

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MACH

GAS-FIRED BOILER

CM300/CM399/CM500

With ENVI

Control

(PART # 1004905968)

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 #:_______

Serial #______________________

Start-Up Date:

_______________________

Harsco Industrial, Patterson-Kelley

155 Burson Street

East Stroudsburg, PA 18301

Telephone: (570) 476-7261

Facsimile: (570) 476-7247

www.harscopk.com

MACH212

MACH

CM300/CM399/CM500

Rev. 1.01 (03/07/13)

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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
® CM SERIES MACH Gas Fired Boiler INTRODUCTION ..................... 4 SAFETY ........................4 General.......................... 4 Training ......................... 4 Safety Features ............Error! Bookmark not defined. Safety Labels ........................ 5 Safety Precautions ......................6 INSTALLATION ...................... 8 Receiving and Storage ....................8 Compliance with Codes ....................
Page 3 ® CM SERIES 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 Reorder No. 6020-V2WHPK 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
® CM SERIES MACH Gas Fired Boiler AFETY RECAUTIONS Provide a suitable location for the boiler away from normal personnel traffic. Ensure that you have adequate working space, adequate clearances, proper ventilation and lighting, a structure sufficiently strong and rigid to support the weight of the boiler, all piping and accessories.
Page 7 Use PVC, CPVC, or other corrosion resistant piping for drainage. Collection and disposal 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 •...
Page 8: Installation
® CM SERIES MACH Gas Fired Boiler 3 INSTALLATION 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 sides covers and inspect the boiler. Verify that the total number of pieces shown on the packing slip agrees with those actually received.
Page 9: Setup
® CM SERIES MACH Gas Fired Boiler ETUP 3.3.1 Foundation - Floor mounted installation Provide a firm, level foundation, preferably of concrete. See picture below of the CM series boilers with Optional base. Mounting instructions for the optional base are below. Note: an optional wall mount or floor base will need to be ordered for installation.
Page 10 ® CM SERIES MACH Gas Fired Boiler NOTICE! The boiler may be installed on a combustible floor; however the boiler must never be installed on carpeting. Use the adjustable leveling legs to level the boiler when placed on the floor. Placement The boiler must be level to function properly.
Page 11 ® CM SERIES MACH Gas Fired Boiler Bottom mounting bracket The boiler is heavy. Use caution not to drop the boiler or cause bodily injury while lifting and handling. Verify that the boiler is securely attached to prevent possibility of boiler falling after installation. After the boiler is removed from the shipping carton, DO NOT allow the boiler to sit on its bottom.
Page 12 ® CM SERIES MACH Gas Fired Boiler Boiler model Weight in Pounds CM300 CM399 CM500 1. Stud spacing: Bracket holes are spaced evenly every 2” and bracket length is 24 ¾”. For other stud spacing, provide secure, solid mounting surface on which to attach the boiler wall-mounting bracket.
Page 13 ** Service access need be only from front and top of a boiler or row of boilers. Boilers may be installed immediately adjacent to each other. However, Harsco Industrial, Patterson-Kelley recommends a 16” minimum clearance on the right side of each boiler for required flame observation. A 2” clearance is the recommended minimum on the left side of the boiler while wall mounting adjacent to a perpendicular wall.
Page 14: Electrical Connections
® CM SERIES MACH Gas Fired Boiler Bumping hazard from overhead ducts! Install all components with adequate vertical clearances. LECTRICAL ONNECTIONS TB2 120vac HV or High voltage terminal block Field service connections TB1 24vac LV or Low voltage terminal block Field service connections The boiler is wired for 120 volts, single phase, 60 hertz.
Page 15 ® CM SERIES MACH Gas Fired Boiler 3.4.1 High Voltage (TB2) Terminal Block The boiler power circuit requires 120 VAC, 60 hertz, with a dedicated neutral and ground as labeled. Electrical service must be rated for 15 amps minimum. Before starting the boiler, check to ensure that the proper voltage and amperage are connected to the boiler and that the boiler is connected to a suitable fused disconnect switch or circuit breaker.
Page 16 CM SERIES MACH Gas Fired Boiler ® sensor is available from Harsco Industrial Patterson-Kelley. Refer to the ENVI users guide for parameter changes to enable this sensors operation. DHW Stat/Sensor – TB1-7 and TB1-8 are connected to the DHW temperature sensor or thermostat. The boiler with a 5V potential energizes this circuit.
Page 17: Inlet Air And Exhaust Venting
® CM SERIES MACH Gas Fired Boiler NLET IR AND XHAUST ENTING 3.4.3 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...
Page 18 ® CM SERIES MACH Gas Fired Boiler 3.4.3.1 Gas Vent Categories Several codes and standards have categorized appliances in accordance with the flue gas temperature and pressure produced by the appliance. Categories are defined as follows: • Category II An appliance that operates with a non-positive vent static pressure and with a vent temperature that may cause excessive condensate production in the vent.
Page 19 ® CM SERIES MACH Gas Fired Boiler Table of Acceptable Materials for Venting Systems Manufactured Venting Systems US and Canada • AL29-4C Stainless Steel Vent Systems listed and labeled to UL1738 Venting Systems for Gas-Burning Appliances, Categories II, III, and IV •...
Page 20 ® CM SERIES MACH Gas Fired Boiler chemicals, when burned, form acids which quickly attack the boiler and the boiler stack. The result is improper combustion and premature boiler failure. Under no circumstances shall the boiler room ever be under a negative pressure.
Page 21 ® CM SERIES MACH Gas Fired Boiler NOTICE! The required size of openings for combustion and ventilation air shall be based on the net free area of the opening. 2. Screens for combustion air openings shall not be smaller than ¼” 3.
Page 22 ® CM SERIES MACH Gas Fired Boiler NOTICE! 1. The free area of a combustion air supply opening is calculated by deducting the blockage area of any fixed louvers, grilles or screens from the total area of the opening. 2. Screens shall be not smaller than ¼” 3.
Page 23 ® CM SERIES MACH Gas Fired Boiler 3.4.4.2 STAINLESS STEEL VENTING The following materials are used by venting manufacturers to produce listed venting systems. • AL29-4C Stainless Steel Vent Systems listed and labeled to UL1738 Venting Systems for Gas-Burning Appliances, Categories II, III, and IV •...
Page 24 ® CM SERIES MACH Gas Fired Boiler A customer supplied adapter is required to be installed between the boiler and the CPVC venting. See the table above ® for a list of available adapters for each size MACH boiler. Installer should use Adapters listed in the table or an equivalent adapter.
Page 25 ® CM SERIES MACH Gas Fired Boiler Interior Component Clearances All vent system components shall be installed so as to maintain the following required minimum clearances: Combustible Non-Combustibles Unlisted single wall metal pipe Do NOT Use Do NOT Use Single wall CPVC pipe 18 in.
Page 26 ® CM SERIES MACH Gas Fired Boiler Exterior wall The vent needs to be pitched towards the boiler to ensure condensation within the vent drains back to the boiler. The connection from the boiler to the vent should be as direct as possible and the upward slope of any horizontal breaching should be at least 1/4 inch per linear foot.
Page 27 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 as illustrated in section 3.5.5. A birdscreen with 1” x 1” openings is recommended for the termination. Harsco Industrial, Patterson-Kelley does not recommend using a vent rain cap of any type.
Page 28 ® CM SERIES MACH Gas Fired Boiler 3.4.6 Sealed Combustion/Direct Vent Systems ® The MACH boilers are also certified for operation with a sealed combustion air and pressurized venting system. Such a system employs a sealed combustion air intake duct leading from outdoors and a sealed exhaust vent terminating outdoors.
Page 29 ® CM SERIES MACH Gas Fired Boiler 3.4.6.2 Intake/Exhaust Layout Three basic configurations for the intake/exhaust may be used for the CM300/CM399/CM500. Refer to Section 3.5 for required clearances for all terminations. NOTE: CM series boilers are certified for use with concentric vent terminations, contact vent manufacturer for vent design and use.
Page 30 ® CM SERIES MACH Gas Fired Boiler Note: when installing sidewall INLET termination fittings, Tee’s need to be mounted horizontally and elbow’s if used, need to be mounted downward. Also, INLET roof terminations require a Tee mounted horizontally to impede rain and snow from entering the inlet as shown. Note: When side wall venting the INLET must terminate on the same wall as the vent.
Page 31: Gas Piping
® CM SERIES MACH Gas Fired Boiler IPING Before making the gas hook-up, make sure the boiler is being supplied with the type of fuel shown on the boiler nameplate. The boiler shall be installed such that the gas ignition system components are protected from water (dripping, spraying, rain, etc.) during appliance operation and service (circulator replacement, control replacement, etc.) The boiler is factory fire-tested and adjusted for proper combustion.
Page 32 ® CM SERIES MACH Gas Fired Boiler Must install a Gas Piping Schematic (left) Remote Gas Drip leg Supply Shutoff Install a sediment trap (drip leg) and a union connection ahead of the primary manual shutoff valve on the boiler. Gas piping should be installed in accordance with National Fuel Gas Code, ANSI Drip Leg Z223.1, latest edition, and any other local codes...
Page 33: Boiler Water Piping
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. 3.6.1.2...
Page 34 ® CM SERIES MACH Gas Fired Boiler 3.6.2 Boiler Inlet and Outlet Connections Boiler drain Relief valve piping connection...
Page 35 All water connections should be in compliance with national, state and local code requirements. Adapters from Victaulic to NPT are available from NOTICE! The boiler is furnished with 1 1/2” Harsco Industrial, Patterson-Kelley. grooved connections and Victaulic Style 75 Couplings. These couplings must be used with The bottom left connection to the boiler is the INLET and the EPDM Victaulic seals.
Page 36 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 37: Pre-Start Check List
® CM SERIES MACH Gas Fired Boiler NOTICE! Under no circumstances should petroleum based cleaning or sealing compounds be used in the boiler system. NOTICE! Under no circumstances should the hydronic system be flushed while the boiler is attached to the system since the debris or corrosion products may accumulate in the boiler and plug the boiler heat exchanger.
Page 38 ® CM SERIES MACH Gas Fired Boiler If a control setting is changed manually during testing, return the control to its original setting. NOTICE! If the expected error code(s) do not appear, call for qualified service. 3.8.1 Test of Ignition Safety System Test the ignition system safety shutdown as follows: 1) Cycle the boiler on by generating a heat request.
Page 39: Initial Adjustments
® CM SERIES MACH Gas Fired Boiler The boiler is furnished with a high pressure switch that must be checked by closing the downstream gas cock with the boiler off. When the boiler is started, it should enter its normal starting cycle and fail on high gas pressure when the automatic gas valves open.
Page 40 ® CM SERIES MACH 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. 3.9.2 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.
Page 41: Burner Adjustment
3.10 B 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.
Page 42 ® CM SERIES MACH Gas Fired Boiler Inlet Gas See rating plate for the minimum and maximum inlet gas pressure of Test Port the boiler. The supply pressure during main burner operation must be greater than the minimum indicated on the rating plate. Nominal gas supply pressure is 7”...
Page 43 ® CM SERIES MACH Gas Fired Boiler Manifold gas Inlet gas pressure port pressure port High fire adjustment (Slotted screw) Low fire adjustment Hex adjustment NOTICE! There must be sufficient load to operate the boiler at high fire to perform the following adjustments.
Page 44: Operation
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 45 ® CM SERIES MACH Gas Fired Boiler 3. Set the desired high temperature limit and operating temperature. The controller will now complete the automatic firing sequence. 4.2.2 Normal Shut Down Procedures Turn the on/off switch to the off position. Close all manual gas valves. (for extended period.) 4.2.3 Emergency Shut-Off If overheating occurs or the gas supply fails to shut off, do not turn off or disconnect the...
Page 46: Typical Boiler Utility Requirements
® CM SERIES MACH Gas Fired Boiler YPICAL OILER TILITY EQUIREMENTS Model Input Natural Gas LP Gas Total Number Rating *(1030 Btu/cu. ft.) **(2500 Btu/cu. ft.) Amperage (Btu/hr) (15 amp breaker required) Output Output Rate Capacity Rate Capacity (CFH) (Btu/hr) (CFH) (Btu/hr) CM300...
Page 47 ® CM SERIES MACH Gas Fired Boiler Check daily to be sure that the boiler area is free and clear of any combustible materials, including flammable vapors and liquids. 5.1.2 Weekly Observe the appearance of the main flame. If the flame appearance changes from what was observed after proper combustion adjustment, corrective action should be taken.
Page 48: Cleaning The Burner
If they are absent or have been significantly worn away, replace them with new limestone rocks. Use hi-calcium (or pure) limestone available from your local Harsco Industrial Patterson-Kelley representative. 7. Examine the venting system at least once a year. Refer to the vent manufacturer's instructions for requirements in addition to those listed below.
Page 49: After All Repairs Or Maintenance
® CM SERIES MACH Gas Fired Boiler FTER EPAIRS OR AINTENANCE Follow "Pre-Start Check List" (Section 3.8) and all "Safety Checks" (Section 3.9). 2. Check gas pressure. (Section 3.11) 3. Perform combustion check. Adjust if necessary. (Section 3.11). EQUENCE OF PERATION 1.
Page 50: Troubleshooting
® CM SERIES MACH Gas Fired Boiler Ignition Sequence Timing Ignition Sequence Timing Gas Valve Gas Valve Spark Spark Flame Flame Detection Detection Seconds Seconds Flame must be detected at T = 6 seconds Flame must be detected at T = 6 seconds NOTICE! Once the boiler begins the ignition sequence, the firing sequence will continue until main flame is reached regardless of heat request.
Page 51 ® CM SERIES MACH Gas Fired Boiler 5.5.3 Low Gas Pressure The low gas pressure switch opens when there is insufficient gas pressure available for proper operation of the boiler. If an external gas-supply shut-off valve is closed, a low gas condition will result. Locking LOW GAS PRESSURE is shown on the display, the burner operation is interrupted, and the boiler locks out.
Page 52 ® CM SERIES MACH Gas Fired Boiler 5.5.10 Manual Reset Error Codes – A## A Code Error Int. nr Description unsuccessful ignition attempt IGNIT ERROR Three times flame was lost during on demand TOO MANY FLAME FAILURES Overheat stat is open T MAX LOCK ERROR Problems with gas valve relay= internal hardware error GV RELAY ERROR...
Page 53: Parts/Technical Support
IF COMMUNICATION FAILURE 6 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...
Page 54: Wiring Diagrams
When ordering replacement parts please have the model number and serial number of your boiler available. Drawings showing boiler components are displayed on the following pages. Drawings specific to your particular boiler model can also be supplied by your local Harsco Industrial, Patterson-Kelley representative. IRING IAGRAMS 6.1.1 Terminal Block Assignments –...
Page 55 ® CM SERIES MACH Gas Fired Boiler 6.1.2 Terminal Block Assignments – Low Voltage (Less than 32VAC) Circuit (TB1) Terminal Number Label Description ENABLE / DISABLE Boiler Enable, Contact Closure. These terminals have a low voltage output. DO NOT ENERGIZE. ENABLE / DISABLE EXTERNAL INTERLOCK External Limit, Contact Closure.
Page 56 ® CM SERIES MACH Gas Fired Boiler ® 6.1.3 Wiring MACH Boiler CM300...
Page 57 ® CM SERIES MACH Gas Fired Boiler ® 6.1.4 Wiring MACH Boiler CM399/CM500...
Page 58: Boiler Parts List
® CM SERIES MACH Gas Fired Boiler OILER ARTS ® 6.2.1 MACH Boiler CM300/CM399/CM500 Main Assembly...
Page 59 ® CM SERIES MACH Gas Fired Boiler CM300/CM399/CM500 Control Panel...
Page 60 ® CM SERIES MACH Gas Fired Boiler ® 6.2.2 MACH Boiler CM300/CM399/CM500 Heat Engine...
Page 61 ® CM SERIES MACH Gas Fired Boiler ® 6.2.3 MACH Boiler CM300 Gas Train...
Page 62 ® CM SERIES MACH Gas Fired Boiler ® 6.2.4 MACH Boiler CM399/CM500 Gas Train...
Page 63: Limited Warranty
7 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 64: Mach ® Boiler Fire Test Report
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 65: Appendix 1 - Maintenance Log
® CM SERIES MACH Gas Fired Boiler APPENDIX 1 – MAINTENANCE LOG Date Hi/Low-Fire Stack Temp Adjustments...
Page 66: Appendix 2 - Mach Boiler Altitude Derate Schedule
® CM SERIES MACH Gas Fired Boiler ® APPENDIX 2 – MACH BOILER ALTITUDE DERATE SCHEDULE For installations over 2000 ft elevations, a de-rate schedule is applied. The boiler input rating must be reduced by 4% per 1000 ft above sea level, as illustrated using the following graph. 4% Derate Schedule 2000 3000...
Page 67 ® CM SERIES MACH Gas Fired Boiler...

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Harsco industrial mach cm399 Harsco industrial mach cm500

Patterson-Kelley Harsco Industrial MACH CM300 Installation & Owner's Manual

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