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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.
INSTALLATION
& O W N E R'S
MANUAL
INSTALLATION
& O W N E R'S
MANUAL
INSTALLATION
& O W N E R'S
MANUAL
INSTALLATION
& O W N E R'S
MANUAL
INSTALLATION
& O W N E R'S
MANUAL
INSTALLATION
& O W N E R'S
MANUAL
INSTALLATION
& O W N E R'S
MANUAL
INSTALLATION
& O W N E R'S
MANUAL
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Table of Contents
Related Manuals for Patterson-Kelley MACH C-4000
Summarization of Contents
Safety
General
Covers general installation, operation, and servicing requirements for P-K MACH boilers.
Safety Precautions
Provides guidance on selecting a suitable location for the boiler, ensuring adequate space and support.
Safety Features
Defines customer responsibility for external safety provisions like guards and labels.
Safety Labels
Explains the meaning of signal words used in the manual to denote hazard severity.
Training
Emphasizes the importance of training for safe installation, operation, and service.
Hazard Warnings
Details electrical, crush, and pressure hazards with associated warnings and precautions.
Slip, Fall Hazards
Covers tripping hazards from piping and slip hazards from wet floors or condensate.
Chemical Hazards
Discusses hazards associated with cleaning products and condensate acidity.
Burn, Fire and Explosion Hazards
Details hazards related to installation, fuels, gas leaks, and hot surfaces.
Introduction
Purpose of this Document
States the manual's purpose is to provide installation and owner support for P-K MACH boilers with NURO controls.
Common Abbreviations
Lists common abbreviations used in the manual with their descriptions.
Site Preparation
Initial Inspection upon Receiving
Details how to inspect the boiler for shipping damage upon delivery.
Storage Prior to Installation
Provides guidelines for storing the boiler safely if it's not installed immediately.
Compliance with Codes
Outlines the codes and standards the boiler complies with and installation requirements.
Location Setup
Specifies requirements for boiler placement, including foundation and clearances.
Clearances
Details minimum clearances required around the boiler for safety and service access.
Inlet Air and Exhaust Venting Considerations
Discusses codes, standards, and considerations for inlet air and exhaust venting.
Category II/IV Flue Gas Exhaust Vent Planning
Details planning for Category II/IV flue gas exhaust venting, including draft requirements.
Venting Materials for Flue/Exhaust Systems
Lists acceptable and prohibited venting materials for P-K MACH boilers.
Required Clearances
Specifies required clearances for conventional and direct vent systems.
Installation
Overview
Outlines site preparation and installation requirements covered in Section 3.
Appliance Connections
Summarizes appliance connection types for P-K MACH boilers.
Appliance Connections (C-1500H & C-2000H)
Details appliance connections for C-1500H and C-2000H models.
Appliance Connections (C-2500 & C-3000)
Details appliance connections for C-2500 and C-3000 models.
Appliance Connections (C-4000)
Details appliance connections for the C-4000 model.
Electrical Connections
Covers power requirements and connections for various boiler models.
Power Requirements (C-1500H, C-2000H & C-2500)
Specifies power requirements and connections for single-phase models.
Single Phase Power Supply Connection (C-1500H, C-2000H & C-2500)
Details the single-phase power supply connection to the high voltage terminal block.
Power Requirements (C-3000 & C-4000)
Outlines power requirements for three-phase C-3000 and C-4000 boilers.
Three Phase Power Supply Connection (C-3000 & C-4000)
Explains the three-phase power supply connection and control transformer function.
High Voltage (TB2) Terminal Block
Describes the function of terminals on the High Voltage (TB2) terminal block for safety devices and relays.
Low Voltage (TB1) Terminal Block
Details the function of terminals on the Low Voltage (TB1) terminal block for inputs and outputs.
Combustion Air
Air Inlet Requirements – United States
Specifies requirements for combustion air inlets based on US codes (NFPA 54/ANSI Z223.1).
Air Inlet Requirements - Canada
Outlines combustion air inlet requirements for Canadian provinces (CAN/CSA B149.1).
P-K MACH® Combustion Air Requirements
Summarizes combustion air requirements and intake connections for P-K MACH boilers.
Direct Vent / Sealed Combustion Installations
Discusses direct vent/sealed combustion systems and ductwork requirements.
Motorized Combustion Air Dampers
Recommends motorized dampers for combustion air intake and provides model information.
Flue Gas / Exhaust Venting
Category II or IV Venting Installation
Details installation requirements for Category II/IV venting systems.
Vent Termination
Illustrates vent termination requirements and clearances.
Venting for Multiple Boilers
Discusses complexity and requirements for venting multiple boilers together.
Sealed Combustion/Direct Vent Systems
Covers configurations for sealed combustion/direct vent systems and termination illustrations.
Inlet Duct Connection to Boiler
Explains how to connect the air supply duct to the boiler's inlet air collar.
Intake Duct Materials and Sizes
Details acceptable materials and rigidity requirements for intake ductwork.
Category II Installations
Lists requirements for reliable operation in Category II conditions, including adapters and dampers.
Category IV Installations
Outlines installation requirements for Category IV conditions, emphasizing positive pressure.
Stainless Steel Venting
Discusses materials used for stainless steel venting systems and installation care.
CPVC Vent System Installation
Provides instructions for installing CPVC vent systems, including parameters and support spacing.
Piping
Gas Piping Overview
Covers gas piping before hook-up, including fuel type, pressure, and code compliance.
Natural Gas Piping
Provides tables for sizing natural gas piping based on capacity and pressure drop.
Propane Gas Piping
Provides tables for sizing propane gas piping based on capacity and pressure drop.
Pressure Testing the Gas Piping
Details procedures for pressure testing gas piping and checking for leaks.
Boiler Water Piping
Discusses boiler water piping for heating coils in air handling units and preventing gravity circulation.
Boiler Inlet and Outlet Connections
Covers water connections, adapters, and stresses on the boiler.
Boiler Water Piping (for Installer)
Provides installer guidance on strainers, relief valve piping, and connections.
Safety Checks
Ignition Safety System Test
Details how to test the ignition system safety shutdown procedure.
Low Water Cut-Out Test
Explains how to test the probe-type low water cut-off device.
Manual Reset High Temperature Limit Test
Describes how to test the manual reset high temperature limit control.
Gas Pressure Switch Tests
Details testing procedures for the low and high gas pressure switches.
Fuel/Air Adjustments
Gas Pressure Adjustment
Guides on adjusting gas pressure based on the rating plate and supply pressure.
Manual Control Mode for High and Low Fire Adjustment
Explains how to use the NURO control's manual mode for adjusting combustion at high and low fire.
Adjusting High Fire
Provides steps for adjusting high fire combustion settings using a combustion analyzer.
Adjusting Low Fire
Provides steps for adjusting low fire combustion settings using a combustion analyzer.
Checking Flame Signal
Explains how to check the flame signal value on the NURO display.
Initial NURO Control Setup and Adjustment
Startup
Describes the initial startup screen and local representative information display.
Home Screen
Details the Home Screen display, showing boiler operating conditions.
Information Screen
Explains the Information Screen for viewing real-time boiler data.
Setup Wizard
Guides users through setting up the boiler for various applications using the wizard.
Typical Boiler Operating Conditions
Presents typical operating conditions, including input ratings, voltage, and gas flow rates.
Dual Fuel Boiler Operation
Overview
Introduces dual fuel boilers and their independent gas trains for Natural Gas and Propane.
Changing Fuel Types
Provides step-by-step instructions for changing between Natural Gas and Propane fuel types.
P-K MACH C1500GG & C2000GG
Details specific information for C1500GG and C2000GG dual fuel models.
Natural Gas Train and Propane Gas Train Locations
Shows the locations of gas valves/cocks for dual fuel models.
Fuel Selector Switch Location
Illustrates the location of the fuel selector switch for C1500GG and C2000GG models.
P-K MACH C2500GG, C3000GG & C4000GG
Details specific information for C2500GG, C3000GG, and C4000GG dual fuel models.
Natural Gas Train and Propane Gas Train Locations (C2500GG & C3000GG)
Shows gas train locations for C2500GG and C3000GG models.
Natural Gas Train and Propane Gas Train Locations (C4000GG)
Illustrates gas train locations for the C4000GG model.
Fuel Selector Switch Location
Shows the fuel selector switch location for C2500GG, C3000GG, and C4000GG models.
P-K MACH C1500T & C2000T
Details specific information for C1500T and C2000T models.
Natural Gas Train Location
Shows the natural gas train location for C1500T and C2000T models.
High Turndown C1500T & C2000T
Mentions leveling requirement for high turndown models.
Operations
NURO Control Panel
Describes accessing the NURO control panel and power switch.
NURO Touch Screen Interface
Explains how to operate and program the boiler using the touch screen interface.
Factory Tests
States that safe lighting and performance criteria were met during factory tests.
Normal Lighting and Shut-down Procedures
Covers procedures for normal lighting and shutting down the boiler.
Normal Lighting Procedures
Details steps for normal boiler startup, including system fill and electrical connection.
Normal Shut Down Procedures
Outlines the steps for safely shutting down the boiler.
Maintenance
Preventative Maintenance
Provides a schedule for preventative maintenance tasks.
Daily Preventative Maintenance
Lists daily checks for operating conditions, air flow, and error codes.
Weekly Preventative Maintenance
Details weekly checks for flame conditions and combustion air adjustments.
Monthly Preventative Maintenance
Lists monthly checks including flame signal, water cut-off, and gas pressure switches.
Semi-Annually
Outlines semi-annual maintenance tasks, including burner cleaning and pH checks.
Annually
Lists annual maintenance tasks such as inlet screen cleaning and heat exchanger inspection.
Cleaning the Burner & Combustion Chamber
Provides instructions for cleaning the burner and combustion chamber.
MACH C-1500H & C-2000H
Details the specific steps for cleaning the burner and chamber for these models.
MACH C-2500, C-3000 & C-4000
Details the specific steps for cleaning the burner and chamber for these models.
Maintenance and Inspection Schedule
Refers to the schedule for critical semi-annual and annual maintenance.
After Repairs or Maintenance
Lists steps to follow before returning the boiler to service after repairs.
Troubleshooting
Loss of Power
Addresses issues related to power failure and system de-energization.
Loss of Water Level
Describes the lockout condition for low water level and its resolution.
Low Gas Pressure
Explains the lockout for low gas pressure and the conditions that cause it.
High Water Temperature
Details the lockout for high water temperature and manual reset procedures.
Low Air
Covers troubleshooting issues related to improper airflow through the boiler.
Flame Failure
Lists error messages and causes for flame failure during operation.
Flame Error
Discusses flame errors like premature or late flame signals and potential causes.
Flue Problem
Addresses issues related to high exhaust back pressure switches and flue obstructions.
Parts/Technical Support
Terminal Block Assignments
Provides assignments for terminal blocks used for connections.
Terminal Block Assignments – Power Box (C-3000 & C-4000 Only)
Details terminal block assignments within the power box for C-3000/C-4000 models.
Terminal Block Assignments — Low Voltage (TB1) Terminal Block
Lists terminal assignments for the low voltage (TB1) terminal block and their functions.
Terminal Block Assignments — High Voltage (TB2) Terminal Block
Lists terminal assignments for the high voltage (TB2) terminal block for various boiler models.
Boiler Parts Identification (C-1500H & C-2000H)
Main Boiler Assembly (C-1500H & C-2000H)
Identifies main components of the C-1500H and C-2000H boiler assembly.
NURO Control Panel (C-1500H & C-2000H)
Identifies components of the NURO control panel for C-1500H and C-2000H models.
Heat Exchanger Assembly (C-1500H & C-2000H)
Identifies parts of the heat exchanger assembly for C-1500H and C-2000H models.
Natural Gas Train, Burner & Blower Assembly (C-1500H & C-2000H)
Identifies components of the natural gas train, burner, and blower assembly.
Natural Gas Train, Burner & Blower Assembly High Turndown (C1500T & C2000T)
Identifies components of the high turndown gas train, burner, and blower assembly.
Propane Gas Train, Burner & Blower Assembly (C-1500H & C-2000H)
Identifies components of the propane gas train, burner, and blower assembly.
Boiler Parts Identification C-2500, C-3000 & C-4000
Main Boiler Assembly (C-2500, C-3000 & C-4000)
Identifies main components of the C-2500, C-3000, and C-4000 boiler assemblies.
NURO Control Panel (C-2500, C-3000 & C-4000)
Identifies components of the NURO control panel for C-2500, C-3000, and C-4000 models.
Main Power Box (C-3000 & C-4000 Only)
Identifies components within the main power box for C-3000 and C-4000 models.
Heat Exchanger Assembly (C-2500, C-3000 & C-4000)
Identifies parts of the heat exchanger assembly for C-2500, C-3000, and C-4000 models.
Natural Gas / Propane Gas Train, Burner & Blower Assembly (C-2500 & C-3000)
Identifies components of the gas train, burner, and blower assembly for C-2500/C-3000 models.
Natural Gas / Propane Gas Train, Burner & Blower Assembly (C-4000)
Identifies components of the gas train, burner, and blower assembly for the C-4000 model.
Appendix E – Installation and Quick Reference
Fuel/Gas Supply
Provides quick reference for gas supply sizing and regulator requirements.
Electrical/Power Supply
Summarizes power supply requirements for different boiler models and connection checks.
Exhaust Venting
Provides quick reference for Category II/IV venting requirements and material suitability.
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