Harsco Industrial MACH C750 Installation & Owner's Manual
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Harsco Industrial MACH C750 Installation & Owner's Manual

Gas-fired boiler
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MACH
GAS-FIRED BOILER
®
C750-C900-C1050
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 #:_______
Start-Up Date:
_______________________
Harsco Industrial, Patterson-Kelley
100 Burson Street,
East Stroudsburg, PA 18301
Telephone: (570) 476-7261
Facsimile: (570) 476-7247
www.harscopk.com
© 2010 Harsco Industrial, Patterson-Kelley
Printed: 7/1/2013
Serial #______________________
MACH
C750-C900-C1050
®
Rev. 1.05 (07/01/2013)
1004905947

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Summary of Contents for Harsco Industrial MACH C750

  • 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

    ® MACH Gas Fired Boiler INTRODUCTION ..................... 4 SAFETY ........................4 General.......................... 4 Training ......................... 4 Safety Features ......................5 Safety Labels ........................ 5 Safety Precautions ......................6 INSTALLATION ...................... 8 Receiving and Storage ....................8 Compliance with Codes ....................8 Setup ..........................
  • Page 3 ® 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

    ® 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

    ® 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

    ** Service access need be only on one side of a boiler or row of boilers. Boilers may be installed immediately adjacent to each other. However, Harsco Industrial, Patterson-Kelley recommends this clearance between each boiler when there is insufficient access at the rear to allow for service and adjustment.

  • Page 10: Electrical Connections

    The total operating amperage is indicated on ® the rating nameplate. MACH boiler units C750/C900/C1050 require less than 8 amps. Before starting the boiler, check to ensure that the proper electrical service is connected to the boiler. An external electrical disconnect (not supplied with the boiler) with 15 amp overload protection is required.
  • Page 11 The outdoor air sensor and programming help are available from the local Harsco Industrial, Patterson-Kelley Representative. This circuit is energized by the boiler with a 5V potential. The temperature sensor must be a NTC having 12k@25°C.

  • Page 12: Inlet Air And Exhaust Venting

    ® MACH Gas Fired Boiler NLET IR AND XHAUST ENTING 3.5.1 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 Venting Systems for Gas-Burning Appliances, Categories II, III, and IV...
  • Page 13 ® The MACH C750, C900 and C1050 boilers are dual-certified as both Category II and Category IV appliances, which vent with a temperature that is likely to cause condensation in the vent. Refer to Section 3.5.3.2 for requirements of Category II installations and Section 3.5.3.3 for requirements of Category IV installations. Any venting system used ®...
  • Page 14 AL29-4C 316L SS CPVC C750 – C1050 CAN C750 – C1050 Note 2 Note 2: In Canada, any CPVC used for venting must be listed to ULC S636. 3.5.2 Combustion Air Combustion air must be free from dust, lint, etc. The presence of such materials in the air supplied to the burner could cause nuisance "Low Air"...
  • Page 15 DIFF VERT HORIZ FLOOR FLOORS OPENING DIRECT DUCT DUCT C750 1500 C900 1800 C1050 1050 2100 3.5.2.2 Air Inlet Requirements – Canada (CAN/CSA B149.1) A. Ventilation of the space occupied by fuel burning appliance(s) or equipment shall be supplied by a ventilation opening at the highest practicable point communicating with the outdoors.
  • Page 16 3.5.3.2 CATEGORY II INSTALLATIONS The MACH C750, C900 and C1050 are dual-certified for both Category II and Category IV operation. Category II appliances operate with a non-positive vent static pressure and with a vent temperature that may cause excessive condensate production in the vent.
  • Page 17 3.5.3.6 for information on installing condensate drains in the exhaust vent. Table of Required Stainless Steel Vent Adapters and Category II Motorized Dampers Stainless Vent Normally-Closed Nominal Boiler Size Adapter Motorized Damper Stack Size C750 6" 2620000181 (OEM) 1004906943 6” 6” 9” 1.38” C900 8"...
  • Page 18 ® MACH Gas Fired Boiler Use caution if installing a barometric damper in the exhaust vent. The vent pressure must be negative (Category II) from the barometric to the vent termination at all times to prevent leakage of harmful flue gases into the room. Leakage of flue gases can cause serious injury or death.
  • Page 19 Table of Stainless Steel Adapter for CPVC Part Numbers Vent Size Sch 40 Sch 80 Nominal Stainless Adapter for CPVC 4-1/2 Boiler Size Stack Size Part Number 4-1/2 C750 6" 2620000237 5-1/2 C900 8" 2620000238 5-1/2 C1050 8" 2620000238 6-1/2 A customer supplied adapter is required to be installed between the boiler and the CPVC venting.
  • Page 20 ® MACH Gas Fired Boiler Conventional Vent Systems Clearances The following termination clearance requirements are for conventional, non-direct vent installations. • The vent system shall terminate at least 3 ft above a forced air inlet within 10 feet horizontally. • The vent system shall terminate at least 4 ft below, 4 ft horizontally from or 1 ft above any door, operable window or gravity inlet into any building.
  • Page 21 ® MACH Gas Fired 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. The complete exhaust with drain system is shown in the figure below.
  • Page 22 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 bird screen 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 23 MACH Gas Fired Boiler 3.5.5.2 Intake/Exhaust Layout Four basic configurations for the intake/exhaust may be used for the C750/C900/C1050. Refer to Section 3.5 for required clearances for all terminations. NOTICE! Drains have been omitted for clarity. Vertical Exhaust Vent Terminations...

  • Page 24: Gas Piping

    ® MACH Gas Fired Boiler 3.5.6 Removing an Existing Boiler When an existing boiler is removed from a common venting system, the common venting system is likely to be too large for proper venting of the appliances remaining connected to it. At the time of removal of an existing boiler, while the other appliances remaining connected to the common venting system are not in operation, the following steps should be followed with each appliance remaining connected to the common venting system placed in operation:...
  • Page 25 ® MACH Gas Fired Boiler Gas Piping Schematic (left) Remote Gas 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 which may apply;...

  • Page 26: Boiler Water Piping

    Min Flow Pressure Drop (ft.) at max flow For minimum flow rates at other than maximum Model ® firing rate, see MACH Boiler Variable 20°F ΔT 40°F ΔT Pumping Graph (below) 1050 MACH Variable Pumping C1050 C900 C750 Firing Rate (%)
  • Page 27 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.
  • Page 28 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 29: Pre-Start Check List

    ® MACH Gas Fired Boiler 3.7.4 Flushing and Filling Water Quality ® The MACH boiler heat exchanger is made of an aluminum alloy. The heat exchanger requires proper water conditions to remain efficient and function properly. NOTICE! Glycol or other treatment chemicals added to the system must be certified by the chemical manufacturer for use in multi-metal systems that include cast aluminum boilers.

  • Page 30: Safety Checks

    ® MACH Gas Fired Boiler AFETY HECKS The following checks of safety systems must be made before putting the boiler into operation. Before firing the boiler refer to Sections 4.1 and 4.2 for information on the use of the controls, lighting, and shut-down procedures.

  • Page 31: Initial Adjustments

    3.10 I NITIAL DJUSTMENTS Operating Temperature Controller 3.10.1 ® The MACH boiler C750-1050 is equipped with ® ENVI control; an intelligent control system with advanced features such as text-based display, communication capabilities, and boiler sequencing. Errors are date and time stamped providing built-in history of boiler status and performance.
  • Page 32 ® 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. 3.10.2 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 33 ® MACH Gas Fired Boiler 3.10.4 Other Parameters Other parameters include the settings for DHW (Domestic Hot Water), Boiler Settings and OEM Settings. Boiler and OEM Settings are used during the initial programming of the control and are not accessible. 3.10.5 Additional Menu Items In the main menu, Standby, Information, Errors, Program Parameters, Configuration, Cascade, and Service Menus ®...

  • Page 34: Burner Adjustment

    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. Inlet Gas See rating plate for the minimum and maximum inlet gas pressure of Test Port the boiler.
  • Page 35 NOTICE! There must be sufficient load to operate the boiler at high fire to perform the following adjustments. Start the boiler and observe proper operating parameters for the C750/900/1050 Adjusting Screws for Low and High Fire system. ® Required Tools: TORX T40 or 5 mm hex wrench, 3 mm or 7/64 in hex wrench, Combustion analyzer ®...

  • Page 36: 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 Fire test”...

  • Page 37: Typical Boiler Utility Requirements

    ® 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) 750,000 728* 712,500...
  • Page 38 ® 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 39: Cleaning The Burner

    ® MACH Gas Fired Boiler 2. Check burner and clean off any soot or foreign material that may have accumulated. See Section 5.2 on "Cleaning the Burner." Check for corrosion of the burner and its parts. If there is evidence of deterioration or corrosion, replace immediately.

  • Page 40: Sequence Of Operation

    ® MACH Gas Fired Boiler EQUENCE OF PERATION 1. When the Boiler On/Off switch is turned on, power is provided through a circuit breaker to the boiler control and the combustion blower. 2. If the high gas, low gas or low water level control is open, the boiler control locks out and displays an error. 3.

  • Page 41: Troubleshooting

    ® MACH Gas Fired Boiler ROUBLESHOOTING If any “Manual Reset” limit device trips, DO NOT reset without determining and correcting the cause. (Manual Reset Limits include: Flame safeguard, high or low gas pressure, high temperature limit, stack temperature, low water level.) ®...
  • Page 42 ® MACH Gas Fired Boiler When AIR SWITCH NOT CLOSED is shown on the display, check that the air switch is closed when the fan is running. If the air switch does not close within 5 minutes during purge, the boiler locks out. Check that the burner is clean (refer to "Cleaning the Burner,"...
  • Page 43 ® MACH Gas Fired Boiler 5.5.10 Manual Reset Error Codes – A## A Code Error Int. nr Description Three unsuccessful ignition attempts in a row 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 44 ® MACH Gas Fired Boiler 5.5.11 Auto-reset Error Codes – E## A Code Error Int. nr Description Three unsuccessful ignition attempts in a row 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 45: Parts/Technical Support

    Gas Fired Boiler 6.0 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 the Harsco Industrial, Patterson-Kelly website www.harscopk.com.

  • Page 46: Wiring Diagrams

    ® MACH Gas Fired Boiler IRING IAGRAMS 5.6.1 Terminal Block Assignments – High Voltage (120 VAC) Circuit (TB2) Terminal Number Label Description Boiler Supply Power, 120 VAC, 1 ph , 60 Hz 120 VAC LINE Boiler Supply Neutral, 0 VAC 120 VAC NEUTRAL Neutral for use with TB2-10, Switched Output 120 VAC NEUTRAL...
  • Page 47 ® MACH Gas Fired Boiler 5.6.2 Terminal Block Assignments – Low Voltage (Less than 32VAC) Circuit (TB1) Terminal Number Label Description ENABLE / DISABLE Boiler Enable, Contact Closure. DO NOT ENERGIZE. ENABLE / DISABLE EXTERNAL INTERLOCK External Limit, Contact Closure. DO NOT ENERGIZE.
  • Page 48 ® MACH Gas Fired Boiler ® 5.6.3 Wiring MACH Boilers C750/900/1050...

  • Page 49: Boiler Parts List

    ® MACH Gas Fired Boiler OILER ARTS ® 5.7.1 MACH Boiler 750-900-1050 Main Assembly Mark Description Heat Engine Boiler Gas Train Cabinet Control Panel...
  • Page 50 ® MACH Gas Fired Boiler 5.7.2 Control Panel Front view Mark Description Control Panel Aluminum Door Display Label Display Cover ® ENVI Control Display Module Circuit Breaker On/Off Switch ® ENVI Control Interface Board Low Water Cut-off ® ENVI Control Board TB1 Low Voltage (right rear of boiler) Rear view TB2 High Voltage (left rear of boiler)
  • Page 51 ® MACH Gas Fired Boiler ® 5.7.3 MACH Boiler C750/900/1050 Heat Engine Mark Description Gasket, Blower to Burner Hood Burner Hood Burner Hood Gasket Burner View Glass Assembly Heat Exchanger Sectional Castings Exhaust Gasket Condensate Collector Inspection Cover w/ gasket...
  • Page 52 ® MACH Gas Fired Boiler ® 5.7.4 MACH Boiler C750/900/1050 Gas Train Mark Description Main Gas Shut-off Valve Low Gas Pressure Switch High Gas Pressure Switch Dual Main Gas Valve / Regulator Gas Manifold Shut-off Valve Flex Hose with Gas Valve Adaptor...

  • Page 53: 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 54: 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 55: Appendix 1 - Maintenance Log

    ® MACH Gas Fired Boiler APPENDIX 1 – MAINTENANCE LOG Date Hi/Low-Fire Stack Temp Adjustments...

  • Page 56: Appendix 2 - Mach Boiler Altitude Derate Schedule

    ® 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 57 ® MACH Gas Fired Boiler...
  • Page 58 ® MACH Gas Fired Boiler...

This manual is also suitable for:

Mach c900Mach c1050

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