Harsco Industrial C750, Installation & Owner'S Manual

Page 1: ...et East Stroudsburg PA 18301 Telephone 570 476 7261 Facsimile 570 476 7247 www harscopk com MACH C750 C900 C1050 Rev 1 05 07 01 2013 C S A Design Certified Complies with ANSI Z21 13 CSA 4 9 Gas Fired...

Page 2: ...ty Checks 30 3 10 Initial Adjustments 31 3 11 Burner Adjustment 34 4 OPERATION 36 4 1 General 36 4 2 Normal Lighting and Shut Down Procedures 36 4 3 Typical Boiler Utility Requirements 37 5 MAINTENANC...

Page 3: ...plier It is essential to read understand and follow the recommendations of this manual before installing operating or servicing this equipment Installation and service must be performed by a qualified...

Page 4: ...ture sensors pumps flow switches balancing valves and check valves will be required for satisfactory operation of any system Harsco Industrial Patterson Kelley cannot be responsible for the design or...

Page 5: ...e 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 replacem...

Page 6: ...omponents could be hot Do not touch piping or stack surfaces during operation or immediately after shutdown of the boiler Burn hazard Hot fluids Use caution when servicing or draining the boiler Fire...

Page 7: ...utralization kit is available Please contact your local Harsco Industrial Patterson Kelley representative 2 5 5 Pressure Hazards Pressure hazard Hot fluids Install isolation valves on boiler water inl...

Page 8: ...diction or in the absence of such requirements to the National Fuel Gas Code ANSI Z223 1 NFPA 54 latest edition in the U S In Canada the equipment shall be installed in accordance with the current Ins...

Page 9: ...described in the National Fuel Gas Code NFPA 54 ANSI Z223 1 Latest Edition Clearances from Adjacent Walls Ceiling and Obstructions Side Clearances for a Row of Boilers Type of Surface Dimensions inche...

Page 10: ...erminal Block The boiler power circuit requires 120 VAC 60 hertz with a dedicated neutral and ground as labeled Electrical service must be rated for 8 amps minimum Before starting the boiler check to...

Page 11: ...to the outdoor temperature sensor The temperature control must be programmed to run an outdoor air schedule The outdoor air sensor and programming help are available from the local Harsco Industrial...

Page 12: ...or death due to fire or asphyxiation Before connecting a boiler to a venting system it must be determined whether the boiler is to be installed in a conventional or Direct Vent configuration In the US...

Page 13: ...es Maintain clearances to combustibles as listed in the vent manufacturer s installation instructions or as set forth in the codes and standards listed in this section Do not use these vent pipes for...

Page 14: ...e considered part of the required volume The minimum volume is 50 ft 3 per 1000 Btu hr 4 8 m 3 kW of installed appliance input capacity Openings used to connect indoor spaces to obtain the required mi...

Page 15: ...tilation opening must be either 10 of the net free area required for combustion air or 10 sq in 6500 mm 2 whichever is greater B Use the following opening calculation for MACH or MODU FIRE FD boilers...

Page 16: ...ombustion Air Opening Ventilation Air Opening Model Input Btu Hr in 2 mm 2 in 2 mm 2 C750 750 000 25 16 129 10 6 452 C900 900 000 30 19 355 10 6 452 C1050 1 050 000 35 22 581 10 6 452 3 5 3 Flue Venti...

Page 17: ...ondensate drains in the exhaust vent Table of Required Stainless Steel Vent Adapters and Category II Motorized Dampers The normally closed motorized damper operates on 120 VAC and features an end limi...

Page 18: ...and the SMACNA Thermoplastic Duct Construction Manual Install manufactured vent systems in accordance with the manufacturer s listing and instructions When venting this boiler using CPVC vent material...

Page 19: ...er should use Adapters listed below or equivalent 3 5 3 5 Required Clearances Provide clearances between combustion air intake exhaust vent roof and wall surfaces doors and window and snow line Refer...

Page 20: ...operation of regulators relief valves or other equipment Interior Component Clearances All vent system components shall be installed so as to maintain the following required minimum clearances Combus...

Page 21: ...drain section not provided NOTICE The condensate formed from natural gas flue gases is acidic The condensate shall be drained in accordance with local code requirements A condensate neutralizer may be...

Page 22: ...rized venting system Such a system employs a sealed combustion air intake duct leading from outdoors and a sealed exhaust vent terminating outdoors Air flow through the system is maintained by the com...

Page 23: ...for all terminations NOTICE Drains have been omitted for clarity Sidewall Vent Sidewall Air Inlet above Vertical Vent Room Air Inlet above Vertical Vent Sidewall Air Inlet above Vertical Vent Vertical...

Page 24: ...cigarette cigar or pipe 6 After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above return doors windows exhaust fa...

Page 25: ...feet 90 Ell Feet Tee Feet 20 40 60 80 100 150 200 1 2 0 622 1 55 3 1 120 82 66 57 50 40 35 3 4 0 824 2 06 4 12 250 170 138 118 103 84 72 1 1 049 2 62 5 24 465 320 260 220 195 160 135 1 1 4 1 380 3 45...

Page 26: ...ered by warranty Proper flow rates may be achieved through a combination of primary and secondary flow loops Multiple zones and pumps may result in different flow rates at different times Consideratio...

Page 27: ...t Connections All water connections should be in compliance with national state and local code requirements Adapters from Victaulic to NPT are available from Harsco Industrial Patterson Kelley The bot...

Page 28: ...l in the boiler is insufficient It does not detect low water conditions in other parts of the system Installation of high point vents or additional low water safety devices to protect the system shoul...

Page 29: ...quate capacity refer to Section 3 5 7 The boiler is placed the proper distance from any combustible walls in accordance with Section 3 3 3 8 Relief valves have been piped to an acceptable drain refer...

Page 30: ...on 3 9 2 Test of Low Water Cut off The boiler is furnished with a probe type low water cut off in the outlet nozzle Test as follows Push and hold the red Push to test button for at least 5 seconds A...

Page 31: ...e stamped providing built in history of boiler status and performance This control constantly tracks the load by recording burner high low and mid run hours One control to do it all temperature contro...

Page 32: ...e 0 CH settings Setpoint 180 F BLR OP 1 CH mode 0 CH settings Setpoint 180 F BLR OP 1 CH mode 0 For example selecting the Setpoint parameter opens up a screen that allows the setpoint to be changed CH...

Page 33: ...ERS menu allows the user to set up selected boiler functions and operating modes The CONFIGURATION menu covers basic display information such as language units date time etc The CASCADE menu is used t...

Page 34: ...port This port is located on the upstream side of the valve body for measuring supply pressure Seefigure right The air flow is pre set at the factory prior to shipment Gas flow is dependent primarily...

Page 35: ...astic cap from the gas valve Using a 3mm 7 64 hex wrench adjust the high fire screw see the figure below on each of the gas control valves by turning clockwise or counterclockwise to achieve the desir...

Page 36: ...back of the boiler 4 2 NORMAL LIGHTING AND SHUT DOWN PROCEDURES Do not use this boiler if any part has been under water Immediately call a qualified service technician to inspect the boiler and to rep...

Page 37: ...tion Use care when reassembling main gas line to assure all connections are tight Use care when servicing boiler in order to prevent the accumulation of gas in or around the combustion chamber Determi...

Page 38: ...ion 3 9 3 Test operating temperature controls by reducing or increasing temperature setting as necessary to check burner operation 4 Test the low water cut off Refer to Section 3 9 5 Test low gas pres...

Page 39: ...for requirements in addition to those listed below a Check all joints and pipe connections for tightness b Check pipe for corrosion or deterioration If any piping needs replacing do so immediately c...

Page 40: ...below 7 After ignition the fan may be driven to low fire before the boiler is released to modulation 8 The control modulates the firing rate between low and high fire to maintain the desired outlet w...

Page 41: ...reset button and the sequence of operation will resume at Step 4 5 5 3 Low Gas Pressure The low gas pressure switch opens when there is insufficient gas pressure available for proper operation of the...

Page 42: ...trial for ignition Check that the spark electrode ignition wire and gas valve are functioning properly When FLAME FAILURE is shown on the display the boiler lost the flame during run Check that the co...

Page 43: ...TOO LATE ERROR 20 Flame still present 10 sec after closing the gas valve A20 FLAME ERROR I 21 Flame detected just before gas valve opened A30 HIGH GAS PRESSURE ERROR 32 Gas pressure is to high A31 LOW...

Page 44: ...A16 20 MS XLR ERROR 22 Internal software error A18 STACK ERROR 19 Internal software error A19 FLAME OUT TOO LATE ERROR 20 Flame still present 10 sec after closing the gas valve A20 FLAME ERROR I 21 Fl...

Page 45: ...mmended for this equipment All control components are engineered for safety and are designed to work in unison with each of the other components Use of non factory authorized replacement parts jeopard...

Page 46: ...ith TB2 14 Damper Output 8 GROUND Boiler Supply Ground 0 VAC 9 GROUND Boiler Supply Ground 0 VAC 10 120VAC SW OUTPUT 120VAC output when boiler is switched on pilot duty only 11 120VAC 3 WAY VALVE 120V...

Page 47: ...TAT OR SENSOR Domestic Hot Water sensor or thermostat 8 DHW STAT OR SENSOR 9 HEADER TEMP SENSOR Header temperature sensor 10 HEADER TEMP SENSOR 11 DHW FLOW SWITCH Domestic Hot Water flow switch output...

Page 48: ...MACH Gas Fired Boiler 48 5 6 3 Wiring MACH Boilers C750 900 1050...

Page 49: ...MACH Gas Fired Boiler 49 5 7 BOILER PARTS LIST 5 7 1 MACH Boiler 750 900 1050 Main Assembly Mark Description 1 Heat Engine 2 Boiler Gas Train 3 Cabinet 4 Control Panel...

Page 50: ...Display Cover 4 ENVI Control Display Module 5 Circuit Breaker 6 On Off Switch 7 ENVI Control Interface Board 8 Low Water Cut off 9 ENVI Control Board 10 TB1 Low Voltage right rear of boiler 11 TB2 Hi...

Page 51: ...lower to Burner Hood 2 Burner Hood 3 Burner Hood Gasket 4 Burner 5 View Glass Assembly 6 Heat Exchanger Sectional Castings 7 Exhaust Gasket 8 Condensate Collector 9 Inspection Cover w gasket 10 Water...

Page 52: ...Train Mark Description 1 Main Gas Shut off Valve 2 Low Gas Pressure Switch 3 High Gas Pressure Switch 4 Dual Main Gas Valve Regulator 5 Gas Manifold Shut off Valve 6 Flex Hose with Gas Valve Adaptor...

Page 53: ...F Any failure resulting from misuse modification not authorized by Seller in writing improper installation or lack of or improper maintenance G Equipment furnished by the owner either mounted or unmou...

Page 54: ...ency Comb Air Pres intake w c w c F Water Outlet temperature F 3 Flow through boiler GPM 4 Operating Temperature Setpoint F from internal OR external control 5 Stack Pressure measured where stack exit...

Page 55: ...MACH Gas Fired Boiler 55 APPENDIX 1 MAINTENANCE LOG Date Hi Low Fire O2 CO CO2 Stack Temp Adjustments By...

Page 56: ...e is as follows With the boiler at high fire adjust the gas valves as described in section 3 10 4 to get 5 O2 in the flue gas If this cannot be achieved perform the following steps If the O2 is too hi...

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