Patterson-Kelley MACH Series, Installation & Owner'S Manual

Page 1: ...51 Facsimile 570 476 7247 www pkboilers com 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 Patter...

Page 2: ...MACH Series Gas Fired Boiler...

Page 3: ...0 Sealing the Intake Duct 12 3 6 11 Intake Duct Connection to Boiler 12 3 6 12 Intake Duct Terminations 12 3 6 13 Vent Elbows 13 3 7 Gas Piping 13 3 7 1 Gas Supply Piping by Installer 14 3 8 Boiler Wa...

Page 4: ...ING 1998 HCS Inc 800 748 0241 WARNING It is essential to read understand and follow the recommendations of this manual before installing operating or servicing this equipment Failure to do so could re...

Page 5: ...gas fired boiler must be Installed operated and serviced in accordance with instructions contained in this manual Installed by qualified personnel in accordance with designs prepared by qualified fac...

Page 6: ...zard Shock hazard Properly lockout tagout the electrical service and all other energy sources before working on or near the boiler Shock hazard Do not spray water directly on any electrical components...

Page 7: ...hat gas inlet pressure does not exceed 14 inches W C to the regulator Overfire hazard Possible fire and explosion Possible malfunction of regulators and or gas safety shut off control valves Maintain...

Page 8: ...ety relief valve for proper operation Do not operate boiler with faulty relief valve 2 5 6 Slip Fall Hazards Improper use may result in fire or injury Read instructions safety manual before installing...

Page 9: ...heat exchanger is constructed and stamped in accordance with ASME Boiler and Pressure Vessel Code Section IV for 50 psig maximum operating pressure and or 200 F maximum temperature Other codes or app...

Page 10: ...ace A B C D Combustible Surfaces 36 24 24 24 Non combustible Surfaces 36 24 24 C Do not put pipes ducts etc in this area above the boiler CAUTION Bumping hazard from overhead ducts Install all compone...

Page 11: ...Air for Combustion and Ventilation of the National Fuel Gas Code ANSI Z223 1 latest edition or applicable provisions of the local building codes In Canada combustion air openings shall comply with CS...

Page 12: ...es are to be used for vent sizing calculations The installation of a bird screen on the vent termination is recommended Consult your local vent manufacturer for proper sizing 3 6 1 Barometric Damper W...

Page 13: ...e boilers Dimensions listed above or those illustrated are minimum and may or may not be sufficient for conditions at a specific job site A tee must be of approved design and adequate capacity 3 6 5 V...

Page 14: ...se an unsafe condition 3 Insofar as is practical close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are locat...

Page 15: ...on optional when roof venting Air Inlet tee mounted horizontally Roof Sidewall Exhaust Vent Sidewall venting requires vertical tee termination Air Inlet Tee mounted horizontal Sidewall Roof Exhaust Ve...

Page 16: ...space Joints in PVC or CPVC must be cemented For galvanized duct wrap each joint and seam with adhesive aluminum tape 3 6 11 Intake Duct Connection to Boiler Connect the air supply duct to the collar...

Page 17: ...r of the lock up type must be provided to reduce the pressure to less than 14 W C WARNING All threaded connections must be made using a pipe compound that is resistant to the action of liquefied petro...

Page 18: ...sted and must be checked for leaks before being placed into service Test with compressed air or inert gas if possible The boiler must be disconnected at the boiler manual shut off valve located at the...

Page 19: ...refrigerated air circulation must be equipped with flow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle 3 8 2 Boiler Inlet and Outl...

Page 20: ...t the system should be considered Installation of external limit controls may be required by certain codes or in certain installations Review applicable local codes for details Drain Valve and Piping...

Page 21: ...debris from construction or maintenance Clean and flush old piping thoroughly before installing the boiler IMPORTANT Under no circumstances should the hydronic system be flushed while the boiler is at...

Page 22: ...re always reset to their proper settings 3 11 1 Test of Ignition Safety System Test the ignition system safety shutdown as follows 1 Loosen the retaining screw and remove the 5 pin connector from one...

Page 23: ...d shut down the main burner When the gas pressure switch opens a manual reset lockout displaying E 12 on the display panel will occur Upon re opening the gas cock the E 12 indicator will remain on unt...

Page 24: ...ner off Domestic Hot Water pump running on delay No system call for heat 9 and b flashing Burner off auto reset lockout A code is displayed indicating the reason for the lockout See Troubleshooting Se...

Page 25: ...nt 4 160 68 185 Low Temp Differential 22 10 0 36 High Temp Differential 23 9 0 36 Low Temp Setpoint 5 68 59 140 The boiler will modulate to try to maintain 160 F If the temperature increases above 169...

Page 26: ...er automatically defaults to outdoor air reset for setting boiler temp The parameters should be set according to the following table Item Parameter Value F Allowable Range F Maximum Setpoint 4 180 68...

Page 27: ...igh limited by maximum and minimum setpoint parameters The controlled setpoint voltage range narrows when these limits are used If the above tables values are used the boiler setpoint will be 80 F whe...

Page 28: ...t gas air ratio for optimum performance and efficiency The combustion blower speed is controlled automatically and determines the amount of negative pressure felt at the gas safety shut off control va...

Page 29: ...wer the O2 level turn each of the maximum flow restrictors equivalent amounts i e or turn each and allow the analyzer readings to respond and stabilize before proceeding with additional adjustment Ade...

Page 30: ...the pressure regulator offset adjustment see the figure below item R to achieve the CO2 O2 level prescribed in Table 3 1 Note that equal adjustments must be made to each of the valves Adjustments to...

Page 31: ...prior to start up WARNING Do not use this boiler if any part has been under water Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system a...

Page 32: ...oiler 4 3 TYPICAL BOILER OPERATING CONDITIONS Natural Gas 1030 Btu cu ft LP Gas 2500 Btu cu ft Model Number Input Rating Btu hr Gas Rate CFH Output Capacity Btu hr Gas Rate CFH Output Capacity Btu hr...

Page 33: ...free and clear of any combustible materials including flammable vapors and liquids 5 1 2 Weekly Observe the conditions of the main flame A normal high fire flame is blue If the high fire flame is yell...

Page 34: ...efer to the vent manufacturer s instructions 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...

Page 35: ...ntrol initiates a flame stabilization period of 5 seconds at the ignition rpm of the fan The fan is driven to low fire for 1 minute before the boiler is released to modulation 10 The unit modulates be...

Page 36: ...and then the front display panel reset button is pressed High Water Temperature When the boiler water has exceeded both the operating and high limit temperature the high limit switch opens and E 12 i...

Page 37: ...return water temperature has exceeded the internal high limit temperature setting E 25 Outlet temp rapid change The outlet water temperature is increasing too fast Indicating low flow condition E 28...

Page 38: ...The outlet water temperature is increasing too fast Indicating low flow condition b 26 High exhaust back pressure The high exhaust back pressure switch is tripped indicating a blocked stack inlet or...

Page 39: ...n Kelley by calling toll free 877 728 5351 Ask for the Heat Transfer Department The fax number is 570 476 7247 Refer to the parts list shown on the assembly drawing provided with this manual Technical...

Page 40: ...UTRAL DHW Circ Pump 6 GROUND Boiler Supply Ground 7 GROUND 8 GROUND Aux Ground 9 115 VAC SW OUTPUT Aux Switched Output Pilot duty only 1 amp max 10 115 VAC CIRC PMP CONTACTOR Boiler Circ Pump Pilot du...

Page 41: ...ure DO NOT ENERGIZE 5 DHW TEMP SENSOR 6 OUTDOOR TEMP SENSOR Thermistor factory option 7 CIRC PMP PWM SIGNAL Pulse Width Modulation 8 COMMON Common to be used with 5 6 7 and 10 when used 9 COMMON Commo...

Page 42: ...MACH Series Gas Fired Boiler Parts and Technical Support Page 38 6 1 2 Wiring Series C 300...

Page 43: ...MACH Series Gas Fired Boiler Parts and Technical Support Page 39 6 1 2 Wiring Series C 450...

Page 44: ...l Support Page 40 6 2 BOILER PARTS LIST 6 2 1 Main Assembly Mark Description 1 Blower and Gas Train 2 Manifold System Return Boiler Outlet 3 Manifold System Supply Boiler Inlet 4 Cabinet 5 High Temper...

Page 45: ...ries Gas Fired Boiler Parts and Technical Support Page 41 6 2 2 Control Panel Mark Description 1 AM 3 Relay Module 2 Boiler Control MACH Series MCBA 3 Transformer 4 Low Water Cutoff 5 Control Mounting...

Page 46: ...echnical Support Page 42 6 2 3 Display Panel 3 2 1 5 6 7 4 8 Mark Description 1 Circuit Breaker 2 Air Pressure Switch 3 Fastening Clip 4 Display Panel 5 On Off Switch 6 Pressure Temperature Gauge 7 Pa...

Page 47: ...MACH Series Gas Fired Boiler Parts and Technical Support Page 43 6 2 4 Heat Engine Refer to next page for parts listing...

Page 48: ...er Hood Gasket 5 Burner 6 Burner Flange With Insulation 7 Sight Glass 8 Seal Sight Glass 9 Sight Glass Holder 10 Exhaust Pipe Lip Ring 11 Exhaust Manifold 12 Inspection Cover Gasket 13 Inspection Cove...

Page 49: ...pport Page 45 6 2 5 Series C 300 Boiler Gas Train Mark Description 1 Main Gas Shut off Valve 2 Low Pressure Gas Switch 3 Gas Safety Shut off Control Valve 4 Air Gas Manifold 5 Swirlplate 6 Blower 7 Ga...

Page 50: ...50 Boiler Gas Train Mark Description 1 Main Gas Shut off Valve 2 Low Pressure Gas Switch 3 High Pressure Gas Switch 4 Gas Safety Shut off Control Valve 5 Gas Manifold Shut off Valve 6 Air Gas Manifold...

Page 51: ...which such Product is usually tested under industry standards at of the time of shipment C Any damage to the Product due to abrasion erosion corrosion deterioration abnormal temperatures or the influ...

Page 52: ...all respects conform and be limited to one 1 year from the date of shipment SEVERABILITY To the extent that any provision of this warranty would be void or prohibited under applicable law such provisi...

Page 53: ...MACH Series Gas Fired Boiler Appendix Page 49 8 0 APPENDIX Date Hi Low Fire O2 CO CO2 Stack Temp Action By...

Page 54: ...F 77 F 70 70 70 70 8 Frost protection at OA Temp 22 F 50 F 32 32 32 32 9 Correction Outdoor Air Sensor 9 F 9 F 0 0 0 0 10 CH shutdown setpoint temp OAR 32 off 34 F 140 F 32 32 32 32 11 Booster time 0...

Page 55: ...equest Type 00 00 00 00 1st digit 2nd CH circuit 0X 2nd CH circuit off X X X X 1X 2nd CH circuit slave 2X 2nd CH circuit master 3X 2nd CH slave Tset depends on potmeter 4X 2nd CH master Tset depends o...

Page 56: ...normally closed 36 Manual fanspeed 1 off 1 1 1 1 37 PWM level CH pump 41 41 41 41 38 Hold boiler water DHW only 32 off 34 F 176 F 32 32 32 32 39 Max Setpoint 2nd CH circuit 50 F 176 F 100 100 100 100...