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

Page 1: ...et P O Box 458 East Stroudsburg PA 18301 Telephone 877 728 5351 Facsimile 570 476 7247 www pkboilers com XLMACH 09 C S A Design Certified Complies with ANSI Z21 13 CSA 4 9 Gas Fired Low Pressure Steam...

Page 2: ...6 3 11 Additional Menu Items 28 4 OPERATION 31 4 1 General 31 4 2 Normal Lighting and Shut Down Procedures 31 4 3 Emergency Shut Off 32 4 4 Typical Boiler Operating Conditions 32 5 MAINTENANCE 33 5 1...

Page 3: ...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 and...

Page 4: ...switches balancing valves and check valves will be required for satisfactory operation of any system Patterson Kelley cannot be responsible for the design or operation of such systems and a qualified...

Page 5: ...rds 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 Patterson Kelley toll free at 877 728 535...

Page 6: ...t 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 boiler Fire and explosion hazards Use...

Page 7: ...ions A condensate neutralization kit is available Please contact your local Patterson Kelley representative 2 5 5 Pressure Hazards Pressure hazard Hot fluids Install isolation valves on boiler water i...

Page 8: ...blished by the authorities having jurisdiction 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 insta...

Page 9: ...eels may be left attached 3 3 2 Placement The boiler must be level to function properly There are six 9 16 holes in the base that may be used for 3 8 seismic anchors 3 3 3 Clearances If the boiler is...

Page 10: ...electrical service is connected to the boiler An external electrical disconnect not supplied with the boiler is required The boiler electrical service must be installed and grounded in accordance with...

Page 11: ...ir openings shall comply with CAN CSA B 149 1 Natural Gas and Propane Installation Code For correct installation of vent system read all of these instructions and refer to vent manufacturer s instruct...

Page 12: ...r PVC US C2500 X X No CAN C2500 X X No 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 13: ...y or by way of ducts with free outdoor air The minimum net free area of the openings shall be calculated in accordance with the following When air is taken directly from outside the building each open...

Page 14: ...ing electrical equipment or mechanical equipment F When combustion air is supplied by mechanical means an airflow sensing device must be installed It must be wired into the pre ignition limit string t...

Page 15: ...exhaust vent roof and wall surfaces doors and window and snow line Refer to Figure below Termination Clearances Forced Draft and Direct Vent Installations Reference NFPA 54 ANSI Z223 1 National Fuel...

Page 16: ...etal pipe Do NOT Use Do NOT Use Single wall CPVC PVC pipe Do NOT Use Do NOT Use UL 1738 listed Category IV vent Per manufacturer s listing Per manufacturer s listing 3 5 3 3 Flue Connection The boiler...

Page 17: ...gs is recommended for the termination Vertical Vent Terminations The vent shall extend at least three 3 feet above the roof or at least two 2 feet above the highest part of any structure within ten 10...

Page 18: ...ied 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 outd...

Page 19: ...r multiple boilers must be designed by experienced and knowledgeable professionals and verified by the stack manufacturer The venting system must prevent backflow of exhaust gas through idle boilers w...

Page 20: ...inlet pressure of 14 W C 1 2 psig Typical gas pressure supply for natural gas is 7 W C 11 W C for propane If the available gas pressure exceeds 14 W C a suitable additional intermediate gas pressure...

Page 21: ...y piping system during any pressure testing of the system at pressures in excess of 1 2 psig 14 W C During any pressure testing of the gas supply piping system at pressures equal to or less than 1 2 p...

Page 22: ...r water during the cooling cycle 3 7 2 Boiler Inlet and Outlet Connections All water connections should be in compliance with national state and local code requirements Adapters from Victaulic to NPT...

Page 23: ...insufficient It does not detect low water conditions in other parts of the system Installation of additional low water safety devices to protect the system should be considered Installation of extern...

Page 24: ...on 3 7 10 Verify system water quality is within specifications refer to Appendix B 3 9 SAFETY CHECKS The following checks of safety systems must be made before putting the boiler into normal operation...

Page 25: ...e outlet nozzle Test as follows Push and hold the red Push to test button for at least 5 seconds A manual lockout reset error displaying LOCKOUT LOW WATER LEVEL on the display panel should occur The L...

Page 26: ...d time 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 c...

Page 27: ...ameters CH settings DHW settings Boiler settings Parameters CH settings DHW settings Boiler settings Select the CH settings to adjust parameters related to the boilers Comfort Heat function CH setting...

Page 28: ...User s Guide These menu items will be described briefly here STANDBY is the default screen and is shown during normal boiler operation The INFORMATION menu lists items that the boiler monitors such as...

Page 29: ...must be greater than the minimum indicated on the rating plate Nominal gas supply pressure is 7 W C for natural gas The gas pressure must not exceed 14 W C which is the maximum allowable pressure on t...

Page 30: ...eck and adjust low fire if necessary To adjust low fire Required Tools 2 5 mm hex wrench and Combustion analyzer Start the boiler and observe proper operating parameters for the system Set boiler to t...

Page 31: ...Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system and any gas control which has been under water 4 2 1 Lighting Procedures 1 Make sur...

Page 32: ...s Rate CFH Output Capacity Btu hr C2500 2 500 000 Less than 17 2427 2 375 000 1000 2 375 000 NOTICE The heat exchanger is constructed and stamped for 100 psig maximum operating pressure and 220 F maxi...

Page 33: ...or operating conditions and make the necessary corrections Notify responsible individuals for required corrective action or repair Check daily to be sure that the boiler area is free and clear of any...

Page 34: ...ign 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 Ins...

Page 35: ...9 Reassemble being sure to install all gaskets and seals properly 5 3 REMOVING THE HEAT EXCHANGER Heat Exchanger is heavy and may cause injury if improperly handled Removal of the heat exchanger shou...

Page 36: ...BLESHOOTING 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...

Page 37: ...the boiler will remain locked out until the water high limit switch is manually reset and the front panel reset button is pressed Once reset the control will restart the sequence of operation at Step...

Page 38: ...Water Flow or Open Interlock Jumper Water Flow is Inadequate or Interlock Jumper is Open A09 INTERAL ERROR 9 or 27 or 28 or 29 or 30 Internal Error 9 or 27 or 28 or 29 or 30 Call for service A10 INT...

Page 39: ...Outlet Temperature Sensor Short Boiler outlet water temperature sensor short circuit E12 IN TEMP SENS SHORT Inlet Temperature Sensor Short Boiler inlet water temperature sensor short circuit E13 FLUE...

Page 40: ...nents are engineered for safety and are designed to work in unison with each of the other components Use of non factory authorized replacement parts jeopardizes the functionality of the safety feature...

Page 41: ...NABLE DISABLE Boiler Enable Contact Closure DO NOT ENERGIZE 3 EXTERNAL INTERLOCK 4 EXTERNAL INTERLOCK External Limit Contact Closure DO NOT ENERGIZE 5 OUTDOOR TEMP SENSOR Outdoor temperature sensor 6...

Page 42: ...ACH Series Gas Fired Boiler Appendix 42 6 1 3 Wiring Diagram for MACH C 2500 East Stroudsburg PA 18301 570 476 7261 www pkboilers com Patterson Kelley P K MACH C 2500 ENVI Control 2640000055 REV 0 0 T...

Page 43: ...ries Gas Fired Boiler Appendix 43 6 2 BOILER PARTS LIST 6 2 1 Main Assembly Mark Description 1 Cabinet Top 2 Boiler Outlet 3 Boiler Inlet 4 Blower Burner Assembly 5 Front Control Panel 6 Cabinet 1 2 3...

Page 44: ...play Screen 1 Terminal Block 1 TB1 7 ENVI IF Board 2 Terminal Block 2 TB2 120 V 8 Low Water Cut Off LWCO 3 High Temperature Limit 9 ENVI Main Board 4 Air Switch 10 10 Amp Circuit Breaker 5 High Exhaus...

Page 45: ...urner Transition 3 Burner Gasket 4 Burner 5 Ignition 6 Sight Glass Window 7 Outlet Water Manifold 8 Heat Exchanger Sectional Castings 9 Relief Valve 10 Inlet Water Connection 11 Boiler Drain Valve 12...

Page 46: ...on 1 Burner 2 Burner Transition Piece 3 Blower Transition Piece 4 Blower 5 Venturi 6 Secondary Manual Shutoff Valve 7 Automatic Gas Valve 8 Main Gas Shutoff Valve 9 High Gas Pressure Switch 10 Low Gas...

Page 47: ...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 unmo...

Page 48: ...MACH Series Gas Fired Boiler Appendix 48 8 APPENDIX A MAINTENANCE LOG Date Hi Low Fire O2 CO CO2 Stack Temp pH Action By...

Page 49: ...MACH Series Gas Fired Boiler Appendix 49...

Page 50: ...of copper and steel piping incorporates chemicals having a pH of 10 to 12 This extremely high pH is not compatible with aluminum and will reduce the boiler life Most glycols are typically designed fo...

Page 51: ...Phone 414 421 2070 Toll Free 800 944 9746 Fax 414 421 2077 www hohchemicals com Sentinel Performance Solutions Ltd Marathon Distributors Mississauga ON Canada Toll Free 888 602 5360 www sentinel solut...