Harsco Industrial P-K MACH C1500H Installation & Owner'S Manual Download Page 1

Page: 1 / 84

MACH

GAS FIRED BOILER

C1500H/C2000H/C2500/C3000/C4000
Natural Gas/Propane/Dual Fuel

Model #:_______ Serial #______________________

Start-Up Date:

_______________________

Harsco Industrial, Patterson-Kelley
100 Burson Street
East Stroudsburg, PA 18301
Telephone: 570.476.7261
Toll Free: 877.728.5351
Facsimile: 570.476.7247
www.harscopk.com

MACH

C1500H – C4000

Rev. 1.03 (06/08/2012)

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

Summary of Contents for P-K MACH C1500H

Page 1: ...ey 100 Burson Street East Stroudsburg PA 18301 Telephone 570 476 7261 Toll Free 877 728 5351 Facsimile 570 476 7247 www harscopk com MACH C1500H C4000 Rev 1 03 06 08 2012 C S A Design Certified Compli...

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

Page 3: ...ng and Shut Down Procedures 45 4 3 Emergency Shut Off 46 4 4 Typical Boiler Operating Conditions 46 5 MAINTENANCE 47 5 1 Maintenance and Inspection Schedule 47 5 2 Cleaning the Burner 49 5 3 Removing...

Page 4: ...ler service agency or the gas supplier AVERTISSEMENT Assurez vous de bien suivre les instructions donn es dans cette notice pour r duire au minimum le risqu d incendie ou d explosion ou pour viter tou...

Page 5: ...ledgeable individual who has been trained on the Harsco Industrial Patterson Kelley MACH boiler The same features which permit this boiler to achieve high efficiency performance make it unlike most ot...

Page 6: ...MACH Gas Fired Boiler 6...

Page 7: ...owed by a prefix or suffix letter in some cases to indicate special features or different options While details may differ slightly basic operation is the same for all models Check the rating plate fo...

Page 8: ...0 476 7261 or toll free at 877 728 5351 2 3 SAFETY FEATURES It is the responsibility of the customer to maintain the safety features such as but not limited to guards safety labels safety controls int...

Page 9: ...d vent lines for gas devices Refer to Section 3 6 Hazard from incorrect fuels Possible fire explosion overheating and damage Do not use any fuels except the design fuels for the unit Over fire hazards...

Page 10: ...ion is recommended Over fire and under fire hazards Possible fire explosion overheating and component failure Do not attempt to adjust firing rate of the boiler The firing rate must be adjusted only b...

Page 11: ...ving the boiler inspect it for signs of shipping damage Since some damage may be hidden unpack the boiler open the front and side doors and inspect the boiler Verify that the total number of pieces sh...

Page 12: ...t Provide a firm level foundation preferably of concrete The wheels provided with this boiler are for positioning purposes only When positioning this boiler maintain positive control of it at all time...

Page 13: ...ed for pipes ducts etc in this area above the boiler B Clearance depends upon exhaust vent configuration Do not put pipes ducts vents etc in this space Electrical conduit must be installed vertically...

Page 14: ...st allow the side doors to be opened The electrical junction boxes are located at the upper front sides of the boiler The MACH C3000 C4000 boilers have an added electrical junction box at the lower fr...

Page 15: ...alve is a field sourced part DHW Pump Relay w Delay Off This output is enabled when there is a call for DHW When the call for heat is removed the output remains enabled for the post pump time paramete...

Page 16: ...are connected to the header temperature sensor This circuit is energized by the boiler with a 5 V potential The temperature sensor must be a NTC having 12 k 77 F DHW Flow Switch TB1 11 is energized by...

Page 17: ...anufacturer s instructions Failure to use a proper vent system types and materials as described in this manual will void the boiler warranty and may result in rapid deterioration of the venting system...

Page 18: ...An appliance that operates with a positive vent static pressure and with a vent temperature that may cause excessive condensate production in the vent Direct Vent An appliance that is constructed and...

Page 19: ...PVC CPVC POLYPROPYLENE C1500H US X X No X NOTE 3 C2000H US X X No X NOTE 3 C2500 US X X No X NOTE 3 C3000 US X X No X NOTE 3 C4000 US X X No X NOTE 3 C1500H Canada X X No NOTE 2 NOTE 2 C2000H Canada...

Page 20: ...he boiler and the boiler stack The result is improper combustion and premature boiler failure Under no circumstances shall the boiler room ever be under a negative pressure Particular care should be t...

Page 21: ...r 2 000 Btu per hour 1100 mm2 kW of total boiler input is required NOTE 1 The required size of openings for combustion and ventilation air shall be based on the net free area of the opening 2 Screens...

Page 22: ...into the pre ignition limit string to prevent the burner from starting or to stop an operating burner in case of air supply failure G When all combustion air is supplied through a make up air heater...

Page 23: ...use a barometric damper with this boiler when installed with Category IV venting Positive exhaust pressure may exist which may leak flue gases into the room All boiler venting systems should be desig...

Page 24: ...s shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators relief valves or other equ...

Page 25: ...designed to accept standard nominal vent pipe sizes This connector incorporates provisions to drain condensate formed in the vent system using a 3 4 OD drain stub This vent drain stub can be either pi...

Page 26: ...icient for conditions at a specific job site 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 i...

Page 27: ...nd exhaust vent must not exceed 0 44 W C This pressure drop includes both the inlet and vent ducts friction loss For example if the inlet air duct loss is 0 2 W C the vent duct loss cannot exceed 0 24...

Page 28: ...to their previous conditions of use Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CAN...

Page 29: ...efore making the gas hook up make sure the boiler is being supplied with the type of fuel shown on the boiler nameplate The boiler shall be installed such that the gas ignition system components are p...

Page 30: ...4350 3000 2400 2050 1850 1500 1280 3 3 068 7 67 15 3 7700 5300 4300 3700 3250 2650 2280 4 4 026 10 1 20 2 15800 10900 8800 7500 6700 5500 4600 3 6 1 Gas Supply Piping by Installer The boiler and all...

Page 31: ...ation must be given to all possible conditions and their consequences The flow rates published for both boiler models are applicable at 100 firing rate Model Max Flow GPM for 20 F T Min Flow GPM for 4...

Page 32: ...he 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 applicat...

Page 33: ...e return from the system The top vertical connection to the boiler is the OUTLET and must be connected as the supply to the system Piping must be installed such that no piping stresses are transmitted...

Page 34: ...y The bottom rear connection to the boiler is the INLET and must be used for the return from the system The top vertical connection to the boiler is the OUTLET and must be connected as the supply to t...

Page 35: ...ation of external limit controls may be required by certain codes or in certain installations Review applicable local codes for details Drain Valve and Piping A drain valve is factory installed in the...

Page 36: ...l heat exchangers require proper water conditions to remain efficient and function properly For information log on to our website www harscopk com for Multi Metal Systems Water Quality Standards infor...

Page 37: ...eptable drain refer to Section 3 7 9 Condensate piping is properly connected refer to Section 3 7 10 Verify system water quality is within specifications 3 9 SAFETY CHECKS The following checks of safe...

Page 38: ...ng turn down the temperature setting on the high limit thermostat until the main burner shuts off A manual reset lockout displaying LOCKING HIGH LIMIT on the display panel will occur The high limit sw...

Page 39: ...used to setup and monitor boiler operation by means of six push buttons MENU BACK ENTER UP DOWN and RESET as shown above The buttons across the bottom are used to navigate through the various screens...

Page 40: ...ter opens up a screen that allows the setpoint to be changed CH settings Setpoint Value 180 F Range 45 F 185 F CH settings Setpoint Value 180 F Range 45 F 185 F The up or down buttons are used to adju...

Page 41: ...tus of switches and components The ERRORS menu has information about the boiler status at the time of an error The PARAMETERS menu allows the user to set up selected boiler functions and operating mod...

Page 42: ...EST LOW modes These test modes should be used when checking and setting the gas safety shut off control valves on the MACH boiler In this mode a heat request is required Once the boiler cycles on use...

Page 43: ...ses the combustion exhaust O2 There will be a slight time delay between the adjustment and the response of the CO2 O2 measuring instrument Adjust the settings in small increments and allow the combust...

Page 44: ...l assembly provided on this boiler when the boiler underwent factory tests specified in ANSI Z21 13 CSA 4 9 latest edition See Factory Fire test label located on the back left side of the boiler Do no...

Page 45: ...he controller will now complete the automatic firing sequence 4 2 2 Fuel Selection Dual Fuel Only 1 Before switching fuels ensure that the boiler is turned off 2 Ensure that both fuel lines are correc...

Page 46: ...of the boiler depending on your model boiler 4 4 TYPICAL BOILER OPERATING CONDITIONS Model Number Input Rating BTU Hr Voltage Total Amperage Gas Flow Rate CFH Natural Gas 1030 Btu cu ft LP Gas 2500 B...

Page 47: ...iler If able to determine cause of lockout then appropriate corrective action should be taken If unable to determine cause of the problem call a qualified service technician Verify proper operation af...

Page 48: ...signs of deterioration or corrosion Replace immediately if deterioration or corrosion is evident 3 Check the pH level of the system fluid 4 Inspect and clean the condensate system and check for leaks...

Page 49: ...instructions 11 Test pressure safety relief valve Installation and service must be performed by a qualified installer or service agency that has been trained on the Harsco Industrial Patterson Kelley...

Page 50: ...an speed When the air pressure switch closes the 25 second pre purge time is started After the pre purge the blower is driven to the ignition speed 6 A trial for ignition begins The sequence of events...

Page 51: ...the liquid level control board indicating when the probe is sensing water level 5 6 3 Low Gas Pressure The low gas pressure switch opens when there is or has been insufficient gas pressure available f...

Page 52: ...hown on the display The cause of flame failure must be diagnosed and repaired before the control is reset When A01 IGNITION FAILURE is shown on the display the boiler did not light during a trial for...

Page 53: ...FLAME OUT 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 h...

Page 54: ...No earth ground connected or internal hardware error E23 NET FREQ ERROR 47 Main supply voltage frequency differs more than 2 from 60HZ E24 FAULTY EARTH ERROR 48 Faulty earth ground to boiler E30 FLUE...

Page 55: ...ctory Authorized replacement parts are not recommended 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 n...

Page 56: ...MACH Gas Fired Boiler 56 6 1 WIRING DIAGRAMS 6 1 1 MACH Boiler C1500H C2000H Wiring Diagram...

Page 57: ...MACH Gas Fired Boiler 57 6 1 2 MACH C2500 Wiring Diagram East Stroudsburg PA 18301 570 476 7261 www harscopk com MACH C 2500 ENVI Control 2640000055 REV 0 4 TM...

Page 58: ...MACH Gas Fired Boiler 58 6 1 3 MACH C3000 C4000 240VAC Boiler Wiring Diagram...

Page 59: ...MACH Gas Fired Boiler 59 6 1 4 MACH C3000 C4000 480VAC Wiring Diagram...

Page 60: ...MACH Gas Fired Boiler 60 6 1 5 MACH C1500H GG C2000H GG Dual Fuel Boiler Wiring Diagram...

Page 61: ...MACH Gas Fired Boiler 61 6 1 6 MACH C2500GG Dual Fuel Boiler Wiring Diagram...

Page 62: ...MACH Gas Fired Boiler 62 6 1 7 MACH C3000GG C4000GG 240VAC Dual Fuel Boiler Wiring Diagram...

Page 63: ...MACH Gas Fired Boiler 63 6 1 8 MACH C3000GG C4000GG 480VAC Dual Fuel Boiler Wiring Diagram...

Page 64: ...MACH Gas Fired Boiler 64 6 1 9 MACH C1500HGG C2000HGG C2500GG C3000GG 4000GG Dual Fuel Control Wiring...

Page 65: ...ht This junction box houses the transformer the fuses the power block terminal strip circuit breakers and the blower relay The three space terminal strip circuit breakers are mounted on DIN rail and a...

Page 66: ...T 120V AC output when boiler is switched on 0 5 amp max 11 120V AC 3 WAY VALVE 120V AC output during CH Mode 3 way valve is normally closed not powered for DHW and powered open for CH Mode 12 120V AC...

Page 67: ...STAT 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 12 D...

Page 68: ...ee phase 60 hertz service Do not reconfigure for any other voltage Improper configuration of the transformer could result in serious injury or death NOTICE Check for correct transformer wiring on the...

Page 69: ...2000H Natural Gas NG Propane P and Dual Fuel GG boilers 1 2 3 4 5 6 7 8 9 1 Boiler supply 2 Boiler return 3 Nat gas inlet 4 LP gas inlet 5 Relief valve 6 Condensate drain 7 Boiler drain 8 Combustion a...

Page 70: ...as and the rear connection is propane or LP gas For a MACH C4000GG the top connection is propane or LP gas and the rear connection is natural gas Back of Boiler Side of boiler 1 Boiler supply 2 Boiler...

Page 71: ...re Switch HEBP 4 High Temperature Limit 5 ENVI Control Main Board 6 Low Water Cut Off LWCO 7 On Off Switch 8 5 Amp Circuit Breaker 9 ENVI User Interface Display Screen 10 Terminal Block 2 TB2 120 V 11...

Page 72: ...st Back Pressure Switch HEBP 4 High Temperature Limit 5 ENVI Control Main Board 6 Low Water Cut Off LWCO 7 On Off Switch 8 5 Amp Circuit Breaker 9 ENVI User Interface Display Screen 10 Terminal Block...

Page 73: ...Outlet Water Manifold 3 Pressure Relief Valve 4 Heat Exchanger Sectional Castings 5 Inlet Water Victaulic Connection 6 Manual Drain valve 7 Condensate Collector 8 Inlet Water Manifold 9 Ignition Asse...

Page 74: ...2 Outlet Water Manifold 3 Pressure Relief Valve 4 Heat Exchanger Sectional Castings 5 Inlet Water Victaulic Connection 6 Manual Drain valve 7 Condensate Collector 8 Heat Exchanger Sectional Castings 9...

Page 75: ...e switch 9 Low gas pressure switch Mark Description 1 Burner 2 Burner transition piece 3 Blower 4 Venturi 5 Propane gas Manual shut off gas valve with service port 6 Natural gas Manual shut off gas va...

Page 76: ...e same Mark Description 1 Burner 2 Burner Transition Piece 3 Blower Transition Piece 4 Blower 5 Venturi 6 Secondary Manual Gas Shutoff 7 Natural automatic gas valve 8 Main Gas Shutoff Valve with test...

Page 77: ...y Manual Shutoff Valve quantity of two second not shown 7 Propane or LP Automatic Gas Valve 8 Natural automatic gas valve 9 Main Gas Shutoff Valve 10 Natural Gas high Pressure Switch 11 Natural Gas Lo...

Page 78: ...ral location are the same Mark Description 1 Venturi 2 High Gas Pressure Switch 3 Main Gas Valve 4 Primary Manual Shutoff Valve 5 Low Gas Pressure Switch 6 Secondary Manual Shutoff Valve 7 Burner 8 Bl...

Page 79: ...4 Natural Automatic Gas Valve 5 Propane Automatic Gas Valve 6 Primary Manual Shutoff Valves 7 Natural High Gas Pressure Switch not pictured 8 Propane or LP High Gas Pressure Switch 9 Secondary Manual...

Page 80: ...ny 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 unmounte...

Page 81: ...fficiency 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...

Page 82: ...MACH Gas Fired Boiler 82 8 2 APPENDIX 2 MACH BOILER MAINTENANCE LOG Date Hi Low Fire O2 CO CO2 Stack Temp pH Action By...

Page 83: ...lows 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 high then the...

Page 84: ...MACH Gas Fired Boiler 84...

Search results

Summary of Contents for P-K MACH C1500H

Reviews:

Related manuals for P-K MACH C1500H

Brands by name

Popular brands

Harsco Industrial P-K MACH C1500H, Installation & Owner'S Manual

Search results

Summary of Contents for P-K MACH C1500H

Reviews:

Related manuals for P-K MACH C1500H

Brands by name

Popular brands