Patterson-Kelley MACH-05 Installation Manual Download Page 1

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PATTERSON-KELLEY

MACH SERIES BOILER
GAS-FIRED BOILER

Installation Date

_______________________

100 Burson Street, P.O. Box 458,
East Stroudsburg, PA 18301
Telephone: (877) 728-5351, Facsimile: (570) 476-7247
www.pkboilers.com

MACH-05

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 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 MACH-05

Page 1: ...18301 Telephone 877 728 5351 Facsimile 570 476 7247 www pkboilers com MACH 05 C S A Design Certified Complies with ANSI Z21 13 CSA 4 9 Gas Fired Low Pressure Steam and Hot Water Boilers ASME Code Sect...

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

Page 3: ...6 10 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 Boile...

Page 4: ...installing operating or servicing boiler c WARNING 1998 HCS Inc 800 748 0241 WARNING It is essential to read understand and follow the recommendations of this manual before installing operating or ser...

Page 5: ...erated and serviced in accordance with instructions contained in this manual Installed by qualified personnel in accordance with designs prepared by qualified facility engineers including structural m...

Page 6: ...n any electrical components 2 5 2 Burn Fire and Explosion Hazards General Warning Hot Surface Reorder No 6020 V2WHPK Improper use may result in fire or injury Read instructions safety manual before in...

Page 7: ...shut off control valves Maintain all gas train components in good condition Do not alter wiring connections Annual inspection by factory trained personnel for proper set up and operation is recommende...

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: ...The 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...

Page 10: ...Surface 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 com...

Page 11: ...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 CSA B 149...

Page 12: ...recommended Consult your local vent manufacturer for proper sizing 3 6 1 Barometric Damper WARNING Do not use a barometric damper with this boiler This is a positive pressure system combustion gas ma...

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: ...per sealing of the intake ductwork is necessary to prevent infiltration of air from conditioned space Joints in PVC or CPVC must be cemented For galvanized duct wrap each joint and seam with adhesive...

Page 17: ...ressure 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 petroleum gases Do not use Teflon tape on gas line threads...

Page 18: ...sure tested 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...

Page 19: ...y be exposed to 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...

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: ...ING After checking controls by manual adjustment make sure they are always reset to their proper settings 3 11 1 Test of Ignition Safety System MACH C300 C450 Test the ignition system safety shutdown...

Page 23: ...t be manually reset prior to resetting the boiler at the display panel Readjust the high limit thermostat to the desired setpoint 3 11 4 Test of Gas Pressure Switch Low Gas Pressure Switch The boiler...

Page 24: ...Parameter PArA Parameter settings 1st digit with a dot 1 125 Information InFo display boiler sensors 1st digit with a blinking dot 1 180 Standby Mode The display defaults to this mode at startup or re...

Page 25: ...used 68 158 2 DHW system ON OFF 0 OFF 1 ON 2 OFF pump continuous 3 ON pump continuous 3 Comfort heat system ON OFF 0 OFF 1 ON 2 OFF pump continuous 3 ON pump continuous 4 Setpoint or max boiler temp o...

Page 26: ...h below Internal Setpoint 145 150 155 160 165 170 175 0 10 20 30 40 Time Boiler Temperature Boiler Set Point Boiler Turns On Boiler Turns Off Domestic Priority If an indirect domestic hot water DHW ta...

Page 27: ...setpoint of the boiler is increased The boiler modulates to maintain this setpoint The setpoint is adjusted according to the above parameters The boiler setpoint will be the maximum value 180 F when...

Page 28: ...8 5 VDC when it will be 180 F The setpoint will remain at 180 F even if voltage is increased further Analog Input to Control Firing Rate Analog Input Firing Rate 0 10 20 30 40 50 60 70 80 90 100 0 1 2...

Page 29: ...n and the button for 3 seconds activates the Test Mode High function to drive the boiler output to maximum The display will blink and indicate H in the first digit of the display to indicate the boile...

Page 30: ...the boiler Check combustion readings using a combustion analyzer If combustion readings are not in accordance with Table 3 1 adjust as follows Using a slotted screw driver or 2 mm hex wrench set the m...

Page 31: ...eve the desired CO2 or O2 level see Table 3 1 for correct settings There will be a slight time delay between the adjustment and the response of the CO2 O2 measuring instrument Adjust the settings in s...

Page 32: ...er to Troubleshooting Section 5 5 to determine the cause of the fault prior to start up WARNING Do not use this boiler if any part has been under water Immediately call a qualified service technician...

Page 33: ...0 275 000 8 amps or less 450 450 000 437 414 000 180 414 000 8 amps or less 750 750 000 728 712 500 300 712 500 8 amps or less 900 900 000 873 846 000 360 846 000 8 amps or less 1050 1 050 000 1019 98...

Page 34: ...corrective action or repair WARNING 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 conditio...

Page 35: ...uired separate from system flush 6 Examine the venting system at least once a year Refer to the vent manufacturer s instructions for requirements in addition to those listed below a Check all joints a...

Page 36: ...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 37: ...e water temperature falls below the high limit temperature the boiler will remain locked out until the switch is manually reset and the front panel reset button is pressed Once the switch and the fron...

Page 38: ...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 39: ...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 40: ...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 41: ...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 42: ...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 43: ...MACH Series Gas Fired Boiler Parts and Technical Support Page 39 6 1 2 Wiring Series C 300...

Page 44: ...MACH Series Gas Fired Boiler Parts and Technical Support Page 40 6 1 3 Wiring Series C 450...

Page 45: ...MACH Series Gas Fired Boiler Parts and Technical Support Page 41 6 1 4 Wiring Series C 750 900 1050...

Page 46: ...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 Temperature Aquastat MACH Series 300 450 MACH Seri...

Page 47: ...ries Gas Fired Boiler Parts and Technical Support Page 43 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 48: ...echnical Support Page 44 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 49: ...4 Outside Burner 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 I...

Page 50: ...Burner Hood 2 Burner Hood 3 Burner Hood Gasket 4 Burner 5 View Glass Assembly 6 Heat Exchanger Sectional Castings 7 Exhaust Pipe Lip Ring 8 Condense Collector Exhaust Manifold 9 Inspection Cover Gask...

Page 51: ...l Support Page 47 6 2 6 C 300 Boiler Gas Train Mark Description 1 Main Gas Shut off Valve 2 Low Gas Pressure Switch 3 Gas Safety Shut off Control Valve 4 Air Gas Manifold 5 Swirlplate 6 Blower 7 Gas L...

Page 52: ...oiler Gas Train Mark Description 1 Main Gas Shut off Valve 2 Low Gas Pressure Switch 3 High Gas Pressure Switch 4 Gas Safety Shut off Control Valve 5 Gas Manifold Shut off Valve 6 Air Gas Manifold 7 S...

Page 53: ...1050 Boiler Gas Train Mark Description 1 Main Gas Shut off Valve 2 Low Gas Pressure Switch 3 High Gas Pressure Switch 4 Gas Safety Shut off Control Valve 5 Gas Manifold Shut off Valve 6 Flex Hose wit...

Page 54: ...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 55: ...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 56: ...MACH Series Gas Fired Boiler Appendix Page 52 8 0 APPENDIX Date Hi Low Fire O2 CO CO2 Stack Temp Action By...

Page 57: ...booster 0 0 0 0 0 0 0 0 0 0 1 minute 30 minutes 12 Outdoor Air Offset 0 F 144 F 0 0 0 0 0 0 0 0 0 0 13 Maximum fanspeed CH hundreds 10 70 60 57 56 54 49 48 56 54 60 58 14 Maximum fanspeed CH units 00...

Page 58: ...1st digit 2nd CH circuit 0X 2nd CH circuit off X X X X X X 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 on potmeter...

Page 59: ...41 41 41 38 Hold boiler water DHW only 32 off 34 F 176 F 32 32 32 32 32 32 32 32 32 32 39 Max Setpoint 2nd CH circuit 50 F 176 F 100 100 100 100 100 100 100 100 100 100 40 Min Setpoint 2nd CH circuit...

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