Patterson-Kelley MACH C1500 Installation And Owner'S Manual Download Page 45

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MACH® Series

Gas-Fired Boiler

Parts and Technical Support

Page 41

6.3.2 Control Panel

Mark Description

Gas Valve Relay Board (GVRB)

Terminal Block 1 (TB1) 120V

120V/24V Transformer

High Temperature Limit

Low Water Cut Off (LWCO)

Terminal Block 2 (TB2) Low V

AM3 Relay Board

Air Switch (on back)

10 Amp Circuit Breaker

High Exhaust Back Pressure Switch
(HEBPS) on back

5 Amp Circuit Breaker

MCBA Boiler Control

Summary of Contents for MACH C1500

Page 1: ...8301 Telephone 877 728 5351 Facsimile 570 476 7247 www pkboilers com LMACH 07 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 Table of Contents...

Page 3: ...oiler 12 3 6 11 Venting for Multiple Boilers 12 3 6 12 Removing an Existing Boiler 12 3 7 Gas Piping 13 3 7 1 Gas Supply Piping by Installer 15 3 8 Boiler Water Piping 15 3 8 1 Piping Design 15 3 8 2...

Page 4: ...re installing operating or servicing this equipment Failure to do so could result in fire or explosion and serious injury death and or property damage The same features which permit this boiler to ach...

Page 5: ...1 GENERAL The MACH C1500 C2000 gas fired boiler must be Installed operated and serviced in accordance with instructions contained in this manual Installed by qualified personnel in accordance with de...

Page 6: ...oll free at 877 728 5351 for replacement labels 2 5 SAFETY PRECAUTIONS Provide a suitable location for the boiler away from normal personnel traffic with adequate working space adequate clearances pro...

Page 7: ...leak hazard Check entire gas train for leaks after installation If there is a smell of gas shut down the boiler and obtain immediate assistance from trained service personnel and or your local fire d...

Page 8: ...nlet and outlet Make sure isolation valves are closed before servicing boiler Pressure hazard Hot fluids Annually test safety relief valve for proper operation Do not operate boiler with faulty relief...

Page 9: ...I Z21 13 CSA 4 9 latest edition Gas Fired Low Pressure Steam and Hot Water Boilers The heat exchanger is constructed and stamped in accordance with ASME Boiler and Pressure Vessel Code Section IV for...

Page 10: ...ms servicing the boiler Maintain a clearance from the vent to combustible surfaces of 18 or as specified in the vent manufacturer s listed installation instructions The boiler must be installed in a s...

Page 11: ...s freon trichlorethylene perchlorethylene chlorine etc These chemicals when burned form acids which quickly attack the boiler and the boiler stack The result is improper combustion and premature boile...

Page 12: ...2 000 Btu per hour of total boiler input is required NOTE 1 The required size of openings for combustion ventilation and dilution air shall be based on the net free area of the opening 2 Screens shall...

Page 13: ...an upward slope at least 1 4 inch per linear foot This boiler should not be connected into any portion of another mechanical draft system without consulting your venting manufacturer This boiler shal...

Page 14: ...tical without offsets elbows tees etc which results in 0 44 or less of resistance and without a sealed air inlet Typical through the roof venting 3 6 5 Vent Terminations Vertical Vent Termination Deta...

Page 15: ...all of the building and must utilize the same type of termination fitting with the same orientation Allowable termination fittings are 90 elbows tees or straight vents Do not install this boiler with...

Page 16: ...in operation the following steps should be followed with each appliance remaining connected to the common venting system placed in operation 1 Seal any unused openings in the common venting system 2 V...

Page 17: ...readed 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 In the Commonwealth of Massachusetts the g...

Page 18: ...be pressure 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...

Page 19: ...heating coils located in air handling units where they may be exposed to refrigerated air circulation must be equipped with flow control valves or other automatic means to prevent gravity circulation...

Page 20: ...s or additional low water safety devices to protect the system should be considered Installation of external limit controls may be required by certain codes or in certain installations Review applicab...

Page 21: ...hile the boiler is attached to the system since the debris or corrosion products could accumulate in the boiler and plug the boiler heat exchanger IMPORTANT If the piping system attached to this unit...

Page 22: ...valve and turn the boiler back on 3 11 2 Test of Low Water Cut out The boiler is furnished with a probe type low water cut out in the outlet nozzle Test as follows Operation of the switch can be check...

Page 23: ...STEP Press STEP Moving Through the Control Modes Press MODE Press MODE High Gas Pressure Switch The boiler is furnished with a high pressure switch that must be checked by closing the downstream gas c...

Page 24: ...r 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 Sect...

Page 25: ...5 68 59 140 The boiler will modulate to try to maintain 160 F If the temperature increases above 169 F which is the setpoint 160 F High Temp Differential 9 F the boiler will shut off Once it shuts of...

Page 26: ...according to the following table Item Parameter Value F Allowable Range F Maximum Setpoint 4 180 68 185 Minimum Setpoint 5 80 60 140 Outdoor Air Minimum Temp 6 20 4 50 Outdoor Air Maximum Temp 7 70 59...

Page 27: ...t voltage range narrows when these limits are used If the above tables values are used the boiler setpoint will be 80 F when the voltage is anything less than approximately 3 VDC It will then increase...

Page 28: ...listed in the following Table 3 1 3 12 5 Gas Valve Setup and Adjustment Note Verify gas pressure at inlet to boiler is in accordance with Table 3 1 below Gas flow is dependent primarily on fan speed...

Page 29: ...ll increments and allow the combustion readings to stabilize before readjusting When desired adjustments are complete reinstall the blue plastic cap on the cover Low Fire Setting Set boiler to the Tes...

Page 30: ...st Table 3 1 Combustion Reading For Setting Gas Safety Shut Off Control Valves Nominal High Fire Setting Low Fire Setting Fuel Gas Pressure O2 CO2 O2 CO2 Natural Gas 7 W C 4 8 0 2 9 2 0 1 5 0 0 2 9 1...

Page 31: ...der water 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...

Page 32: ...Btu cu ft Model Number Input Rating BTU Hr Total Amperage Gas Rate CFH Output Capacity Btu hr C1500 1 500 000 Less than 15 1456 1 440 000 C2000 2 000 000 Less than 15 1942 1 920 000 Note The heat exc...

Page 33: ...fy responsible individuals for required 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 li...

Page 34: ...r as required 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...

Page 35: ...prepurge the high exhaust backpressure switch circuit is checked to ensure the air flow is within design parameters 6 When the blower speed is within 200 rpm of the ignition fan speed a trial for ign...

Page 36: ...iler will restart provided that all the limits are satisfied If any manual reset lockout was present when the power is lost the display will flash E 04 when the power is resumed This indicates that th...

Page 37: ...all other limits are satisfied Fan running and No Display The fuse in the control may have opened and the blower will run at high speed even though the boiler is not firing Shut off the power to the b...

Page 38: ...ast Indicates low flow condition E 28 No blower feedback The blower should be running but it is not or the feedback signal has been interrupted E 29 Blower feedback will not zero The blower will not g...

Page 39: ...on b 26 High exhaust back pressure The high exhaust back pressure switch is tripped indicating a blocked stack inlet or condensate system or external interlock jumper is open b 30 Max delta T The temp...

Page 40: ...e of Non Factory 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 componen...

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: ...PER External Limit auto reset Contact Closure 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...

Page 43: ...CH Series Gas Fired Boiler Parts and Technical Support Page 39 C1500 C2000 Harsco East Stroudsburg PA 18301 570 476 7261 www pkboilers com Patterson Kelley 6 2 2 Wiring Diagram for Series C 1500 C 200...

Page 44: ...as Fired Boiler Parts and Technical Support Page 40 6 3 BOILER PARTS LIST 6 3 1 Main Assembly Mark Description 1 Cabinet Top 2 Boiler Outlet 3 Boiler Inlet 4 Blower Burner Assembly 5 Front Control Pan...

Page 45: ...e Relay Board GVRB 1 Terminal Block 1 TB1 120V 7 120V 24V Transformer 2 High Temperature Limit 8 Low Water Cut Off LWCO 3 Terminal Block 2 TB2 Low V 9 AM3 Relay Board 4 Air Switch on back 10 10 Amp Ci...

Page 46: ...DESCRIPTION 1 Blower Outlet Gasket 2 Blower Outlet Transition 3 Burner Gasket 4 Burner 5 Ignition 6 Sight Glass Window 7 Outlet Water Manifold 8 Heat Exchanger Sectional Castings 9 Relief Vavle 10 In...

Page 47: ...0 C2000 Gas Train Mark Description 1 Burner 2 Burner Gasket 3 Blower Outlet Transition Piece 4 Blower Outlet Gasket 5 Blower 6 Automatic Gas Valve 7 Main Gas Shutoff Valve 8 High Low Gas Pressure Swit...

Page 48: ...lication 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...

Page 49: ...MACH Series Gas Fired Boiler Limited Warranty Page 45...

Page 50: ...MACH Series Gas Fired Boiler Appendix Page 46...

Page 51: ...MACH Series Gas Fired Boiler Appendix Page 47 8 0 APPENDIX Date Hi Low Fire O2 CO CO2 Stack Temp pH Action By...

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Patterson-Kelley MACH C1500, Installation And Owner'S Manual

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