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  MACH®  Series

 

Gas-Fired Boiler 

Installation 

 

 

Page  12 

 

3.6.8  Intake Duct Materials and Sizes: 

Material:  PVC, CPVC, single wall galvanized steel, or 
other suitable materials.   

The intake duct must be sized for a pressure drop as 
indicated in paragraph 3.6.7 and  for the SCFM as 
specified below. 

Boiler Size 

Required SCFM 

1500 350 

2000 467 

 

The installation of a bird screen on the intake 
termination is recommended.  Ensure that the screen 
does not become blocked with snow, ice, etc. 

 

3.6.9  Sealing the Intake Duct 

Proper 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 aluminum tape. 

 

3.6.10  Intake Duct Connection to Boiler 

Connect the air supply duct to the 10” OD collar on 
the top of the boiler.  Fasten the duct to the collar with 
sheet metal screws at 90º angles.  Seal the joint.  

 

3.6.11  Venting for Multiple Boilers 

The venting instructions in this manual apply to a 

single

 boiler.   

Venting systems for multiple boilers must be 
designed by qualified professionals and verified by 
the stack manufacturer.  The venting system must 
prevent backflow of exhaust gas through idle 
boilers which are not operating.  

 
3.6.12  Removing an Existing Boiler  

(from a common venting system) 

When an existing boiler is removed from a common 
venting system, the common venting system is likely 
to be too large for proper venting of the appliances 
remaining connected to it. 

At the time of removal of an existing boiler, while the 
other appliances remaining connected to the common 
venting system are not 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.  Visually inspect the venting system for proper 

size and horizontal pitch and determine that there 
is no blockage or restriction, leakage, corrosion 
or other deficiency which could cause 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 located and other 
spaces of the building.  Turn on clothes dryers 
and any appliances not connected to the common 
venting system.  Turn on any exhaust fans, such 
as range hoods and bathroom exhausts, so they 
will operate at maximum speed.  Do not operate a 
summer exhaust fan.  Close fireplace dampers. 

4.  Place the appliance being inspected in operation. 

Follow the lighting instructions.  Adjust the 
thermostat so that the appliance will operate 
continuously. 

5.  Test for spillage at the draft hood relief opening 

after 5 minutes of main burner operation.  Use the 
flame of a match or candle or smoke from a 
cigarette, cigar or pipe. 

6.  After it has been determined that each appliance 

remaining connected to the common venting 
system properly vents when tested as outlined 
above, return doors, windows, exhaust fans, 
fireplace dampers and any other gas-burning 
appliance 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 and CSA B149 Installation Code.  When 
resizing any portion of the common venting system, 
the common vent system should be resized to 
approach the minimum size as determined using the 
appropriate tables. 

 

Содержание MACH C1500

Страница 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...

Страница 2: ...MACH Series Gas Fired Boiler Table of Contents...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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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