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MACH® Series

Gas-Fired Boiler

Parts and Technical Support

Page 36

6.0 PARTS/TECHNICAL SUPPORT

Spare parts and replacement parts can be ordered from
Patterson-Kelley by calling toll free (877) 728-5351.
The fax number is (570) 476-7247. Refer to the parts
list shown on the assembly drawing provided in this
manual. Technical information is also available at the
above number and at the Patterson-Kelly website
www.pkboilers.com.

WARNING! Use 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 components. Use of non-factory-authorized
replacement parts jeopardizes the functionality of the
safety features as well as the performance of the
boiler.

When ordering replacement parts please have the

model number

and

serial number

of your boiler

available.

6.1

S

CHEMATIC

D

IAGRAMS

Typical schematic drawings are shown on the
following pages. Drawings specific to your particular
boiler can also be supplied by your local P-K
representative.

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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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