Instruction/ maintenance manual of the product MACH-05 Patterson-Kelley
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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 - 0 5 C.S.A Design-Certified Complies with ANSI Z21.
MACH® Series Gas-Fired Boiler.
MACH® Series Gas-Fired Boiler Table of Contents 1.0 INTRODUCTION ........................................ 1 2.0 SAFETY ...................................................... 1 2.1 General ..............................................................
MACH® Series Gas-Fired Boiler Table of Contents 5.1.3 Monthly (Dur ing Operation) .................... 30 5.1.4 Semi-Annually (every 6 months) ............ 31 5.1.5 A nnually ................................................. 31 5.2 Cleaning the Bur ner .
MACH® Series Gas-Fired Boiler Safety Page 1 1.0 INTRODUCTION The P-K MACH® Series Gas-Fired Boilers are fully modulating using a variable speed combustion blower, sophisticated microprocessor contro.
MACH® Series Gas-Fired Boiler Safety Page 2 2.4 S A FETY L AB EL S NOTE Reorder No. 80 32-01NHPK c When opening leak test valves, always follow instruc tions in operation and safety ma nual. 1998 HCS, Inc. 800-748 - 02 41 Reorder No. 6020-V2WHPK Improp er use ma y result in fir e or injury .
MACH® Series Gas-Fired Boiler Safety Page 3 • Burn hazard! Hot fluids. Use caution when servicing or draining boiler. • Fire and explosion hazards! Use caution when servicing burner. Propane (LPG) is heavier than air and may linger in the combustion chamber, vent lines, or elsewhere.
MACH® Series Gas-Fired Boiler Safety Page 4 2.5.5 Pressure Hazards Improper u se may result in fire or injury . Read instr uctions/saf ety manua l before insta lling, operating or s ervicing boile r . c ! W ARNING 1998 HCS , Inc. 800- 748-0241 • Pressure hazard! Hot fluids.
MACH® Series Gas-Fired Boiler Installation Page 5 3.0 INST ALLA TION 3.1 R ECEIVING AND S TORAGE 3.1.1 Initial Inspection Upon receiving the boiler, inspect it for signs of shipping damage. Since some damage may be hidden, we recommend unpacking the boiler and removing the top cover and inspecting the boiler.
MACH® Series Gas-Fired Boiler Installation Page 6 clearance and prevent distortion of the cabinet, (twisting, etc.) in addition to leveling. Adjustable Legs for Leveling and Floor Clearance 3.3.3 Clearances If the boiler is to be installed near combustible surfaces, the minimum clearances shown in the table below must be maintained.
MACH® Series Gas-Fired Boiler Installation Page 7 An external electrical disconnect (not supplied with the boiler) with adequate overload protection is required. The boiler must be grounded in accordance with local codes or in the absence of such requirements, in the U.
MACH® Series Gas-Fired Boiler Installation Page 8 If air is taken from another interior space, each opening should have a net fr ee area of 1 square inch for each 1,000 Btu per hour of boiler input (450 square inches for a 450,000 Btu per hour.) 3.6 F LUE V ENTING This boiler requires a special vent system.
MACH® Series Gas-Fired Boiler Installation Page 9 WARNING! Do not locate intake or exhaust terminations directly above a walkway; dripping of conden- sation can cause icing of the walking surface. Reference: ANSI Z223.1 - 2002 Sidewall Installa tions Rooftop Installations 3.
MACH® Series Gas-Fired Boiler Installation Page 10 3.6.6 Sealed Combustion Air/Venting System The MACH Series Boilers are also certified for operation with a sealed combustion air and pressurized venting system. Such a system employs a sealed combustion air intake duct leading from outdoors and a sealed exhaust vent terminating outdoors.
MACH® Series Gas-Fired Boiler Installation Page 11 Sidewall Inlet, Roof Vent Sidewall Inlet and Ve nt Roof Inlet and Vent Roof Inlet, Side w all Vent Basic Air Inlet/Vent Configu rations Exhaust Vent (type of flue termination optional when roof venting.
MACH® Series Gas-Fired Boiler Installation Page 12 C750/900/1050 Sidewall Inlet and Vent 3.6.9 Intake Duct Materials and Sizes: Material: PVC, CPVC (Schedule 40), single wall galvanized steel, or other suitable materials. The intake duct must be sized for a maximum pressure drop of 0.
MACH® Series Gas-Fired Boiler Installation Page 13 Intake Termination Details 3.6.13 Vent Elbows The turn from horizontal to vertical should be made with two 45º ells or with one long radi us 90º ell for best operation. Do not use "short radius" ells.
MACH® Series Gas-Fired Boiler Installation Page 14 Pipe Capacity for Natural Gas Equivalent Pipe Le ngth Maximum Capacity in Cubic Feet o f Natu ral Gas per Hour Pressure Drop of 0.
MACH® Series Gas-Fired Boiler Installation Page 15 Proper flow rates may be achieved through a combination of primary and secondary flow loops. Multiple zones and pumps may result in different flow rates at different times. Consideration must be given to all possible conditions and their consequences.
MACH® Series Gas-Fired Boiler Installation Page 16 3.8.3 Boiler Water Piping by Installer Strainer To avoid possible contamination of t he boiler with dirt, rust or sediment from the system, a strainer near the boiler inlet is strongly recommended.
MACH® Series Gas-Fired Boiler Installation Page 17 untreated make-up water will cause premature failure due to buildup of scale; such failure is not covered by warranty. Scale can also reduce efficiency. For example, a scal e thickness of 1/16" will result in a 12.
MACH® Series Gas-Fired Boiler Installation Page 18 3.10 P RE -S TA RT C HECK L IST Before attempting to start the boiler, make sure the following items have been completed. 1. Section 3.9.1 Inspection. 2. Flue gas from the boiler is properly vented; (refer to Section 3.
MACH® Series Gas-Fired Boiler Installation Page 19 3. Smoothly close the downstream manual isolation valve to reduce the gas flow and cause flame failure. 4 The display will flash E-02 indicating a flame failure. The E-02 lockout will remain until reset on the display.
MACH® Series Gas-Fired Boiler Installation Page 20 3.12 I NITIAL A DJUSTMENTS 3.12.1 Operating Temperature Controller The MACH boiler is equipped with a combination combustion and temperature control. This control monitors combustion and lighting of the boiler, as well as maintaining temperature of the supply water.
MACH® Series Gas-Fired Boiler Installation Page 21 First Digit Boiler Status delay. No system call for heat. 8 Burner 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 indic ating the reason for the lockout.
MACH® Series Gas-Fired Boiler Installation Page 22 Internal Setpoint: The internal setpoint is set with parameter 4. The boiler temperature control modulates the boiler to maintain this internal setpoint.
MACH® Series Gas-Fired Boiler Installation Page 23 CAUTION! Terminal 10 and 11 on TB2 are for pilot duty only. they should not be connected directly to the pump.
MACH® Series Gas-Fired Boiler Installation Page 24 Analog Input to Adjust Setpoint: Anal o g I nput Setpoi nt 0 50 100 150 200 01 23 4 56789 1 0 Vol ta ge Bo i l er S e t p oi n t B oi l e r Se tpoin.
MACH® Series Gas-Fired Boiler Installation Page 25 This port is located on the upstream side of the valve body for measuring supply pressure. (See figure below.) Gas Pressure Test Port The supply pressure during main burner operation must be greater than the minimum indicated on the rating plate (3.
MACH® Series Gas-Fired Boiler Installation Page 26 Table 3-1 Combustion Reading For Setting Gas Safety Shut Off / Control Valves Nominal High Fire Setting Low Fire Setting Fuel Gas Pressure % O 2 % CO 2 % O 2 % CO 2 Natural Gas 7" W.C 5.0 + 0.2 9.
MACH® Series Gas-Fired Boiler Installation Page 27 MACH C750, C900 & C450 Required Tools: TORX ® T40 or 5 mm hex wrench 3 mm or 7/64 in hex wrench Combustion analyzer The MACH C750,C900 and C1050 boilers are equipped with a Honeywell combined gas/air control and gas safety shut off control valves.
MACH® Series Gas-Fired Boiler Operation Page 28 4.0 OPERA TION 4.1 G ENERAL 4.1.1 Control Panel Front Control Panel Become familiar with the basic operation of the boiler.
MACH® Series Gas-Fired Boiler Operation Page 29 4.2.3 Emergency Shut-Off The main gas cock should be closed immediately if an emergency situation occurs. 4.3 T YPICAL B OILER O PERATING C ONDITIONS Natural Gas *(1030 Btu/cu. ft.) LP Gas **(2500 Btu/cu.
MACH® Series Gas-Fired Boiler Maintenance Page 30 5.0 MAINTENANCE 5.1 M AINTENANCE A ND I NSPECTION S CHEDULE WARNING! Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. WARNING! Use care when reassembling main gas line to assure all connections are tight.
MACH® Series Gas-Fired Boiler Maintenance Page 31 5.1.4 Semi-Annually (every 6 months) In addition to the recommended monthly service: 1. Clean burner of any accumu lated dust or lint. See Section 5.2 on "Cleaning the Burner." 2. Inspect burner for any signs of deterioration or corrosion.
MACH® Series Gas-Fired Boiler Maintenance Page 32 5.4 S EQUENCE OF O PERATION 1. When the On/Off (Main power) switch is turned on, power is provided through a circuit breaker to the boiler control and the combustion blower. The boiler control powers a 24 V transformer.
MACH® Series Gas-Fired Boiler Maintenance Page 33 Loss of Water Level The low water switch opens when there is insufficient water level in the boiler.
MACH® Series Gas-Fired Boiler Maintenance Page 34 5.5.1 Manual Reset Service Codes Code Lockout Description E 00 False flame. A flame signal is present when it shouldn’t be. E 02 Flame failure. The burner did not light on startup, or loss of flame dur ing run.
MACH® Series Gas-Fired Boiler Maintenance Page 35 5.5.2 Auto-reset Service Codes Code Lockout Description b 08 Air pressure switch open. T he air pressure switch failed to close to indicate sufficient air flow to start the boiler. b 18 Outlet high limit temp.
MACH® Series Gas-Fired Boiler Parts and Technical Support Page 36 6.0 P ARTS/TECHNICAL SUPPORT Spare parts and replacement parts can be ordered from Patterson-Kelley by calling toll free (877) 728-5351. Ask for the Heat Transfer Department. The fax number is (570) 476-7247.
MACH® Series Gas-Fired Boiler Parts and Technical Support Page 37 6.1 W IRING D IA GRA MS 6.1.1 Terminal Block Assignments – High Voltage Circuit (TB2) Terminal Number Label Description 1 115 VAC LINE 2 115 VAC NEUT RAL Boiler Supply Power, 115 VAC, 60 HZ, 1 ph, 8 amp 3 115 VAC NEUT RAL Aux.
MACH® Series Gas-Fired Boiler Parts and Technical Support Page 38 6.1.1a Terminal Block Assignments – Low Voltage Circuit (TB1) Terminal Number Label Description 1 HEAT REQUEST 2 HEAT REQUEST Boiler Enable, Contact Closur e. DO NOT ENERGIZE. 3 INTERLOCK JUMPER 4 INTERLOCK JUMPER External Limit (auto re set), Contact Closure.
MACH® Series Gas-Fired Boiler Parts and Technical Support Page 39 6.1.2 Wiring Series C-300.
MACH® Series Gas-Fired Boiler Parts and Technical Support Page 40 6.1.3 Wiring Series C-450.
MACH® Series Gas-Fired Boiler Parts and Technical Support Page 41 6.1.4 Wiring Series C-750/900/1050.
MACH® Series Gas-Fired Boiler Parts and Technical Support Page 42 6.2 B OILER P ART S L IST 6.2.1 Main Assembly Mark Description 1 Blower and Gas Train 2 Manifo ld, S ystem Re turn, Boiler Outlet 3 M.
MACH® Series Gas-Fired Boiler Parts and Technical Support Page 43 6.2.2 Control Panel Mark Description 1 AM-3 Rel ay Module 2 Boil er Control MACH Series - MCBA 3 Transformer 4 Lo w Water Cutoff 5 Co.
MACH® Series Gas-Fired Boiler Parts and Technical Support Page 44 6.2.3 Display Panel 3 2 1 5 6 7 4 8 Mark Description 1 Circuit Breaker 2 Air Pressure S witch 3 Fastening Clip 4 Display Panel 5 On/O.
MACH® Series Gas-Fired Boiler Parts and Technical Support Page 45 6.2.4 C-300/450 Heat Engine Mark Description 1 Gasket Blower to Burner Hood 2 Burner Hood 3 Inside Burner Hood Gasket 4 Outside Burne.
MACH® Series Gas-Fired Boiler Parts and Technical Support Page 46 6.2.5 C-750/900/1050 Heat Engine MARK DESCRIPTION 1 Gasket Blower to Burner Hood 2 Burner Hood 3 Burner Hood Gasket 4 Burner 5 View G.
MACH® Series Gas-Fired Boiler Parts and Technical 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.
MACH® Series Gas-Fired Boiler Parts and Technical Support Page 48 6.2.7 C-450 Boiler Gas Train Mark Description 1 Main Gas Shut-off Valve 2 Low Gas Pressure Switch 3 High Gas Pressure Switch 4 Gas Sa.
MACH® Series Gas-Fired Boiler Parts and Technical Support Page 49 6.2.8 C-750/900/1050 Boiler Gas Train Mark Description 1 Main Gas Shut-off Valve 2 Low Gas Pressure Switch 3 High Gas Pressure Switch.
MACH® Series Gas-Fired Boiler Limited Warranty Page 50 7.0 LIMITED W ARRANTY Subject to the terms and conditions herein and except as provided below with respect to products or parts not manufactured by Patterson-Kelley Co.
MACH® Series Gas-Fired Boiler Limited Warranty Page 51 charges to return the boiler and or components. Seller's liability under this warranty shall not in any case exceed the amount paid for the Product found to be defective.
MACH® Series Gas-Fired Boiler Appendix Page 52 8.0 APPENDIX Date Hi/Low-Fire O 2 CO CO 2 Stack Temp Action By.
Parameter Settings for MCBA Controls Parameter Settings for MCBA Controls No. Description Lower Limit Upper Limit Installed MCBA Parameter Settings End User Settings NG LPG NG LPG NG LPG NG LPG NG LPG.
Parameter Settings for MCBA Controls No. Description Lower Limit Upper Limit Installed MCBA Parameter Settings MACH 1050 PK Factory Setting for MCBA MACH 300 PK Factory Setting for MCBA MACH 450 PK Fa.
Parameter Settings for MCBA Controls No. Description Lower Limit Upper Limit Installed MCBA Parameter Settings MACH 1050 PK Factory Setting for MCBA MACH 300 PK Factory Setting for MCBA MACH 450 PK Fa.
An important point after buying a device Patterson-Kelley MACH-05 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Patterson-Kelley MACH-05 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Patterson-Kelley MACH-05 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Patterson-Kelley MACH-05 you will learn all the available features of the product, as well as information on its operation. The information that you get Patterson-Kelley MACH-05 will certainly help you make a decision on the purchase.
If you already are a holder of Patterson-Kelley MACH-05, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Patterson-Kelley MACH-05.
However, one of the most important roles played by the user manual is to help in solving problems with Patterson-Kelley MACH-05. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Patterson-Kelley MACH-05 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
