Patterson-Kelley MACH-05 manual Test of Ignition Safety System, Mach C300 & C450

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MACH® Series Gas-Fired Boiler

Installation

 

 

3.10PRE-START CHECK LIST

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 3.6)

3.Gas connection has been made, pressure tested for leakage, and the line purged of air. Make sure all required vents have been installed.

4.Water connections are complete, and the boiler and system have been filled and purged of air.

5.The boiler is connected to a 120 volt power source with a disconnect having adequate overload protection.

6.Combustion air openings are not obstructed in any way and have adequate capacity.

7.The boiler is placed the proper distance from any combustible walls, in accordance with Section 3.3.3.

8.Relief valves have been piped to floor drains.

9.Condensate piping is properly connected.

10.Verify system fluid pH level is within specification.

3.11SAFETY CHECKS

The following checks of safety systems must be made before putting the boiler into normal operation.

Before firing the boiler refer to Sections 4.1 and 4.2 for information on the use of the controls, lighting, and shut-down procedures.

WARNING!

Never attempt to operate a boiler that has failed to pass all the safety checks described below.

WARNING!

After checking controls by manual adjustment, make sure they are always reset to their proper settings.

3.11.1Test of Ignition Safety System

MACH (C300 & C450)

Test the ignition system safety shutdown as follows:

1.Loosen the retaining screw and remove the 5 pin connector from one of the two gas safety shut- off/control valves.

2.Cycle the boiler on by generating a heat request. (The method for this will depend on your boiler configuration. See Section 3.12.1.2)

3.The boiler should run through the normal startup sequence, checking all of the limits and switches as in a normal start up. (See Sequence of Operation, Section 5.4)

4.When the boiler reaches the ignition period, a 2 will display as the first digit in the display, the spark terminal will energize, and one of the gas safety shut off / control valves will open. One open gas valve should not provide sufficient fuel to light the burner.

5.After 3 seconds the combustion control should lock out, and the display will flash E-02indicating a flame failure.

After completing this test, turn off the boiler and reconnect the 5 pin connector to the gas safety shut off / control valves retightening the retaining screw.

MACH (C750, C900 & C1050)

Test the ignition system safety shutdown as follows:

1.Cycle the boiler on by generating a heat request. (The method for this will depend on your boiler configuration. See Section 3.12.1.2)

2.Place the boiler in operation at the high fire setting. See section 3.12.4 Gas Valve Setup and Adjustment , Test Mode High

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Contents PATTERSON-KELLEY Mach Series Gas-Fired Boiler Operation What to do if you smell gas Safety IntroductionBurn, Fire, and Explosion Hazards Electrical HazardsChemical Hazards Weight in PoundsCrush Hazards Boiler SizePressure Hazards Slip, Fall HazardsPlacement InstallationStorage Prior to Installation Initial InspectionAdjustable Legs for Leveling and Floor Clearance ClearancesAir Inlet Requirements Electrical Connections at Rear of BoilerRequired Clearances Flue Connection at BoilerVent Terminations Sidewall InstallationsRooftop Installations Venting for Multiple BoilersRemoving an Existing Boiler Sealed Combustion Air/Venting SystemIntake/Exhaust Layout Sidewall Inlet, Roof Vent Roof Inlet and Vent Sealing the Intake Duct Intake Duct TerminationsIntake Duct Materials and Sizes Intake Duct Connection to BoilerIntake Termination Details Vent ElbowsTape on gas line threads Gas PipingFeet Gas Supply Piping by InstallerPiping Design InchesBoiler Inlet and Outlet Connections Boiler Inlet and Outlet ConnectionsBoiler Water Piping by Installer Flushing and FillingInspection Test of Ignition Safety System Mach C300 & C450Test of Low Water Cut-out Test of Gas Pressure SwitchTest of High-Limit Control Operating Temperature Controller Description Lower Limit UpperStep Value Parameter Value Allowable Range Parameter ValueOutdoor AIR vs Boiler Setpoint Parameter Value Allowable Range FGas Pressure Adjustment Gas Valve Setup and Adjustment Air Flow AdjustmentsGas Pressure Test Port C300/450 Adjusting Low and High Fire CO2C750/900/10500 Adjusting Low and High Mach C750, C900 & C450Operation Lighting ProceduresNormal Shut Down Procedures Control Panel FrontEmergency Shut-Off Emergency Shut-OffRate Monthly During Operation MaintenanceWeekly DailySemi-Annually every 6 months AnnuallyLoss of Power Loss of Water Level Manual Reset Service Codes Code LockoutAuto-reset Service Codes Do notPARTS/TECHNICAL Support Terminal Block Assignments High Voltage Circuit TB2 Terminal Number Label Description1a Terminal Block Assignments Low Voltage Circuit TB1 Wiring Series C-300 Wiring Series C-450 Wiring Series C-750/900/1050 Main Assembly Mach Series 300/450Control Panel Mark DescriptionDisplay Panel 4 C-300/450 Heat Engine Mark Description 5 C-750/900/1050 Heat Engine Mark Description6 C-300 Boiler Gas Train Mark Description7 C-450 Boiler Gas Train 8 C-750/900/1050 Boiler Gas Train Mark Description Limited Warranty RemedyThird Party Warranties Appendix CO2Parameter Settings for Mcba Controls Description Lower Limit Upper Limit Installed 2X = 3 way valve normally closed

MACH-05 specifications

The Patterson-Kelley MACH-05 is an innovative high-efficiency boiler designed to meet the demanding needs of today’s commercial and industrial applications. Known for its remarkable performance and advanced technologies, the MACH-05 stands out in the market with its ability to provide reliable heating solutions while minimizing energy consumption and environmental impact.

One of the key features of the MACH-05 is its cascading capability. This allows multiple units to be linked together for enhanced capacity and redundancy. By operating in a modular system, users can achieve optimal energy efficiency by adjusting the number of active units based on real-time demand. This ensures that the system operates at peak efficiency, increasing overall reliability and reducing operational costs.

The MACH-05 is equipped with a fully modulating burner system, which ensures precise control of output and efficiency across a broad range of operating conditions. This advanced burner technology facilitates a significant reduction in fuel usage compared to traditional fixed-output systems. Combined with its high thermal efficiency rating, the MACH-05 is not only environmentally friendly but also economically advantageous for facilities looking to lower energy expenses.

In terms of construction, the MACH-05 features a compact, lightweight design that allows for easy installation and integration into existing systems. Its stainless steel heat exchanger is built to provide superior durability and resistance to corrosion, ensuring a long operational lifespan and reducing maintenance requirements. This design advantage translates into lower lifecycle costs for end-users.

The boiler also incorporates intelligent control systems that enhance operational efficiency. These controls can monitor and adjust parameters in real-time, optimizing performance and offering detailed diagnostics to anticipate maintenance needs. The user-friendly interface makes it easy for operators to manage the system and access vital information regarding performance metrics.

Additionally, the MACH-05 is designed with safety in mind, featuring multiple safety controls and alarms that function to protect both the equipment and personnel. This commitment to safety ensures that facilities can operate with peace of mind, knowing that they have a reliable and secure heating solution.

In summary, the Patterson-Kelley MACH-05 combines advanced engineering, efficiency, and safety features to provide a versatile and dependable heating solution. Its key advantages, including cascading capabilities, fully modulating burner technology, and intelligent controls make it an ideal choice for commercial and industrial applications, paving the way toward sustainable and cost-effective heating systems.
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