Patterson-Kelley MACH-05 manual Air Flow Adjustments, Gas Valve Setup and Adjustment

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MACH® Series Gas-Fired Boiler

Installation

 

 

This port is located on the upstream side of the valve body for measuring supply pressure. (See figure below.)

Boiler Test Mode:

The test mode should be used when checking and setting the gas safety shut off / control valves on the MACH Series boilers. In this mode an automatic heat request is simulated as follows:

Test Mode High:

Simultaneously pressing the “Mode” button and the “+” button for 3 seconds activates the “Test Mode High” function to drive the boiler output to maximum. The display will blink and indicate “H” in the first digit of the display to indicate the boiler is being driven to the maximum output rating. This test mode will automatically terminate after 15 minutes or can be terminated from the control/display panel by simultaneously pressing the “+” and “-“ buttons for three seconds.

Test Port

Gas Pressure Test Port

Test Mode Low:

The supply pressure during main burner operation must be greater than the minimum indicated on the rating plate (3.5". W.C. for natural gas, 7" W.C. for propane).

3.12.3 Air Flow Adjustments

The air flow is pre-set at the factory prior to shipment. In unusual situations the air/gas ratio may have to be adjusted to obtain proper combustion readings for specific local conditions.

Combustion measurement instrumentation must be used to adjust the boiler for local conditions (See instructions below). Adjust the carbon dioxide (CO2) or oxygen (O2) reading to achieve conditions as listed in the following Table 3-1.

3.12.4 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 not upstream gas pressure. When set up for natural gas operation, the boiler is capable of operating with gas supply pressure as low as 3.5” W C.

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Simultaneously pressing the “Mode” button and the “-” button for 3 seconds activates the “Test Mode Low” function to drive the boiler output to minimum. The display will blink and indicate “L” in the first digit of the display to indicate the boiler is being driven to the minimum output rating. This test mode will automatically terminate after 15 minutes or can be terminated from the control/display panel by simultaneously pressing the “+” and “-“ buttons for three seconds.

MACH C300 & C450

Required Tools:

2 mm hex wrench Slotted screwdriver Combustion analyzer

The MACH C300 and C450 boilers are equipped with two combined gas/air control and gas safety shut off control valves. The valves function in parallel with the variable speed combustion blower to supply the correct gas air ratio for optimum performance and efficiency. The combustion blower speed is controlled automatically and determines the amount of negative pressure felt at the gas safety shut off / control valves. The gas valve servo regulators adjust gas flow for each valve to maintain zero pressure at the outlet nozzle of the associated valves.

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Contents PATTERSON-KELLEY Mach Series Gas-Fired Boiler Operation What to do if you smell gas Introduction SafetyElectrical Hazards Burn, Fire, and Explosion HazardsCrush Hazards Weight in PoundsChemical Hazards Boiler SizeSlip, Fall Hazards Pressure HazardsStorage Prior to Installation InstallationPlacement Initial InspectionClearances Adjustable Legs for Leveling and Floor ClearanceElectrical Connections at Rear of Boiler Air Inlet RequirementsFlue Connection at Boiler Required ClearancesRooftop Installations Sidewall InstallationsVent Terminations Venting for Multiple BoilersIntake/Exhaust Layout Sealed Combustion Air/Venting SystemRemoving an Existing Boiler Sidewall Inlet, Roof Vent Roof Inlet and Vent Intake Duct Materials and Sizes Intake Duct TerminationsSealing the Intake Duct Intake Duct Connection to BoilerTape on gas line threads Vent ElbowsIntake Termination Details Gas PipingPiping Design Gas Supply Piping by InstallerFeet InchesBoiler Inlet and Outlet Connections Boiler Inlet and Outlet ConnectionsFlushing and Filling Boiler Water Piping by InstallerInspection Mach C300 & C450 Test of Ignition Safety SystemTest of High-Limit Control Test of Gas Pressure SwitchTest of Low Water Cut-out Operating Temperature Controller Step Value UpperDescription Lower Limit Parameter Value Parameter Value Allowable RangeParameter Value Allowable Range F Outdoor AIR vs Boiler SetpointGas Pressure Adjustment Gas Pressure Test Port Air Flow AdjustmentsGas Valve Setup and Adjustment CO2 C300/450 Adjusting Low and High FireMach C750, C900 & C450 C750/900/10500 Adjusting Low and HighNormal Shut Down Procedures Lighting ProceduresOperation Control Panel FrontRate Emergency Shut-OffEmergency Shut-Off Weekly MaintenanceMonthly During Operation DailyAnnually Semi-Annually every 6 monthsLoss of Power Loss of Water Level Code Lockout Manual Reset Service CodesDo not Auto-reset Service CodesPARTS/TECHNICAL Support Terminal Number Label Description Terminal Block Assignments High Voltage Circuit TB21a Terminal Block Assignments Low Voltage Circuit TB1 Wiring Series C-300 Wiring Series C-450 Wiring Series C-750/900/1050 Mach Series 300/450 Main AssemblyMark Description Control PanelDisplay Panel 4 C-300/450 Heat Engine Mark Description Mark Description 5 C-750/900/1050 Heat EngineMark Description 6 C-300 Boiler Gas Train7 C-450 Boiler Gas Train 8 C-750/900/1050 Boiler Gas Train Mark Description Remedy Limited WarrantyThird Party Warranties CO2 AppendixParameter 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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