Patterson-Kelley MACH-05 manual Maintenance, Weekly, Monthly During Operation, Daily

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MACH® Series Gas-Fired Boiler

Maintenance

 

 

5.0MAINTENANCE

5.1MAINTENANCE AND INSPECTION SCHEDULE

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.

WARNING!

Use care when servicing boiler in order to prevent the accumulation of gas in or around the combustion chamber.

WARNING!

General lockout/ tagout procedure must be employed when servicing this unit.

WARNING!

Determine the cause of the lockout before resetting the boiler. If able to determine cause of lockout, then appropriate corrective action should be taken. If not able to determine cause of the problem, call a qualified service technician.

Verify proper operation after servicing.

WARNING!

Check daily to be sure that the boiler area is free and clear of any combustible materials, including flammable vapors and liquids.

5.1.2 Weekly

Observe the conditions of the main flame. A normal high fire flame is blue. If the high fire flame is yellow then corrective action must be taken. In normal low fire the burner will glow a yellowish-orange.

Correct air adjustment is essential to the efficient operation of this boiler. If an adjustment in the combustion is necessary, the flue gas composition should be checked with a carbon dioxide (CO2) or oxygen (O2) analyzer to set conditions. Refer to Table 3-1, Section 3.12.4 for proper combustion readings.

5.1.3 Monthly (During Operation)

1.Test flame detection by voltage reading at the terminal strip (Terminal 9 on TB-1 and ground screw). The voltage reading should be between (5 and 10 VDC).

2.Test high-limit Control. Refer to Section 3.11.3.

3.Test operating temperature controls by reducing or increasing temperature setting as necessary to check burner operation.

4.Test the low water level cut-out. Refer to Section 3.11.2.

5.Test low gas pressure switch. Refer to Section 3.11.4.

6.Check the condensate drain system. Clean and flush as necessary.

5.1.1 Daily

Observe operating temperature and general conditions. Make sure that the flow of combustion and ventilating air to the boiler is not obstructed. Determine the cause of any service codes or lockouts on the display panel.

Observe any unusual noises or operating conditions and make the necessary corrections. Notify responsible individuals for required corrective action or repair.

Installation and service must be performed by a qualified installer or service agency who has been trained on the Patterson-Kelley MACH boiler.

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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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