MACH® Series Gas-Fired Boiler

5.4SEQUENCE OF OPERATION

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. The boiler control supplies 24 V power through a high limit temperature switch and a low water level control.

2.The low water level control is closed when there is water in the boiler up to the probe.

3.When the temperature sensed by the high limit temperature control is below the set limit, the switch is closed. Manual reset of the switch is required following conditions exceeding high limit temperature.

4.If either the high limit temperature control or the low water level control is open, the boiler control locks out and indicates E 12 on the display.

5.Depending on the settings in the boiler control, a heat request is generated.

6.The controller checks that the low air pressure switch is open indicating no airflow. The blower is driven towards the prestart fan speed. When the air pressure switch closes the 15 second prepurge time is started, and the blower is driven toward the ignition speed.

7.After the 15 second prepurge the gas pressure switch circuit is checked to ensure the gas pressure is within design parameters.

Maintenance

10.The unit modulates between the low fire setting and the high fire setting to maintain the desired outlet water temp set point.

11.When the load is below the low fire rating of the boiler the boiler will continue firing and the outlet water temperature will rise until it reaches the set point + temperature differential. At this point the burner is turned off, and the fan continues to run to post purge the boiler for 15 seconds.

12.When the water temperature is reduced by the load on the system, a heat request is again generated. The operating sequence will recycle to step 6, provided the limits on water level, gas pressure and high temperature are all met.

5.5TROUBLESHOOTING

The MACH Series boiler will display service codes to indicate some problems with the boiler. There are two types of lockouts the control may experience: manual reset lockouts requiring an operator to press the reset button, and automatic reset lockouts, where the control will automatically attempt to restart the boiler. A listing of service codes is included at the end of this section.

Should the unit fail to operate, call a qualified service technician to troubleshoot the problem and implement corrective action.

8.If there are no lockouts then when the blower speed is within 200 rpm of the ignition fan speed, a trial for ignition period of 3 seconds is initiated. The internal spark generator and the gas safety shut off / control valves are energized.

9.The internal spark generator is de-energized .3 seconds before the end of the trial for ignition period. After the trial for ignition period, if a flame signal is detected by the flame rectification system, the control initiates a flame stabilization period of 5 seconds at the ignition rpm of the fan. The fan is driven to low fire for 1 minute before the boiler is released to modulation.

The Loss of Power

In the event of a power failure (or when the On/Off switch is in the Off position), the display panel is not illuminated and the entire system is de-energized, closing all automatic valves and halting all boiler operations. When power is restored the sequence of operation will resume at Step 5, 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 the control was in lockout mode but does not indicate which service code was present.

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Patterson-Kelley MACH-05 manual Loss of Power
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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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