Harsco Industrial C1500H, C2000H, C2500, C3000, C4000 Installation & Owner's Manual

MACH® C1500H – C4000 Rev. 1.03 (06/08/2012)

MACH

GAS FIRED BOILER C1500H/C2000H/C2500/C3000/C4000 Natural Gas/Propane/Dual Fuel

C.S.A Design-Certified Complies with ANSI Z21.13/CSA 4.9 Gas-Fired Low Pressure Steam and Hot Water

Model #:_______ Serial #______________________

Start-Up Date:

Harsco Industrial, Patterson-Kelley 100 Burson Street East Stroudsburg, PA 18301 Telephone: 570.476.7261 Toll Free: 877.728.5351 Facsimile: 570.476.7247 www.harscopk.com

Boilers

ASME Code, Section IV Certified by Harsco Industrial, Patterson-Kelley

C.S.A Design-Certified Complies with ANSI Z21.13/CSA 4.9 Gas-Fired Low Pressure Steam and Hot Water Boilers

_______________________

MACH

Gas Fired Boiler

MACH

Gas Fired Boiler

.....INTRODUCTION ................................................................................................................................................ 7

2.....SAFETY .............................................................................................................................................................. 7

2.1 General ............................................................................................................................................. 7

2.2 Training ............................................................................................................................................. 8

2.3 Safety Features ................................................................................................................................ 8

2.4 Safety Labels .................................................................................................................................... 8

2.5 Safety Precautions ........................................................................................................................... 9

3.....INSTALLATION ................................................................................................................................................ 11

3.1 Receiving and Storage ................................................................................................................... 11

3.2 Compliance with Codes .................................................................................................................. 12

3.3 Setup .............................................................................................................................................. 12

3.4 Electrical Connections .................................................................................................................... 13

3.5 Inlet Air and Exhaust Venting ......................................................................................................... 16

3.6 Gas Piping ...................................................................................................................................... 29

3.7 Boiler Water Piping ......................................................................................................................... 31

3.8 Pre-Start Check List ....................................................................................................................... 37

3.9 Safety Checks ................................................................................................................................. 37

3.10Initial Adjustments .......................................................................................................................... 39

3.11Fuel/Air Adjustment ........................................................................................................................ 42

4.....OPERATION ..................................................................................................................................................... 44

4.1 General ........................................................................................................................................... 44

4.2 Normal Lighting and Shut-Down Procedures ................................................................................. 45

4.3 Emergency Shut-Off ....................................................................................................................... 46

4.4 Typical Boiler Operating Conditions ............................................................................................... 46

5.....MAINTENANCE ............................................................................................................................................... 47

5.1 Maintenance and Inspection Schedule .......................................................................................... 47

5.2 Cleaning the Burner ........................................................................................................................ 49

5.3 Removing the Heat Exchanger ....................................................................................................... 50

5.4 After All Repairs or Maintenance .................................................................................................... 50

5.5 Sequence of Operation ................................................................................................................... 50

5.6 Troubleshooting .............................................................................................................................. 51

5.7 Manual reset error codes-A##A (OR LOCKING ERROR CODES) ............................................... 53

5.8 Auto-reset error codes-E## (or blocking error codes) .................................................................... 54

6.....PARTS/TECHNICAL SUPPORT ..................................................................................................................... 55

6.1 Wiring Diagrams ............................................................................................................................. 56

6.2 Boiler Parts List ............................................................................................................................... 69

7.....MACH® BOILER LIMITED WARRANTY ......................................................................................................... 80

8.....APPENDIX ........................................................................................................................................................ 81

8.1 Appendix 1 – MACH® Boiler Fire Test Report ................................................................................ 81

8.2 Appendix 2 – MACH® Boiler Maintenance Log .............................................................................. 82

8.3 Appendix 3 – MACH® Boiler Altitude Derate schedule ................................................................... 83

1998 HCS, Inc. 800-748-0241

MACH

WARNING

Improper use may result in fire or injury.

Read instructions/safety manual before installing, operating or servicing boiler.

Reorder No. 6020-V2WHPK

Gas Fired Boiler

If the information in these instructions are not followed exactly, a fire or explosion may result causing property damage, personal injury or death.

Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance.

What to do if you smell gas:

 Do not try to light any appliance.  Do not touch any electrical switch; do not use any phone in your building.  Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions.  If you cannot reach your gas supplier, call the fire department.

Installation and service must be performed by a qualified installer, service agency, or the gas supplier.

AVERTISSEMENT! Assurez-vous de bien suivre les instructions données dans cette notice pour réduire au minimum le risqué d'incendie ou d'explosion ou pour éviter tout dommage matériel, toute blessure ou la mort.

— Ne pas entreposer ni utiliser d'essence ni d'autres vapeurs ou liquids inflammables dans le voisinage de cet appareil ou de tout autre appareil.

— QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:

• Ne pas tenter d’allumer d’appareils.

• Ne touchez à aucun interrupteur. Ne pas vous servir des téléphones dans le bâtiment où vous vous trouvez.

• Appelez immédiatement votre fournisseur de gaz depuis un voisin. Suivez les instructions du fournisseur.

• Si vous ne pouvez rejoindre le fournisseur de gaz, appelez le service des incendies.

— L’installation et l’entretien doivent être assurés par un installateur ou un service d’entretien qualifié ou par le fournisseur de gaz.

It is essential to read, understand, and follow the recommendations of this manual

before installing, operating, or servicing this equipment.

who has been trained on the Harsco Industrial, Patterson-Kelley MACH® boiler. The same features which permit this boiler to achieve high-efficiency performance make it unlike most other boilers of this general size, so it is important to understand how this boiler operates.

MACH

Installation and service must be performed by a qualified and knowledgeable individual

Gas Fired Boiler

MACH

Gas Fired Boiler

MACH

Gas Fired Boiler

1 INTRODUCTION

This manual describes the installation and operation of MACH® boilers with inputs from 1.5 million through 4 million BTUH. Natural gas, propane, and dual fuel (natural and propane) units are described. It also includes 208/3/60, 240/3/60, or 480/3/60 voltages for the 3 and 4 million BTUH input boilers. This manual describes the natural gas design. Information for operation with other fuels is included in the various sections of this manual as applicable. If you have any questions on the information contained within, or do not fully and completely understand the content, please contact Harsco Industrial, Patterson-Kelley Technical Service at 570.476.7261 or toll free at 877.728.5351.

The MACH combustion blowers, sophisticated microprocessor controls, modulating gas safety shut off / control valves and a unique aluminum alloy heat exchanger capable of operating in a fully condensing mode to provide maximum efficiency in a minimum amount of space. The high quality materials and thoroughly tested design of the boiler should provide years of trouble free service if the instructions in this manual are followed carefully.

This manual covers the installation of MACH fuel (natural gas and propane) boilers. The model number may be followed by a prefix or suffix letter in some cases to indicate special features or different options.

While details may differ slightly, basic operation is the same for all models. Check the rating plate for correct fuel usage and gas pressures.

The boiler is only a part of the complete heating system. This boiler may be fully operational and yet because of poor circulation, control, or other operating characteristics not deliver heat to the desired location. Additional equipment such as temperature sensors, pumps, flow switches, balancing valves, and check valves will be required for satisfactory operation of any system. Harsco Industrial, Patterson-Kelley cannot be responsible for the design or operation of such systems and a qualified engineer or contractor must be consulted.

C1500H/C2000H/C2500/C3000/C4000 gas fired boilers are fully modulating using variable speed

C1500H/C2000H/C2500/C3000/C4000 natural gas, propane, and dual

2 SAFETY

2.1 G

The MACH

 Installed, operated, and serviced in accordance with instructions contained in this manual and other supplemental

 Installed by qualified personnel in accordance with designs prepared by qualified facility engineers including:

 Operated and serviced in accordance with a comprehensive safety program determined and established by the

 Operated and serviced by experienced, qualified, and properly trained personnel in accordance with all applicable

NOTICE! Each safety device must be maintained and checked per the recommended schedule. Refer to Section

5.1 of this manual.

ENERAL

C1500H/C2000H/C2500/C3000/C4000 gas fired boilers must be:

manuals.

structural, mechanical, electrical, and other applicable disciplines.

customer. Do not attempt to operate or service until such a program has been established.

codes, laws, and regulations.

MACH

Gas Fired Boiler

2.2 T

RAINING

Proper training is the best protection against accidents.

It is essential to read, understand, and follow the

recommendations of this manual before installing, operating, or servicing this equipment. Failure to do so could result in fire or explosion and serious injury, death, and/or property damage.

Operating and service personnel must be thoroughly familiar with the basic construction of the MACH

C1500H/C2000H/C2500/C3000/C4000 boilers, the use and locations of the controls, the operation of the boilers, adjustment of their various mechanisms, and all applicable safety precautions. If any of the provisions of this manual are not fully and completely understood, contact Harsco Industrial, Patterson-Kelley Technical Service at

570.476.7261 or toll free at 877.728.5351.

2.3 S

AFETY FEATURES

It is the responsibility of the customer to maintain the safety features, such as but not limited to: guards, safety labels, safety controls, interlocks, lockout devices, in place and operable.

2.4 S

AFETY LABELS

The following words are used in this manual to de-note the degree of seriousness of the individual hazards.

Indicates an imminently hazardous situation which, if not avoided, will result in death or

serious injury. This signal word is to be limited to the most extreme situations.

Indicates a potentially hazardous situation which, if not avoided, could result in death or

serious injury.

Indicates a potentially hazardous situation which, if not avoided, may result in minor or

moderate injury. It may also be used to alert against unsafe practices.

NOTICE/NOTE

- NOTICE is the preferred signal word to address practices not related to personal injury. The safety

alert symbol is not used with this signal word.

MACH

Gas Fired Boiler

1998 HCS, Inc. 800-748-0241

WARNING

Improper use may result in fire or injury.

Read instructions/safety manual before installing, operating or servicing boiler.

Reorder No. 6020-V2WHPK

The safety labels shown above are affixed to your boiler. Although the labels are of high quality, they may become dislodged or unreadable over time. Contact Harsco Industrial, Patterson-Kelley at 570.476.7261 or toll-free at

877.728.5351 for replacement labels.

2.5 S

AFETY PRECAUTIONS

Provide a suitable location for the boiler, away from normal personnel traffic, with adequate working space, adequate clearances, proper ventilation and lighting, with a structure sufficiently strong and rigid to support the weight of the boiler, all piping, and accessories.

2.5.1 Electrical Hazards

 Shock hazard! Properly lockout/tag out the electrical service and all other

energy sources before working on or near the boiler.

 Shock hazard! Do not spray water directly on this boiler or on any electrical

components.

 Electrical hazard! Do not alter wiring connections.

2.5.2 Burn, Fire, and Explosion Hazards

 Burn, fire, and explosion hazards! Installation must be in strict conformance to all

applicable codes and standards including NFPA 54, ANSI Z223.1 and CAN/CSA B.149. Install all required vent lines for gas devices. Refer to Section 3.6.

 Hazard from incorrect fuels! Possible fire, explosion, overheating, and damage. Do

General Warning

not use any fuels except the design fuels for the unit.

 Over fire hazards! High pressure in gas supply could result in over firing of this or

other devices supplied from the same source.

1998 HCS, Inc. 800-748-0241

WARNING

Improper use may result in fire or injury.

Read instructions/safety manual before installing, operating or servicing boiler.

Reorder No. 6020-V2WHPK

 Fire and explosion hazards! Close the main gas shutoff before servicing boiler.

 Fire and explosion hazards! Do not store or use gasoline or other flammable vapors

or liquids in the vicinity of this or any other gas fired appliance.

 Burn hazard! Possible hot surfaces. Do not touch gas vent during firing operation.

Use only factory recommended vent components.

 Burn hazard! Pipes, vents, and boiler components could be hot. Do not touch piping

or stack surfaces during operation or immediately after shutdown of the boiler.

 Burn hazard! Hot fluids. Use caution when servicing or draining boiler.

Hot Surface

MACH

Gas Fired 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.

 Gas leak hazard! Make sure the burner is installed correctly and blower/transition is securely fastened following

any maintenance performed on them. These connections may leak gas if assembled incorrectly.

 Gas leak hazard! All threaded gas connections must be made using a pipe compound that is resistant to liquefied

petroleum gas. Do not use Teflon tape on threaded gas piping.

 Gas leak hazard! Check entire gas train for leaks after installation. If there is a smell of gas, shut down the boiler

and obtain immediate assistance from trained service personnel and/or your local fire department.

 Over fire hazard! Possible fire and explosion from excess gas pressure. Make sure that gas inlet pressure does

not exceed 14 inches W.C.

 Over fire hazard! Possible fire and explosion. Possible malfunction of regulators and/or gas safety shut off /

control valves. Maintain all gas train components in good condition. Do not alter wiring connections. Annual inspection by factory-trained personnel for proper set-up and operation is recommended.

 Over fire and under fire hazards! Possible fire, explosion, overheating, and component failure. Do not attempt to

adjust firing rate of the boiler. The firing rate must be adjusted only by factory trained personnel.

Gas may lose its odor. Proper gas sensing equipment and procedures should be used for

leak checks.

2.5.3 Crush Hazards

 Lifting hazards! Use properly rated lifting equipment to lift and position the boiler. The

load is unbalanced. Test balance before lifting 3 ft. above the floor. Do not allow personnel beneath the lifted load. Refer to approximate weights in the table.

General Warning

 Bump hazard from overhead ductwork and piping. Install components with adequate

vertical clearance.

2.5.4 Chemical Hazards

Boiler Size Weight in Pounds

C1500H 1,200 lbs

C2000H 1,400 lbs

C2500 1,550 lbs

C3000 1,600 lbs

C4000 1,900 lbs

• Chemical hazards from cleaning products. Use caution when cleaning the system. The use of professional assistance is recommended. Use safe procedures for the disposal of all cleaning solutions.

• Combustion Condensate – an acidic pH of approximately 3.0 to 5.0 can be expected.

General Warning

Use PVC, CPVC, or other corrosion resistant piping for drainage. Collection and disposal must be in accordance with all applicable regulations. A condensate neutralization kit is available. Please contact your local Harsco Industrial, Patterson-Kelley representative.

MACH

2.5.5 Pressure Hazards

 Pressure hazard! Hot fluids. Install isolation valves on boiler water inlet and outlet.

Make sure isolation valves are closed before servicing boiler.

 Pressure hazard! Hot fluids. Annually test safety relief valve for proper operation. Do

not operate boiler with faulty relief valve.

General Warning

2.5.6 Slip, Fall Hazards

 Tripping hazard! Do not install piping on floor surfaces. Maintain clear path around

boiler.

 Slip and fall hazard! Use drip pan to catch water while draining the boiler. Maintain dry

floor surfaces.

Gas Fired Boiler

General Warning

 Slip and fall hazard! Do not locate intake or exhaust terminations directly above a

walkway; dripping of condensation can cause icing of the walking surface. (see section

3.5)

 Fall hazard! Do not stand on boiler.

3 INSTALLATION

Installation and service must be performed by a qualified installer, service agency, or

gas supplier.

3.1 R

3.1.1 Initial Inspection Upon receiving the boiler, inspect it for signs of shipping damage. Since some damage may be hidden, unpack

the boiler, open the front, and side doors and inspect the boiler. Verify that the total number of pieces shown on the packing slip agrees with those actually received.

NOTICE! Note any damage, suspected potential damage, or shortage of materials on the freight bill and immediately notify the carrier. File all claims for shortage or damage with the carrier. Claims for hidden damages must be filed with your carrier within 7 days. The boiler carton is equipped with a “Tip (N) Tell”. If "Tip (N) Tell” arrow point is blue,

that indicates that the package has been on its side or tipped over in transit.

ECEIVING AND STORAGE

3.1.2 Storage Prior to Installation

If the boiler is not installed immediately, it must be stored in a location adequately protected from the weather, preferably indoors. If this is not possible, then it should remain in the shipping container and be covered by a tarpaulin or other waterproof covering.

NOTICE! Controls and other equipment that are damaged or fail due to weather exposure are not covered by warranty.

MACH

Gas Fired Boiler

3.2 C

OMPLIANCE WITH CODES

MACH® boilers with standard components and with many options complies with American National Standard/CSA Standard ANSI Z21.13/CSA 4.9, latest edition, Gas Fired Low Pressure Steam and Hot Water Boilers.

The heat exchanger is constructed and stamped in accordance with ASME Boiler and Pressure Vessel Code, Section IV for 125 psig maximum operating pressure.

Installation of the boiler must conform to all the requirements of all national, state and local codes established by the authorities having jurisdiction or, in the absence of such requirements, to the National Fuel Gas Code, ANSI Z223.1/NFPA 54 latest edition in the U.S. In Canada, the equipment shall be installed in accordance with the current Installation Code for Gas Burning Appliances and Equipment, CAN/CSA-B.149, latest edition, and applicable Provincial Regulations for the class, which should be carefully followed in all cases. Authorities having jurisdiction should be consulted before installations are made.

Where required by local codes, the installation must conform to American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers (ASME CSD-1).

In the Commonwealth of Massachusetts (a) this unit must be installed by a licensed pipe fitter / plumber, (b) field installed gas cocks must be “T” handle type, (c) piping of condensate shall conform to the State Plumbing Code, and (d) refer to the Massachusetts Supplement for further details.

3.3 S

ETUP

3.3.1 Foundation and Placement

Provide a firm, level foundation, preferably of concrete.

The wheels provided with this boiler are for positioning purposes only. When positioning this boiler, maintain positive control of it at all times. Do not attempt to move the boiler on surfaces that are not level. Failure to heed this warning could result in personal injury or death.

Lifting the front of the boiler slightly will allow the boiler to be rolled off the shipping skid onto the concrete foundation. Once in position, the wheel bolts may be removed allowing the wheels to recess up into the boiler. The base will sit

flat on the provided foundation. All of our boilers are supplied with leveling feet to adjust the boiler to a level position on the floor. This is very important to maintain proper condensate drainage and correct op eration of the boiler. If the

boiler is to be pulled out for maintenance, the wheels may be left attached.

3.3.2 Placement

The boiler must be level to function properly. There are six 9/16” holes in the base that may be used for 3/8” seismic anchors.

NOTICE! The boiler may be installed on a combustible floor; however, the boiler must never be installed on carpeting.

3.3.3 Clearances

If the boiler is to be installed near combustible surfaces, the minimum clearances shown in the pictures and table below must be maintained. Failure to provide for the service access clearances, even with non-combustible surfaces, may cause future problems servicing the boiler. Maintain a clearance from the vent to combustible surfaces of 18” or as specified in the vent manufacturer’s listed installation instructions. The boiler must be installed in a space large in comparison to the boiler as described in the National Fuel Gas Code, ANSI Z223.1, latest edition.

MACH

Gas Fired Boiler

Minimum Clearances from Adjacent Walls, Ceiling, and Obstructions

Type of Surface Dimensions (inches)

A B C† D

Combustible Surfaces

Minimum Clearances

Recommended Clearances

for Service Access

† "C" Space required for pipes, ducts, etc. in this area above the boiler.

* “B” Clearance depends upon exhaust vent configuration.

** Do not doors can be opened.

clearances.

put pipes, ducts, vents, etc in this space. Electrical conduit must be installed vertically so that the side

18 6 12 6

30 12* 12 18**

Bumping hazard from overhead ducts! Install all components with adequate vertical

3.4 E

LECTRICAL CONNECTIONS

Be sure to check the nameplate on the boiler before connecting electrical supply.

MACH

Gas Fired Boiler

NOTICE! A dedicated earth ground (green wire) is required to avoid nuisance shutdowns. Do not ground through the conduit.

MACH© C1500H/C2000H/C2500 boilers require 120 volts, single phase, 60 hertz electrical service. The MACH

NOTE: MACH

C3000/C4000 boilers require either 208VAC/ 240VAC OR 480VAC three phase, 60 hertz

C3000/C4000 boilers must be ordered as either 208/240VAC or 480VAC THIS IS NOT FIELD

CONFIGURABLE.

If 208 VAC is used the step down transformer must be reconfigured for 208VAC by changing the connection on the transformer located inside of the power input junction box (see MACH

boiler transformer wiring diagrams for proper

configuration).

The total operating amperage is indicated on the rating nameplate. Before starting the boiler, check to ensure that the proper electrical service is connected to the boiler.

An external electrical disconnect (not supplied with the boiler) is required. The boiler electrical service must be installed and grounded in accordance with local codes or in the absence of such requirements, in the U.S. with National Electrical Codes, ANSI/NFPA No. 70 latest edition or, in Canada, to the Canadian Electrical Code, Part I, CSA C22.1, latest edition. Installed conduit must not block openings and must allow the side doors to be opened.

The electrical junction boxes are located at the upper front sides of the boiler. The MACH

C3000/C4000 boilers have an added electrical junction box at the

lower front left side.

3.4.1 Power Input Junction Box MACH

C3000/C4000 Boilers

Power Input Junction Box

For the C3000 and C4000

The main power connections are connected to the over current safety device rated for a 20 Amp 3 phase circuit (for either 208-240 or 480VAC) and ground terminal located in the main power connection box. This box is located at the lower front left side of the boiler. The power connection has four points of contact: Terminals 1, 3, 5 and G. Connect the three wires supplying the three phase power to terminals 1, 3 and 5. Connect the main boiler ground wire to G.

The MACH

C3000/C4000 boilers internal control transformer is pre-wired

from the factory for operation with 240 VAC or 480VAC. If 208 VAC three phase power is used on the 240VAC model, the internal control transformer must be wired for operation at this lower voltage. The wire in terminal X3 on the load side of the internal control transformer must be moved to terminal X4. This supplies the 120 VAC power to the controls from the 208 VAC main

voltage. Refer to Sections 6.1.4 and 6.1.5 for proper wiring and configuration

of the internal control transformer.

3.4.2 Power Input Junction Box or Terminal Block 2 (TB2) MACH

C1500H/C2000H/C2500 Boilers

The main power connection is made within the TB2/HV terminal block to terminals: 1 - 120VAC LINE L1+ 2 - 120VAC NEUTRAL N1 8 - GROUND G

MACH

3.4.3 High Voltage (TB2) Terminal Block

Gas Fired Boiler

For MACH

C3000/C4000 boilers, the high voltage (TB2) terminal block is for 120VAC

output pilot duty loads only. Do not connect any 120VAC supply voltage to the high voltage (TB2) terminal block. Connecting a 120VAC supply voltage to TB2 can result in serious injury or death.

120 VAC Neutral- These terminals provide the neutral wires for the boiler 120 VAC outputs.

TB2 high voltage terminal block

TB1 low voltage terminal block

120VAC Switched Output- This contact closes when the boiler is switched on. This provides 120 VAC, 0.5 Amp

service to TB2-10. The neutral for this circuit is provided on TB2-3. When the boiler is switched off, this terminal is switched off as well.

3 Way Valve- This output is normally energized, keeping the three way valve open, providing heat to the building.

The Domestic Hot Water (DHW) call for heat de-energizes this circuit, causing the 3 way valve to self close, thereby providing heat to the DHW loop. This output provides 120 VAC, 0.5 Amp service to TB2-11. The neutral for this circuit is provided on TB2-4. Note: the 3 way valve is a field sourced part.

DHW Pump Relay w/ Delay Off - This output is enabled when there is a call for DHW. When the call for heat is

removed, the output remains enabled for the post pump time parameter within the DHW settings. This output provides 120 VAC, 0.5 Amp service to TB2-12. The neutral for this circuit is provided on TB2-5.

Circ Pump Relay w/ Delay Off - This output is enabled when there is a call for heat. When the call for heat is

removed, the output remains enabled for the post pump time parameter within the CH settings. This output provides 120 VAC, 0.5 Amp service to TB2-13. The neutral for this circuit is provided on TB2-6.

Damper Relay - This output is enabled when the call for heat is enabled. This output provides 120 VAC service to

TB2-14. The neutral for this circuit is provided on TB2-7. This circuit is for pilot duty only.

Master Alarm Relay – This is a dry set of contacts that are normally open and will close in the event of an alarm

output from the boiler control, connecting TB2-15 and TB2-16.

Flame Detected Relay – This is a dry set of contacts that are normally open and will close whenever the boiler

control is reading a flame, connecting TB2-17 and TB2-18.

MACH

Gas Fired Boiler

3.4.4 Low Voltage (TB1) Terminal Block Enable/Disable– TB1-1 and TB1-2 are used for enabling the boiler. Closing this circuit allows the boiler to run.

Opening this circuit prevents the boiler from running. This circuit is energized by the boiler. It has a 24 VAC potential. Devices connected to these terminals must be rated for 24 VAC

Note: This circuit will become unusable in certain CH modes and Cascade Master Modes dealing with 0-

10vdc. External Interlock – TB1-3 and TB1-4 are used for attachment of an additional field safety device to the boiler control

circuit. Closing this circuit allows the boiler to run. Opening this circuit prevents the boiler from running. This circuit is energized by the boiler with a 5 V potential. Devices connected to these terminals must be rated for 5 V.

Outdoor Temp Sensor – TB1-5 and TB1-6 are connected to the outdoor temperature sensor. The temperature

control must be programmed to run an outdoor air schedule. The outdoor air sensor and programming help are available from the local Harsco Industrial, Patterson-Kelley Representative. This circuit is energized by the boiler with a 5 V potential. The temperature sensor must be a NTC having 12 k @ 77°F.

DHW Stat/Sensor – TB1-7 and TB1-8 are connected to the DHW temperature sensor or thermostat. This circuit is

energized by the boiler with a 5V potential. The temperature sensor must be a NTC having 12 k @ 77°F.

Header Temp Sensor – TB1-9 and TB1-10 are connected to the header temperature sensor. This circuit is

energized by the boiler with a 5 V potential. The temperature sensor must be a NTC having 12 k @ 77°F.

DHW Flow Switch – TB1-11 is energized by the boiler with a 5 V potential. This circuit connects through a flow

switch on the domestic side of a domestic hot water system. The flow switch should close upon flow to provide a closed circuit back to TB1-12.

Analog Input– Remote signal for controlling the boiler. The boiler can be operated in a remote setpoint or a remote

firing rate control mode. Input 0-10 VDC+ signal on TB1-13 only. The 0 VDC- Analog Input is provided on TB1-14. The temperature control must be programmed to run with the analog input. (See the ENVI

Control Advanced Users

Guide for more information)

MODBUS® – TB1-17 and TB1-18 are used for connecting a MODBUS® building management system. (See the

ENVI

Control Advanced Users Guide for more information)

Cascade – TB1-19 and TB1-20 are used to connect between boilers that are part of a Master/Member Network. Up to

24 boilers may be connected together. (See the ENVI

Control Advanced Users Guide for more information)

3.5 I

NLET AIR AND EXHAUST VENTING

3.5.1 Applicable Codes & Standards CODES

United States: NFPA 54/ANSI Z223.1 National Fuel Gas Code NFPA/ANSI 211 Chimneys, Fireplaces, Vents and Solid Fuel Burning Appliances

Canada CAN/CSA B149.1 Installation Codes for Gas Burning Equipment

STANDARDS

UL 1738 Venting Systems for Gas-Burning Appliances, Categories II, III, and IV ULC S636-95 Standard for Type BH Venting Systems Sheet Metal and Thermoplastic Duct Construction Manual Air Conditioning Contractors National Association (SMACNA)

MACH

Gas Fired Boiler

These codes and standards contain information for the venting of gas fired appliances, including, but not limited to vent sizing, location, clearance to combustibles, and safe installation practices. The installation must comply with both the above Federal Codes and with state, provincial and local codes.

Design and installation of venting systems should be done only by qualified and

knowledgeable venting systems personnel and in accordance with vent system manufacturer’s installation instructions. Installing a boiler or vent system using improper installation methods or materials can result in serious injury or death due to fire or asphyxiation.

Before connecting a boiler to a venting system, it must be determined whether the boiler

is to be installed in a conventional or Direct Vent configuration. In the US, provisions for combustion and ventilation

air must be in accordance with NFPA 54/ANSI Z223.1, National Fuel Gas Code, latest edition, or applicable

provisions of the local building codes. In Canada, combustion and ventilation air openings shall comply with

CAN/CSA B-149.1 Natural Gas and Propane Installation Code.

For correct installation of vent system, read all of these instructions and refer to vent

manufacturer’s instructions. Failure to use a proper vent system (types and materials), as described in this manual will void the boiler warranty

and may result in rapid deterioration of the venting system, creating a health or life safety hazard. Faulty vent installation can allow toxic fumes to be released into living areas. This may cause property damage,

serious bodily injury or death.

Table of Required Stainless Steel Vent Adapters and Category II Motorized Dampers

Boiler

Size

Nominal

vent Size

Stainless

Vent Adapter

Vent

adapter

size

Boiler air

inlet for

combustion

air

Combustion

air Normally-

Closed

Motorized

Damper

C300 4” 2600000593

C450 5” 2600000594

C750 6” 2620000181

C900 8” 2620000366

C1050 8” 2620000366

C1500 10” 2630000226

C2000 10” 2630000225

C2500 10” 2640000133

C3000 10” 2640000133

C4000 10” 2640000133

4” 6”

5” 6”

8”x6” 6”

8” 6”

10”x8” 10”

10” 12”

1004906943 6”

1004906943 6” size

1004906944 8” as

1004906945 10” needed

1004906945 10” size

1004906945 10” as

1004906946 12” need

1004906946 12”

1004906989 14”

NOTICE! This table is for information only. Combustion air dampers and vent adapters are listed for use of design and may or may not be specific to your application.

The optional, but required for Category II venting, normally-closed motorized combustion air damper operates on 120 VAC and features an end limit switch wired into the boiler’s external interlock circuit. Upon a call for heat, the boiler’s

MACH

Gas Fired Boiler

combustion air damper relay will energize and drive the damper open. Once the damper reaches the fully-open position, the end limit switch makes contact and closes the external interlock circuit allowing the boiler to fire. The diagram below shows the wiring necessary to install the normally-closed motorized damper.

Use caution if installing a barometric damper in the exhaust vent. The vent pressure must

be negative from the barometric to the vent termination (Category II) at all times to prevent leakage of harmful flue

gases into the room. Leakage of flue gases can cause serious injury or death. Note: this applies to Category II venting only.

3.5.1.1 Gas Vent Categories

Several codes and standards have categorized appliances in accordance with the flue gas temperature and pressure produced by the appliance. The applicable categories are defined as follows:

 Category II An appliance that operates with a non-positive vent static pressure and with a vent temperature

that may cause excessive condensate production in the vent.

 Category IV An appliance that operates with a positive vent static pressure and with a vent temperature that

may cause excessive condensate production in the vent.

 Direct Vent An appliance that is constructed and installed so that all air for combustion is derived directly

from outdoors and all flue gases are discharged to the outdoors.

3.5.1.2 Venting Materials for Flue/Exhaust Systems

The MACH appliance, which vents with a temperature that is likely to cause condensation in the vent. Therefore, any venting system used with the MACH

C1500H/C2000H/C2500/C3000/C4000 boilers are dual certified as a Category II and Category IV

boiler must comply with the requirements for either Category II or Category IV venting systems as specified in the latest edition of NFPA 54/ANSI Z223.1 in the US or the latest edition of CAN/CSA B-149.1 in Canada.

The venting materials listed below are intended for the venting of gas burning

appliances only. Do not use these venting materials for venting liquid or solid fuel (such as oil, kerosene, wood or coal) appliances

Maintain clearances to combustibles as listed in the vent manufacturer’s installation instructions or as set forth in the codes and standards listed in this section.

Do not use these vent pipes for incinerators of any sort.

MACH

Gas Fired Boiler

This boiler is not certified for use with PVC venting. Use of PVC vent may result in vent failure and possible serious injury or death.

Table of Acceptable Materials for Venting Systems

Table of Applicable Vent Materials

Model C1500H C2000H

C2500 C3000

C4000 C1500H C2000H

C2500

C3000

C4000

Country

US US US US

US Canada Canada Canada Canada Canada

AL29-4C 316L SS PVC

X X No X X No X X No X X No X X No X X No X X No X X No X X No X X No

CPVC POLYPROPYLENE

X NOTE 3 X NOTE 3 X NOTE 3 X NOTE 3

X NOTE 3 NOTE 2 NOTE 2 NOTE 2 NOTE 2 NOTE 2 NOTE 2 NOTE 2 NOTE 2 NOTE 2 NOTE 2

Note 2: When this material is used for venting, it must be listed to ULC-S636. Note 3: When this material is used for venting, it must be listed to UL-1738.

MACH

Gas Fired Boiler

3.5.2 Combustion Air Materials and Sizes Air Requirements – SCFM

MACH® Boiler MODEL

Required SCFM

The air intake duct can be fabricated from PVC, CPVC, single wall galvanized steel, or other suitable materials. The duct must be rigid

C1500H 350

enough to maintain the full required cross sectional area under all operating conditions. Proper sealing of the intake ductwork is necessary

C2000H 467

to prevent infiltration of air from conditioned space. Joints in PVC or CPVC must be cemented. For galvanized duct, wrap each joint and seam with adhesive aluminum tape or other sealant. The installation of a

C2500 584

bird screen on the intake termination is recommended. Ensure that the screen does not become blocked with snow, ice, insects etc. Combustion

C3000 629

C4000 839

air duct should be designed with .22”W.C. friction loss per 100’ of duct.

Combustion air must be free from dust, lint, etc. The presence of such materials in the air supplied to the burner could cause nuisance "Low Air" shutdowns or premature burner failure. The boiler should not be operated during construction while the possibility of drywall dust, demolition dust, etc. exists.

The combustion air supply must be completely free of chemical fumes which may be corrosive when burned in the boiler. Common chemicals which must be avoided are fluorocarbons and other halogenated compounds, most commonly present as refrigerants or solvents, such as Freon, trichloroethylene, perchloroethylene, chlorine, etc. These chemicals, when burned, form acids which quickly attack the boiler and the boiler stack. The result is improper combustion and premature boiler failure.

Under no circumstances shall the boiler room ever be under a negative pressure.

Particular care should be taken when exhaust fans, compressors, air-handling units or other equipment may rob air from the boiler. Note that this equipment might be in rooms other than the boiler room. This applies to both sealed combustion and atmospheric room combustion air applications.

3.5.2.1 Air Inlet Requirements – United States (NFPA 54/ANSI Z223.1 & NFPA/ANSI 211)

When air is supplied from inside the building, the total required volume shall be the sum of the required volume for all the appliances located in the mechanical room. Adjacent rooms furnished with fixed openings communicating directly with the mechanical room are considered part of the required volume. The minimum volume is 50 ft

(4.8 m

/kW) of installed appliance input capacity.

Openings used to connect indoor spaces to obtain the required minimum volume shall be sized as follows:

 When rooms are on the same floor, each opening shall have an area equal to 1 square inch for each 1000 Btu/hr

(2200 mm

/ kW) of installed appliance input capacity, but not less than 100 square inches. One opening should commence less than 12 inches above the floor and the other less than 12 inches below the ceiling. The minimum dimension of air openings shall be 3 inches.

per 1000 Btu/hr

 When rooms are on different floors, each opening shall have an area equal to 2 square inches for each 1000

Btu/hr (4400 mm

/ kW) of installed appliance input capacity.

MACH

Gas Fired Boiler

When combustion air is supplied from outside the building, the boiler room shall be provided with one or two openings to ensure adequate combustion air and proper ventilation.

When using one permanent opening, the opening shall commence within 12 inches of the ceiling and shall communicate directly with the outdoors or through a vertical or horizontal duct that communicates to the outdoors.

 Minimum free area of the opening is 1 square inch for each 3000 Btu/hr (700 mm

/ kW) of installed appliance

input capacity, and

1. Not less than the sum of the areas of all vent connectors in the room.

When using two permanent openings, one opening shall commence within 12 inches above the floor and the other within 12 inches below the ceiling, preferably on opposite walls. The openings shall communicate directly, or by way of ducts, with free outdoor air. The minimum net free area of the openings shall be calculated in accordance with the following:

 When air is taken directly from outside the building, each opening (minimum of two, as outlined above), 1 square

inch for each 4,000 Btu per hour (550 mm

 When air is taken from the outdoors through a vertical duct into the mechanical room, 1 square inch per 4,000 Btu

per hour (550 mm

 When air is taken from the outdoors through a horizontal duct into the mechanical room, 1 square inch per 2,000

Btu per hour (1100 mm

/kW) of total boiler input is required.

NOTE:

1. The required size of openings for combustion and ventilation air shall be based on the net free area of the opening.

2. Screens shall be not smaller than ¼”

3. Motorized louvers shall be interlocked with the appliance so that they are proven open prior to main burner ignition and operation.

Table of US Minimum area of ventilation openings per boiler (sq inches)

AIR SOURCE

INDOOR AIR SUPPLY OUTDOOR AIR SUPPLY

TWO OPENINGS

VERT DUCT

HORIZ

DUCT

MACH

MODEL

Boiler

SAME FLOOR DIFF FLOORS ONE OPENING

DIRECT C1500H 1500 3000 500 375 375 750 C2000H 2000 4000 667 500 500 1000

C2500 2500 5000 833 625 625 1250 C3000 3000 6000 1000 750 750 1500 C4000 4000 8000 1334 1000 1000 2000

3.5.2.2 Air Inlet Requirements – Canada (CAN/CSA B149.1)

A. Ventilation of the space occupied by fuel burning appliance(s) or equipment shall be supplied by a ventilation

opening at the highest practicable point communicating with the outdoors. The total cross sectional area of the ventilation opening must be either 10% of the net free area required for combustion air or 10 sq. in. (6500 mm whichever is greater.

B. Use the following opening calculation for MACH

When combustion air is supplied for a forced draft burner by natural airflow from the outdoors and there is no draft regulator or draft hood in the same space, there shall be a permanent opening with a cross sectional area not less than 1 sq. in/ 30,000 Btu/Hr (70 mm with the ventilation air opening defined in paragraph A.

or MODU-FIRE® FD boilers:

/kW) of the total rated input to the burner(s). This opening must not interfere

MACH

C. Use the following opening calculation for P-K THERMIFIC

Gas Fired Boiler

boilers or other natural draft or fan-assist appliances:

When combustion air is supplied for natural or fan-assisted burners by natural airflow from the outdoors, there shall be a permanent opening with a cross sectional area not less than 1 sq. in/ 7000 Btu/Hr (321 mm and including 1,000,000 Btu/Hr plus 1 sq. in. / 14,000 Btu/Hr (155 mm

/kW) in excess 1,000,000 Btu/Hr. This

/kW) up to

opening must be either located at or ducted to a point not more than 18 in. (450 mm) or less than 6 in. (150 mm) above floor level. This opening is in addition to the ventilation air opening defined in paragraph A.

D. When combustion air is supplied by natural airflow into a space containing both types of appliance described in

paragraphs B and C, the cross sectional area of the opening shall be not less than the sum of the cross sectional areas for all appliances in the space as calculated by the applicable method . This opening is in addition to the ventilation air opening defined in paragraph A.

E. When a duct is used to meet the requirement for combustion air supply, as described in paragraphs A through D,

above, the opening of the duct shall be located so there is no possibility of cold air affecting steam or water piping, electrical equipment or mechanical equipment.

F. When combustion air is supplied by mechanical means, an airflow-sensing device must be installed. It must be

wired into the pre-ignition limit string to prevent the burner from starting or to stop an operating burner in case of air supply failure.

G. When all combustion air is supplied through a make-up air heater, and the appliance is interlocked to the heater,

the requirements of paragraphs A through F do not apply.

NOTE:

1. The free area of a combustion air supply opening is calculated by deducting the blockage area of any fixed louvers, grilles or screens from the total area of the opening.

2. Screens shall be not smaller than ¼”

3. Motorized louvers shall be interlocked with the appliance so that they are proven open prior to main burner ignition and operation

Table of Canadian Minimum Area of Combustion and Ventilation Air Openings

MACH

Boiler

Required Combustion Air

Opening

Ventilation Air Opening

Model Input (Btu/Hr) in2 mm2 in2 mm2 C1500H 1,500,000 50 32,258 10 6,452 C2000H 2,000,000 67 43,226 10 6,452

C2500 2,500,000 83 53,548 10 6,452 C3000 3,000,000 100 64,516 10 6,452 C4000 4,000,000 134 86,451 13.4 8,645

3.5.3 Flue Venting This boiler is not certified for use with Type "B" vent nor with PVC venting.

MACH

C1500H/C2000H/C2500/C3000/C4000 boilers are dual certified as a Category II and Category IV appliances,

as defined in ANSI Z21.13/CSA 4.9, latest edition. The vent material must be as listed in the Table of Acceptable

Materials for Venting Systems in Section 3.5.1.2 above. The exhaust vent can be run horizontally or vertically. Vent installations shall be in accordance with NFPA54/ANSI Z223.1, the National Fuel Gas Code, or CAN/CSA-

B149.1, the Natural Gas and Propane Installation Code, or applicable provisions of the local building codes.

MACH

Gas Fired Boiler

3.5.3.1 VENT SIZING

The vent must be sized in accordance with the ASHRAE Systems and Equipment handbook, Chapter 30 or according to the vent manufacturer’s recommendations. When using manufactured venting systems, consult your vent supplier for correct sizing and structural support requirements.

Table of Vent Design Parameters

MACH

Boiler Model

C1500H/ C2000H/C2500

C3000/C4000

Frictional

Resistance

0.22” W.C. 220 °F 9.2% 10.4%

Stack

Temperature

CO2 Natural Gas CO2 LP Gas

Do not use a barometric damper with this boiler when installed with Category IV

venting. Positive exhaust pressure may exist which may leak flue gases into the room.

All boiler venting systems should be designed by a qualified venting professional

experienced in venting system design. The information contained herein should be used as a guide only and is not

intended to be used in lieu of qualified technical expertise.

3.5.3.2 Required Clearances

Provide clearances between combustion air intake, exhaust vent, roof and wall surfaces, doors and window, and snow line. Refer to Figure below: Termination Clearances – Forced Draft and Direct Vent Installations.

Reference: NFPA 54/ANSI Z223.1 National Fuel Gas Code

MACH

Gas Fired Boiler

Do not locate intake or exhaust terminations directly above a walkway; dripping of

condensation can cause icing of the walking surface. Maintain a minimum clearance of 6 ft (1.83 m) horizontally from

any electric or gas meter, regulator or relief equipment.

Conventional Vent Systems Clearances

The following termination clearance requirements are for conventional, non-direct vent installations.  The vent system shall terminate at least 3 ft above a forced air inlet that is within 10 feet horizontally. As this is a

minimum, your application requirements need to be considered.

 The vent system shall terminate at least 4 ft below, 4 ft horizontally from or 1 ft above any door, operable window

or gravity inlet into any building. The bottom of the vent terminal shall be at least 12 in. above grade or highest expected snow line (if applicable). When deciding on the vent termination consider visibility of the products of combustion.

 Through the wall terminations shall not terminate over public walkways or over an area where condensate or

vapor could create a nuisance or hazard or could be detrimental to the operation of regulators, relief valves or other equipment.

 Direct Vent (Sealed Combustion) Systems Clearances

 The vent termination shall be located at least 36 in. from any air opening into a building. The bottom of the vent

termination shall be at least 12 in. above grade. Both the vent and air intake terminations must be at least 12 in. above the highest expected snow line.

 Through the wall terminations shall not terminate over public walkways or over an area where condensate or

vapor could create a nuisance or hazard or could be detrimental to the operation of regulators, relief valves or other equipment.

 When multiple direct vent appliances are adjacent, the exhaust must terminate at least 10 feet horizontally or

three feet vertically above the air intake of another appliance.

Interior Component Clearances

All vent system components shall be installed so as to maintain the following required minimum clearances:

Combustible Non-Combustibles

Unlisted single wall metal pipe Do NOT Use Do NOT Use

Single wall CPVC pipe sch. 80 Per manufacturer’s listing Per manufacturer’s listing

UL 1738 listed Category IV vent Per manufacturer’s listing Per manufacturer’s listing

NOTICE! Make sure that the weight of the vent is not supported by the boiler vent collar. The collar is not designed to support the weight of the vent. Horizontal vent sections shall be supported in a manner to prevent

sags or low spots where condensate can collect. Structural supports must be connected to building elements of

sufficient strength to withstand the weight of the vent system and any bending forces imposed by the venting system.

ATTENTION! Assurez-vous que le poids de l'évent n'est pas pris en charge par la chaudière évent le collier. Le collier n'est pas conçu pour supporter le poids de l'évent. Aération Horizontal sections doivent être pris en

charge de manière à éviter les affaissements ou points bas où les condensats peut collecter. Supports de structure doit être connecté pour éléments de construction d'une résistance suffisante pour supporter le poids du système d'aération et les forces de torsion imposées par le système de ventilation.

MACH

3.5.3.3 Flue Connection

Gas Fired Boiler

When applying a Category IV vent system, the boiler vent should not be connected into any portion of another mechanical draft system without consulting the vent manufacturer. The boiler shall not be connected to any part of a vent system serving a Category I or II appliance, nor shall a Category I or II appliance be connected to any part of the vent system serving this appliance. Improper interconnection of venting systems may result in leakage of flue gases into occupied spaces.

The connection from the boiler to the vent should be as direct as possible and the upward slope of any horizontal breaching should be at least 1/4 inch per linear foot.

4” Tall Condensate Trap

The complete vent exhaust with drain system is shown in the figure (above, as vent is drained separately). The boiler vent adapter (provided) is designed to accept standard nominal vent pipe sizes. This connector incorporates provisions to drain condensate formed in the vent system using a 3/4” OD drain stub. This vent drain stub can be either piped to the condensate drain on the boiler or drained separately. The condensate drains shall have a 4” tall trap to prevent the passage of flue gases through the condensate system if drained separately.

NOTICE! The condensate formed from combustion flue gases is acidic and has the ability to corrode. The condensate shall be drained in accordance with local code requirements. A condensate neutralizer may be required by local code.

Reference: NFPA 54/ANSI Z223.1 National Fuel Gas Code

ATTENTION! Le condensat formé à partir des fumées de combustion est acide et a la capacité de se corroder. Le condensat doit être drainé, conformément aux exigences du code local. Un neutraliseur de condensats peut être requis par le code local.

Référence: National Fuel Gas Code, ANSI Z223.1/NFPA 54 et (ou) les codes d’installation CAN/CSA B149.1.

MACH

Gas Fired Boiler

3.5.3.4 Vent Terminations

The vent shall extend at least three (3) feet above the roof, or at least two (2) feet above the highest part of any structure within ten (10) feet of the vent. This is illustrated in the following diagram. Additionally the boiler vent shall terminate at least 3 ft above a forced air inlet located within 10 ft. To prevent the possible re-circulation of flue gases, the vent designer must take into consideration such things as prevailing winds, eddy zones, building configurations, etc. Harsco Industrial, Patterson-Kelley cannot be responsible for the effects such adverse conditions may have on the operation of the boilers. Dimensions listed above are minimums and may not be sufficient for conditions at a specific job site.

Vertical vents are allowed to be terminated with a variety of ends, including plain straight pipe, elbow or vent tee. Horizontal vents must be terminated as illustrated in section 3.5.5. A bird screen with 1” x 1” openings is recommended for the termination. Harsco Industrial, Patterson-Kelley does not recommend using a vent rain cap of any type.

3.5.4 Venting for Multiple Boilers

While the vent design parameters outlined in Section 3.5.3 still apply, achieving those same parameters in a combined vent system, adds a significant degree of complexity. Therefore, venting systems for multiple boilers shall be designed by experienced and knowledgeable venting professionals. The venting system shall be designed to prevent backflow of exhaust gas through idle boilers. It is also recommended that combined venting designs be limited to no more than four (4) boilers per combined breeching.

+ 58 hidden pages

Harsco Industrial C1500H, C2000H, C2500, C3000, C4000 Installation & Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual