Patterson-Kelley P-K MACH C900

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Summary

Safety

Training

Hazard Warnings

Electrical Hazards

Warnings and precautions related to electrical shock and wiring.

Crush Hazards

Warnings and precautions regarding lifting and handling the boiler.

Pressure Hazards

Warnings related to hot fluids and pressure relief valves.

Slip, Fall Hazards

Chemical Hazards

Burn, Fire and Explosion Hazards

2 Site Preparation

2.3 Compliance with Codes

2.4 Location Setup

2.4.2 Clearances (CM300-CM399-CM500)

2.4.3 Clearances (C750-C900-C1050)

2.5 Inlet Air and Exhaust Venting Considerations

2.5.3 Category II;IV Flue Gas Exhaust Vent Planning

2.5.4 Venting Materials for Flue;Exhaust Systems

2.5.5 Required Clearances

Flue Connection

2.6 Gas Piping Considerations

2.7 Water Quality Standard

3 Installation

3.2.1 Appliance Connections (CM300-CM399-CM500)

3.2.2 Appliance Connections (C750-C900-C1050)

3.3 Electrical Connections

3.3.1 Power Requirements (CM300-CM399-CM500)

Electrical power requirements for CM300-CM399-CM500 boilers.

3.3.2 Power Requirements (C750-C900-C1050)

3.3.3 High Voltage (TB2) Terminal Block

3.3.4 Low Voltage (TB1) Terminal Block

3.4 Combustion Air

3.4.1 Air Inlet Requirements - United States

Air inlet requirements for US installations per NFPA/ANSI codes.

3.4.2 Air Inlet Requirements - Canada

3.4.3 P-K MACH Combustion Air Requirements

3.4.4 Direct Vent; Sealed Combustion Installations

3.4.5 Motorized Combustion Air Dampers

3.5 Flue Gas; Exhaust Venting

3.5.1 Category II or IV Venting Installation

Specific requirements for Category II or IV venting installations.

Vent Sizing

3.5.2 Vent Termination

3.5.3 CM300-CM399-CM500 Through-the-Roof Venting Configurations

3.5.4 CM300-CM399-CM500 Through-the-Wall Venting Configurations

3.5.5 C750-C900-C1050 (All Models) Through-the-Roof Venting Configurations

3.5.6 C750-C900-C1050 Through-the-Wall Venting Configurations

3.5.7 C750 T-C900 T-C1050 T Through-the-Wall Venting Configurations

3.5.8 Venting for Multiple Boilers

3.5.11 Category II Installations

3.5.12 Category IV Installations

3.7 Piping and External Connections

3.7.1 Gas Piping Overview

General information on gas piping requirements for the boilers.

3.7.2 Natural Gas Piping

3.7.3 Propane Gas Piping

3.7.4 Pressure Testing the Gas Piping

3.7.6 Boiler Inlet and Outlet Connections

3.7.7 Boiler Water Piping (for Installer)

Relief Valve Piping

Guidelines for properly piping the relief valve discharge.

3.8 Water Quality

3.9 Pre-Start Checklist

3.10 Safety Checks

3.10.1 Ignition Safety System Test

Procedure to test the ignition system safety shutdown.

3.10.2 Low Water Cut-out Test

Procedure to test the low water cut-out safety device.

3.10.3 Manual Reset High Temperature Limit Test

Procedure to test the manual reset high temperature limit.

3.10.4 Gas Pressure Switch Tests

Low Gas Pressure Switch

Procedure to test the low gas pressure switch.

High Gas Pressure Switch

Procedure to test the high gas pressure switch.

3.11 Fuel;Air Adjustments

3.11.1 Gas Pressure Adjustment

Instructions for adjusting gas pressure for optimal combustion.

3.11.2 Combustion Setup and Adjustment (CM300-CM399-CM500)

3.11.3 Combustion Setup and Adjustment (C750-C900-C1050 All Models)

3.12 Initial NURO Control Setup & Adjustment

4 Dual Fuel Boiler Operation

4.2 Changing Fuel Types

Steps for changing fuel types on dual fuel boilers.

4.4 P-K MACH C750 T, C900 T & C1050 T

5 Operations

5.1.2 NURO Touch Screen Interface and Control Panel

5.2 Normal Lighting and Shut-down Procedures

5.2.1 Normal Lighting Procedures

Steps for starting the boiler under normal conditions.

5.2.2 Normal Shut Down Procedures

5.3 Emergency Shut-Off

6 Maintenance

6.1 Preventative Maintenance

6.1.1 Daily Preventative Maintenance

6.1.2 Weekly Preventative Maintenance

6.1.3 Monthly Preventative Maintenance

6.1.4 Semi-Annually

6.1.5 Annually

6.2 Cleaning the Burner & Combustion Chamber

6.2.1 MACH CM300-CM399-CM500

6.2.2 MACH C750-C900-C1050

6.3 After Repairs or Maintenance

6.4 Sequence of Operations

6.5 Troubleshooting

6.5.1 Loss of Power

6.5.2 Loss of Water Level

6.5.3 Low Gas Pressure

6.5.4 High Gas Pressure

6.5.5 High Water Temperature

6.5.6 Low Air

6.5.7 Flame Failure

6.5.8 Flame Error

6.5.9 Flue Problem

7.1 Terminal Block Assignments

7.1.1 Terminal Block Assignments - High Voltage (TB2) Terminal Block

7.1.2 Terminal Block Assignments - Low Voltage (TB1) Terminal Block

7.2 Wiring Diagrams

7.2.1 CM300 Wiring Diagram

7.2.2 CM399-CM500 Wiring Diagram

7.2.3 C750-C900-C1050 Single Fuel Wiring Diagram

7.2.4 C750, C900, and C1050 Dual Fuel Wiring Schematic (3 Pages)

8 P-K MACH SPECIFIC LIMITED WARRANTY

I. REMEDY

II. EXCLUSIONS

Appendix C - Water Quality Standards for Hydronic Boilers in Multi-Metal Systems

Appendix D - Best Practices For New & Retrofit Systems

Appendix E - Installation and Quick Reference

Fuel;Gas Supply

Electrical;Power Supply

Exhaust Venting

Boiler Connections (CM300-CM399-C500)

Boiler Connections (C750-C900-C1050)