Patterson-Kelley MACH C1500 Manual de usuario

Instructions

1005101738

ENVI to NURO

Date: 12/19/2017

Revision A

NURO Conversion Instructions

MACH C1500-C2000H

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.

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.

NOTICE!

Each safety device must be maintained and checked per the recommended schedule. Refer to Section 6 in

the O&M Manual for more information.

SAFETY FEATURES

It is the responsibility of the customer to ensure external safety provisions, such as but not limited to:

guards, safety labels, safety controls, interlocks, lockout devices are in place and operable.

SAFETY LABELS

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

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.

Instructions

1005101738

ENVI to NURO

Date: 12/19/2017

Revision A

NURO Conversion Instructions

MACH C1500-C2000H

If the information in these instructions are not followed, fire or explosion may result causing property damage,

personal injury, or loss of life.

It is essential to read, understand, and follow the recommendations of these instructions before installing, operating

or servicing this equipment. Failure to do so could result in personal injury or death.

Installation and service must be performed by a qualified and knowledgeable individual who has been certified on the

P-K MACH®boiler. The features which permit this boiler to achieve high-efficiency performance can be misused

which could result in personal injury or death.

Lockout/tagout procedure must be employed when servicing this unit. Failure to do so could result in electrocution,

injury, or death.

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous

operation.

Use care when reassembling main gas line and ensure all connections are tight. Use a leak detector to check for

leaks before and after servicing any component of the gas piping. Failure to do so could result in injury or death.

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

accumulated gas are subject to combustion and/or explosion which could result in injury or death.

Installation must be in strict conformance to all applicable codes and standards including NFPA54, ANSI Z223.1 and

CAN/CSA B.149.

Instructions

1005101738

ENVI to NURO

Date: 12/19/2017

Revision A

NURO Conversion Instructions

MACH C1500-C2000H

TOOLS Required

•Phillips Head Screwdriver

•Drill and Drill Bit Set

•Adjustable Wrench

•Set of Nut Drivers SAE

•Torx set SAE

•Multimeter

•Gas Analyzer

1. Lock out Tag out all electrical connections and gas supply to appliance. There may be

multiple power sources.

2. Open front door of appliance and remove side panels.

3. Remove terminal block covers. Identify and label all current field wiring on boiler when

disconnecting.

4. Remove 7/16” nuts as required that hold top panel on as shown in Figure 1. Top panel

will need to be lifted at least 2” in front in order to remove front panel.

NOTE: If Cascading multiple appliances, convert all to NURO controls for ideal

operation.

Wire runs and devices connected to the Air Damper Interlock, Auxiliary Input, or Start Interlocks MUST be

rated for 120 VAC.

NOTE: DHW Flow switch terminals are not available.

NOTE: Analog input for the NURO controller must be 4-20mA.

NOTE: If using a Protocol Converter or MODBUS, contact the factory for support.

Instructions

1005101738

ENVI to NURO

Date: 12/19/2017

Revision A

NURO Conversion Instructions

MACH C1500-C2000H

5. Using a 1/8” drill bit, drill out rivets that fasten high and low voltage terminal blocks.

6. Remove 7/16” nuts from 4 inside corners of front frame assembly as shown in Figure 2.

Remove

7/16” nuts

Figure 1

Instructions

1005101738

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Date: 12/19/2017

Revision A

NURO Conversion Instructions

MACH C1500-C2000H

7. Remove 3 T30 Torx screws from front frame as shown in Figure 3. Remove front frame.

Remove

7/16” nuts

Figure 2

Instructions

1005101738

ENVI to NURO

Date: 12/19/2017

Revision A

NURO Conversion Instructions

MACH C1500-C2000H

8. With a T30 Torx bit, loosen 3 screws that hold control panel in place shown in Figure 3.

Figure 3

Loosen T30 Torx screws to control panel

Remove T30 Torx screws to front frame

Instructions

1005101738

ENVI to NURO

Date: 12/19/2017

Revision A

NURO Conversion Instructions

MACH C1500-C2000H

8. Disconnect all wires from internal safety devices and sensors. Take note to wire colors

for sensors as new panel will use same colors for sensor wires.

9. Control panel can now be slid right, lifted off screws, and removed from boiler.

10. Using a 1/2” wrench, remove and replace high and low gas pressure switches (Figure 4)

provided in kit. Be sure to apply gas thread sealant to new switches (Figure 5).

Replace existing

high and low gas

pressure switches

Figure 4

Figure 5

Instructions

1005101738

ENVI to NURO

Date: 12/19/2017

Revision A

NURO Conversion Instructions

MACH C1500-C2000H

11. Install heat exchanger sensor on front section of exchanger. Sensor only needs to be

finger tight. DO NOT OVERTIGHTEN SENSOR.

Heat exchanger sensor

Figure 6

Instructions

1005101738

ENVI to NURO

Date: 12/19/2017

Revision A

NURO Conversion Instructions

MACH C1500-C2000H

12. Install new control panel in place of old one and tighten down T30 Torx bit screws.

13. Install both electrical boxes facing front of boiler using supplied T20 self-tapping Torx

screws.

14. Run all internal wires to appropriate safety devices and sensors.

Types of Wires

Colors/Identification

Return Temperature Sensor Wires

Blue/Gray

Supply Temperature Sensor Wires

Red/Gray

Flue Temperature Sensor Wires

Yellow/Gray

Heat Exchanger Sensor Wires

Orange/Gray

Please refer to wiring diagram for any other connections. Ensure all wiring matches

supplied wiring diagram.

Figure 7

Instructions

1005101738

ENVI to NURO

Date: 12/19/2017

Revision A

NURO Conversion Instructions

MACH C1500-C2000H

15. Run igniter wire and ground to ignition electrode. Install gas valve plug with retaining

screw. High and low gas pressure switches will have matching electric connectors that

will need to be plugged in. Install high limit safety probe in thermal well of supply elbow.

BE SURE NOT TO PINCH OR KINK PROBE COPPER TUBE.

16. Install tubing for air switch and blocked flue switch. Blocked flue tube will need to be cut

to length to ensure that there is not tube slack. Tube should be pitched down from

switch to condensate pan to ensure condensate will not accumulate in tube.

Air switch tube should be

installed on top (-) port

High Back Pressure /

Blocked flue tube should

be installed on bottom

(+) port

NOTE: Verify the orifice pieces are installed in the pressure switches.

Figure 8

Ensure the high back pressure tube continually slopes down from the switch to the condensate pan. If the tube

“traps” moisture then the switch will not function properly.

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