Harsco Industrial, Patterson-Kelley
155 Burson Street
East Stroudsburg, PA 18301
Telephone: (877) 728-5351
Facsimile: (570) 476-7247
www.harscopk.com
© 2015 Harsco Corporation. All Rights Reserved.
Rev. 4/2/2015
Cleaning Instructions for the MACH C1500V & C2000V
An annual inspection is the best insurance to keep your boiler operating at high efficiency and ensure a full
return on your investment.
How often should I inspect the boiler for fireside residue?
As outlined in our O&M manual, we recommend a boiler inspection at least once per year (or every
2,500 run hours). Particular attention should be given to the fireside of the heat exchanger for
residual build up. If residual build-up is detected on the fireside of the heat exchanger, we
recommend a thorough cleaning by a qualified individual. Maintenance at the prescribed intervals
will allow your boiler to operate at peak efficiency.
Figure 1 - Example of residual build up in the Heat Exchanger
© 2015 Harsco Corporation. All Rights Reserved.
Rev. 4/2/2015
Cleaning Instructions for the MACH C1500V & C2000V
Maintenance and installation should only be
performed by qualified and authorized personnel.
Wear appropriate safety gloves and eye protection.
Use the proper tools and the recommended procedure when cleaning the MACH boiler.
Use the MACH Cleaning Tool (P-K Part #26-0000-0664) as shown in Figure 9.
General instruction for inspection of the fireside of the heat exchanger:
Turn off the power.
Wait until the heat exchanger has cooled down sufficiently before removing the side panel
and covers.
Lock out / Tag out gas supply to the boiler.
Lock out / Tag out electrical supply to the boiler.
Disconnect the electrical connectors to the blower and the gas safety shut off / control
valves.
Disconnect the ignition wire from the ignitor.
Remove the ignitor.
Remove the blower motor and the transition piece
Carefully remove the burner. Use water to rinse the burner clean. Do not wipe the mesh side
(flame side) of the burner. Do not use compressed air or high pressure water to clean the
burner. After rinsing, set the burner aside to air dry.
Remove the inspection cover plate from the heat exchanger.
Note: Early C2000 models were built with a removal side panel while newer models were
built with a removable frame.
TOOLS required:
Flashlight for inspection
Hand scraper
13mm socket & 18mm combination wrench
#2 Philips screwdriver
Flat head screwdriver
3mm & 6mm Allen wrench
T30 Torx wrench
Shop towels
MACH Cleaning tool (P-K Part #2600000664)
Annual Maintenance Kit (P-K Part # BP00000448) for MACH C1500V or
(P-K Part # BP00000449) for MACH C2000V
Garden hose
Shop Vacuum
Optional tools:
3/8 Electric impact driver
© 2015 Harsco Corporation. All Rights Reserved.
Rev. 4/2/2015
Cleaning Instructions for the MACH C1500V & C2000V
Figure 2 - Removal of the Heat Exchanger Inspection Cover Plate
Remove left side cabinet panels to get access to the inspection cover of the MACH heat exchanger.
© 2015 Harsco Corporation. All Rights Reserved.
Rev. 4/2/2015
Cleaning Instructions for the MACH C1500V & C2000V
Figure 3 - Cleaning sequence of the MACH Heat Exchanger
Using the MACH Cleaning Tool and follow the recommended procedure outline below.
1. Start at lowest visible pin row of the heat exchanger. Place the MACH Cleaning Tool
horizontally between the pins and push it gently forward and side to side. The blade of the
cleaning tool will need to be guided using both hands. Move the blade in and out over the full
width of the heat exchanger. If resistance occurs due to excessive fouling, increase the force
and move the blade in and out and side to side until the tool can push through the residue.
Repeat this sequence for all rows starting at the bottom row and working to the top row.
Note: Move the MACH Cleaning Tool over the full width of the heat exchanger.
2. Place the MACH Cleaning Tool in between the pins and push it gently forward and side to
side. Starting at the lower row and going up, move the blade in and out and side wards.
3. Now place the MACH Cleaning Tool at an angle of less than 60 degrees and upwards into the
heat exchanger. Starting at the lower row and going up move the blade in and out and side
wards.
4. The loose residue deposits will collect in the condensate pan.
5. Re attach the inspection plate back into position and hand tighten the nuts.
6. Attach the Shop Vacuum hose onto the connection for the stack drain. Turn on the Shop
Vacuum to remove all the debris that collected in the condensate trap.
7. Leave the Shop Vacuum turned on and using a garden hose, wash the heat exchanger with
fresh water through the burner hole. All remaining residue should be flushed out.
8. Shut off and remove the Shop Vacuum.
© 2015 Harsco Corporation. All Rights Reserved.
Rev. 4/2/2015
Cleaning Instructions for the MACH C1500V & C2000V
Assembling the MACH
1. Reassemble the stack drain.
2. Remove the inspection plate and remove the gasket from the side plate. Remove the O ring
gasket and using the scrapper remove & clean the area around the gasket on the Heat
Exchanger. (See Figure 4)
Figure 4 - MACH Heat Exchanger
3. Place the silicone cord gasket in the O ring cavity of the Heat Exchanger. Note: where the
silicone cord ends meet, fill the gap with Red RTV silicone sealer. (See Figure 5)
Figure 5 – Applying Silicone to Gasket Cavity
© 2015 Harsco Corporation. All Rights Reserved.
Rev. 4/2/2015
Cleaning Instructions for the MACH C1500V & C2000V
4. Put Red RTV silicone sealer on the gasket. (See Figure 6)
Figure 6– Applying Red RTV Silicone
5. After a thorough inspection, scrap any residue off the inspection plate before reassembly
6. Place the inspection cover gasket, with the slots on the bottom and the silicone facing out on
the side of the HE (See Figure 7)
Figure 7– Inspection Cover Gasket
© 2015 Harsco Corporation. All Rights Reserved.
Rev. 4/2/2015
Cleaning Instructions for the MACH C1500V & C2000V
7. Place the inspection cover in place (See Figure 8)
Figure 8 - Inspection Cover
8. Hand tighten the nuts and then follow up with a final tightening.
9. Reassemble the burner and blower assembly
10.Install the new ignition electrode / flame rod.
11.Reinstall the side panel using the T-30 Torx wrench
12.Turn on the electrical power and gas
13.Unplug the red wire from the blower motor.
14.Turn on the MASTER power switch and allow the motor to run for five minutes to
help dry out the burner.
15.Turn off the boiler power switch and plug in the blower motor red wire.
16.Start the boiler and verify that the combustion settings are to factory
specification.
© 2015 Harsco Corporation. All Rights Reserved.
Rev. 4/2/2015
Cleaning Instructions for the MACH C1500V & C2000V
Figure 9 - MACH Cleaning Tool
Part #
2600000664
Description
Heat Engine, cleaning tool, C1500 & C2000
Length
23”
Width
¾”
MACH Annual Maintenance Kit
Part #
BP00000448
BP00000449
© 2015 Harsco Corporation. All Rights Reserved.
Description
Annual Maintenance Kit C1500V
Annual Maintenance Kit C2000V
Rev. 4/2/2015