Patterson-Kelley MACH-05 manual Boiler Water Piping by Installer, Flushing and Filling

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MACH® Series Gas-Fired Boiler

3.8.3 Boiler Water Piping by Installer

Strainer

To avoid possible contamination of the boiler with dirt, rust or sediment from the system, a strainer near the boiler inlet is strongly recommended. Even new systems may contain sufficient foreign material to eventually reduce the performance of the heat exchanger. Adequate circulation of good clean water is essential to maximum efficiency and long life of the boiler.

Relief Valve and Piping

Each boiler is supplied with a pressure-relief valve sized in accordance with ASME requirements. The relief valve should be piped to a suitable floor drain. Reducing couplings or other restrictions are not permitted in the discharge line.

Low Water Cut-off

The boiler is furnished with a probe-type low water cut-off; no field piping is required. If the water level in the boiler drops below the probe, the boiler will shut down and a flashing E 12 service code will be displayed on the control panel. The low water cutoff circuit will automatically reset when the low water condition clears; however the boiler controls will retain the lockout condition until the reset button on the display is depressed.

IMPORTANT!

The low water cutout probe only prevents boiler operation when the water level in the boiler is insufficient. It does not detect low water conditions in other parts of the system. Installation of high point vents or additional low water safety devices to protect the system should be considered.

Installation of external limit controls may be required by certain codes or in certain installations. Review applicable local codes for details.

Installation

Drain Valve and Piping

A drain valve is installed in the inlet (system return) header connection to the boiler. Prior to draining the boiler for maintenance or testing, electrical power and gas supply must be turned off to the boiler. The boiler must then be isolated from the system at the supply and return connections prior to draining water from the boiler.

Note: This drain valve is installed for draining of the boiler water only, not the entire system. Draining of the system through the boiler will result in depositing sediment from the system in the boiler which will result in poor heat transfer characteristics of the boiler and early boiler failure.

Condensate Drain

The condensate can be slightly acidic (pH between

3.0and 5.0). This may be corrosive to some building drain systems. A condensate neutralization system may be required.

Disposal of condensate must comply with all state and local codes.

3.8.4 Flushing and Filling

Water Quality

The MACH Series boiler heat exchanger is made of an aluminum alloy. The heat exchanger requires special water conditions to retain efficiency and function properly.

IMPORTANT!

Chemicals added to the system must be approved by the chemical manufacturer for use in aluminum boilers.

IMPORTANT!

Under no circumstances should petroleum based cleaning or sealing compounds be used in the boiler system.

The boiler is designed to operate in a closed-loop system. As such, the system should be tight and not require make-up water. A high percentage of

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Contents PATTERSON-KELLEY Mach Series Gas-Fired Boiler Operation What to do if you smell gas Safety IntroductionBurn, Fire, and Explosion Hazards Electrical HazardsWeight in Pounds Crush HazardsChemical Hazards Boiler SizePressure Hazards Slip, Fall HazardsInstallation Storage Prior to InstallationPlacement Initial InspectionAdjustable Legs for Leveling and Floor Clearance ClearancesAir Inlet Requirements Electrical Connections at Rear of BoilerRequired Clearances Flue Connection at BoilerSidewall Installations Rooftop InstallationsVent Terminations Venting for Multiple BoilersIntake/Exhaust Layout Sealed Combustion Air/Venting SystemRemoving an Existing Boiler Sidewall Inlet, Roof Vent Roof Inlet and Vent Intake Duct Terminations Intake Duct Materials and SizesSealing the Intake Duct Intake Duct Connection to BoilerVent Elbows Tape on gas line threadsIntake Termination Details Gas PipingGas Supply Piping by Installer Piping DesignFeet InchesBoiler Inlet and Outlet Connections Boiler Inlet and Outlet ConnectionsBoiler Water Piping by Installer Flushing and FillingInspection Test of Ignition Safety System Mach C300 & C450Test of High-Limit Control Test of Gas Pressure SwitchTest of Low Water Cut-out Operating Temperature Controller Step Value UpperDescription Lower Limit Parameter Value Allowable Range Parameter ValueOutdoor AIR vs Boiler Setpoint Parameter Value Allowable Range FGas Pressure Adjustment Gas Pressure Test Port Air Flow AdjustmentsGas Valve Setup and Adjustment C300/450 Adjusting Low and High Fire CO2C750/900/10500 Adjusting Low and High Mach C750, C900 & C450Lighting Procedures Normal Shut Down ProceduresOperation Control Panel FrontRate Emergency Shut-OffEmergency Shut-Off Maintenance WeeklyMonthly During Operation DailySemi-Annually every 6 months AnnuallyLoss of Power Loss of Water Level Manual Reset Service Codes Code LockoutAuto-reset Service Codes Do notPARTS/TECHNICAL Support Terminal Block Assignments High Voltage Circuit TB2 Terminal Number Label Description1a Terminal Block Assignments Low Voltage Circuit TB1 Wiring Series C-300 Wiring Series C-450 Wiring Series C-750/900/1050 Main Assembly Mach Series 300/450Control Panel Mark DescriptionDisplay Panel 4 C-300/450 Heat Engine Mark Description 5 C-750/900/1050 Heat Engine Mark Description6 C-300 Boiler Gas Train Mark Description7 C-450 Boiler Gas Train 8 C-750/900/1050 Boiler Gas Train Mark Description Limited Warranty RemedyThird Party Warranties Appendix CO2Parameter Settings for Mcba Controls Description Lower Limit Upper Limit Installed 2X = 3 way valve normally closed

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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