Patterson-Kelley MACH-05 manual Introduction, Safety

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MACH® Series Gas-Fired Boiler

1.0 INTRODUCTION

The P-K MACH® Series Gas-Fired Boilers are fully modulating using a variable speed combustion blower, 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 installation of P-K MACH Series Boilers. The model numbers 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. Boilers may be built to operate with natural gas or liquefied petroleum gas (propane). 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. Patterson-Kelley cannot be responsible for the design or operation of such systems and a qualified engineer or contractor must be consulted.

2.0SAFETY

2.1GENERAL

Safety

•Operated and serviced in accordance with a comprehensive safety program determined and established by the customer. Do not attempt to operate or service until such a program has been established.

•Operated and serviced by qualified, properly trained personnel in accordance with all applicable codes, laws, and regulations.

Note: Each safety device must be maintained and checked per the recommended schedule; refer to Section 5.1 of this manual.

2.2TRAINING

!WARNING

Improper use may result in fire or injury.

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

c 1998 HCS, Inc. 800-748-0241

Reorder No. 6020-V2WHPK

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 property damage, serious injury, or death.

Proper training is the best protection against accidents. Operating and service personnel must be thoroughly familiar with the basic construction of the P-K MACH Series boiler, the use and locations of the controls, the operation of the boiler, adjustment of its various mechanisms, and all applicable safety precautions. If any of the provisions of this manual are not fully and completely understood, contact the Patterson-Kelley Sales Department toll-free at (877) 728-5351 for assistance.

The MACH Series gas-fired boiler must be:

•Installed, operated, and serviced in accordance with instructions contained in this manual.

•Installed by qualified personnel in accordance with designs prepared by qualified facility engineers including: structural, mechanical, electrical, and other applicable disciplines.

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2.3SAFETY FEATURES

It is the responsibility of the customer to maintain the safety features, such as: guards, safety labels, safety controls, interlocks, lockout devices, etc., in place and operable.

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Contents PATTERSON-KELLEY Mach Series Gas-Fired Boiler Operation What to do if you smell gas Introduction SafetyElectrical Hazards Burn, Fire, and Explosion HazardsCrush Hazards Weight in PoundsChemical Hazards Boiler SizeSlip, Fall Hazards Pressure HazardsStorage Prior to Installation InstallationPlacement Initial InspectionClearances Adjustable Legs for Leveling and Floor ClearanceElectrical Connections at Rear of Boiler Air Inlet RequirementsFlue Connection at Boiler Required ClearancesRooftop Installations Sidewall 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 Materials and Sizes Intake Duct TerminationsSealing the Intake Duct Intake Duct Connection to BoilerTape on gas line threads Vent ElbowsIntake Termination Details Gas PipingPiping Design Gas Supply Piping by InstallerFeet InchesBoiler Inlet and Outlet Connections Boiler Inlet and Outlet ConnectionsFlushing and Filling Boiler Water Piping by InstallerInspection Mach C300 & C450 Test of Ignition Safety SystemTest of High-Limit Control Test of Gas Pressure SwitchTest of Low Water Cut-out Operating Temperature Controller Step Value UpperDescription Lower Limit Parameter Value Parameter Value Allowable RangeParameter Value Allowable Range F Outdoor AIR vs Boiler SetpointGas Pressure Adjustment Gas Pressure Test Port Air Flow AdjustmentsGas Valve Setup and Adjustment CO2 C300/450 Adjusting Low and High FireMach C750, C900 & C450 C750/900/10500 Adjusting Low and HighNormal Shut Down Procedures Lighting ProceduresOperation Control Panel FrontRate Emergency Shut-OffEmergency Shut-Off Weekly MaintenanceMonthly During Operation DailyAnnually Semi-Annually every 6 monthsLoss of Power Loss of Water Level Code Lockout Manual Reset Service CodesDo not Auto-reset Service CodesPARTS/TECHNICAL Support Terminal Number Label Description Terminal Block Assignments High Voltage Circuit TB21a Terminal Block Assignments Low Voltage Circuit TB1 Wiring Series C-300 Wiring Series C-450 Wiring Series C-750/900/1050 Mach Series 300/450 Main AssemblyMark Description Control PanelDisplay Panel 4 C-300/450 Heat Engine Mark Description Mark Description 5 C-750/900/1050 Heat EngineMark Description 6 C-300 Boiler Gas Train7 C-450 Boiler Gas Train 8 C-750/900/1050 Boiler Gas Train Mark Description Remedy Limited WarrantyThird Party Warranties CO2 AppendixParameter 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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