Patterson-Kelley MACH-05 manual Operation

MACH® Series Gas-Fired Boiler

1.0 INTRODUCTION			1
2.0 SAFETY			1
2.1	General		1
2.2	Training		1
2.3	Safety Features		1
2.4	Safety Labels		2
2.5	Safety Precautions		2
	2.5.1	Electrical Hazards	2
	2.5.2	Burn, Fire, and Explosion Hazards	2
	2.5.3 Crush Hazards		3
	2.5.4 Chemical Hazards		3
	2.5.5	Pressure Hazards	4
	2.5.6	Slip, Fall Hazards	4
3.0 INSTALLATION			5
3.1	Receiving and Storage		5
	3.1.1	Initial Inspection	5
	3.1.2	Storage Prior to Installation	5
3.2	Compliance with Codes		5
3.3	Setup	.................................................................	5
	3.3.1	Foundation	5
	3.3.2	Placement	5
	3.3.3	Clearances	6
3.4	Electrical Connections		6
3.5	Combustion Air		7
	3.5.1	Air Inlet Requirements	7
3.6	Flue Venting		8
	3.6.1 Barometric Damper		8
	3.6.2	Flue Connection	8
	3.6.3	Required Clearances	8
	3.6.4	Vent Terminations	9
	3.6.5	Venting for Multiple Boilers	9
	3.6.6 Sealed Combustion Air/Venting System 10
	3.6.7	Removing an Existing Boiler	10
	3.6.8	Intake/Exhaust Layout	10
	3.6.9	Intake Duct Materials and Sizes:	12
	3.6.10 Sealing the Intake Duct		12

		Table of Contents
	3.6.11	Intake Duct Connection to Boiler	12
	3.6.12	Intake Duct Terminations	12
	3.6.13 Vent Elbows		13
3.7 Gas Piping			13
	3.7.1	Gas Supply Piping by Installer	14
3.8	Boiler Water Piping		14
	3.8.1	Piping Design	14
	3.8.2	Boiler Inlet and Outlet Connections	15
	3.8.3	Boiler Water Piping by Installer	16
	3.8.4	Flushing and Filling	16
3.9	Burner and Ignition System		17
	3.9.1	Inspection	17
3.10 Pre-Start Check List			18
3.11 Safety Checks			18
	3.11.1	Test of Ignition Safety System	18
	3.11.2	Test of Low Water Cut-out	19
	3.11.3	Test of High-Limit Control	19
	3.11.4	Test of Gas Pressure Switch	19
3.12 Initial Adjustments			20
	3.12.1	Operating Temperature Controller	20
	3.12.2 Gas Pressure Adjustment		24
	3.12.3	Air Flow Adjustments	25
	3.12.4 Gas Valve Setup and Adjustment		25
4.0 OPERATION			28
4.1 General			28
	4.1.1	Control Panel Front	28
	4.1.2	Tests	28
4.2 Normal Lighting and Shut-Down Procedures ..			28
	4.2.1	Lighting Procedures	28
	4.2.2 Normal Shut Down Procedures		28
	4.2.3 Emergency Shut-Off		29
4.3	Typical Boiler Operating Conditions		29
5.0 MAINTENANCE			30
5.1 Maintenance and Inspection Schedule			30
	5.1.1	Daily	30
	5.1.2 Weekly		30