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MACH-05
PATTERSON-KELLEY
MACH SERIES BOILER
GAS-FIRED BOILER
C.S.A Design-Certified
Complies with ANSI Z21.13/CSA 4.9
Gas-Fired Low Pressure Steam and Hot Water
Boilers
ASME Code, Section IV
Certified by Patterson-Kelley
C.S.A Design-Certified
Complies with ANSI Z21.13/CSA 4.9
Gas-Fired Low Pressure Steam and Hot Water
Boilers
Installation Date: _______________________
100 Burson Street, P.O. Box 458,
East Stroudsburg, PA
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MACH® Series Gas-Fired Boiler
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MACH® Series Gas-Fired Boiler Table of Contents 3.6.11 Intake Duct Connection to Boiler .........12 1.0 INTRODUCTION ........................................1 3.6.12 Intake Duct Terminations.....................12 2.0 SAFETY......................................................1 3.6.13 Vent Elbows .........................................13 2.1 General..............................................................1 3.7 Gas Piping .................................................
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MACH® Series Gas-Fired Boiler Table of Contents 5.1.3 Monthly (During Operation)....................30 6.1.3 Wiring Series C-450...............................40 5.1.4 Semi-Annually (every 6 months)............31 6.1.4 Wiring Series C-750/900/1050...............41 5.1.5 Annually .................................................31 6.2 Boiler Parts List ...............................................42 5.2 Cleaning the Burner.........................................31 6.2.1 Main
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MACH® Series Gas-Fired Boiler Safety • Operated and serviced in accordance with a 1.0 INTRODUCTION comprehensive safety program determined and established by the customer. Do not attempt to The P-K MACH® Series Gas-Fired Boilers are fully operate or service until such a program has been modulating using a variable speed combustion blower, established. sophisticated microprocessor controls, modulating gas • Operated and serviced by qualified, properly safety shut off / con
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MACH® Series Gas-Fired Boiler Safety 2.4 SAFETY LABELS 2.5.2 Burn, Fire, and Explosion Hazards NOTE When opening leak test valves, always follow instructions in operation and safety manual. c 1998 HCS, Inc. 800-748-0241 Reorder No. 8032-01NHPK General Warning Hot Surface ! WARNING ! WARNING Improper use may result in fire or injury. Improper use may Read instructions/safety result in fire or injury. manual before installing, Read instructions/safety operating or servicin
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MACH® Series Gas-Fired Boiler Safety • Burn hazard! Hot fluids. Use caution when 2.5.3 Crush Hazards servicing or draining boiler. • Fire and explosion hazards! Use caution when servicing burner. Propane (LPG) is heavier than air and may linger in the combustion chamber, vent lines, or elsewhere. General Warning • Gas leak hazard! Make sure the burner is installed • Lifting hazards! Use properly rated lifting correctly and burner hood is securely fastened equipment
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MACH® Series Gas-Fired Boiler Safety 2.5.5 Pressure Hazards 2.5.6 Slip, Fall Hazards ! ! WARNING WARNING Improper use may Improper use may result in fire or injury. result in fire or injury. Read instructions/safety Read instructions/safety manual before installing, manual before installing, operating or servicing boiler. operating or servicing boiler. c c 1998 HCS, Inc. 800-748-0241 1998 HCS, Inc. 800-748-0241 • Pressure hazard! Hot fluids. Install isolation • Tripping ha
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MACH® Series Gas-Fired Boiler Installation Code, Section IV for 50 psig maximum operating 3.0 INSTALLATION pressure and/or 200º F maximum temperature. Other codes or approvals which apply will be labeled 3.1 RECEIVING AND STORAGE on the boiler. Installation of the boiler must conform to all the requirements of all national, state and local codes 3.1.1 Initial Inspection established by the authorities having jurisdiction or, Upon receiving the boiler, inspect it for sig
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MACH® Series Gas-Fired Boiler Installation clearance and prevent distortion of the cabinet, (twisting, etc.) in addition to leveling. D D Adjustable Leg Bolts Minimum Clearances from Adjacent Walls, Ceiling, and Obstructions Type of Surface Dimensions (inches) Adjustable Legs for Leveling and Floor Clearance A B C† D Combustible Surfaces 36 24 24 24 3.3.3 Clearances Non-combustible Surfaces 36 * 24 24** If the boiler is to be installed near combustible s
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MACH® Series Gas-Fired Boiler Installation An external electrical disconnect (not supplied with when burned, form acids which quickly attack the the boiler) with adequate overload protection is boiler and the boiler stack. The result is improper required. The boiler must be grounded in accordance combustion and premature boiler failure. with local codes or in the absence of such Provisions for combustion and ventilation air must be requirements, in the U.S. with National Electrical
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MACH® Series Gas-Fired Boiler Installation If air is taken from another interior space, each 3.6.2 Flue Connection opening should have a net free area of 1 square inch The connection from the boiler to the vent should be for each 1,000 Btu per hour of boiler input (450 square as direct as possible and the upward slope of any inches for a 450,000 Btu per hour.) horizontal breaching should be at least 1/4 inch per linear foot. The 300 and 450 vent connection incorporates a 4° sl
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MACH® Series Gas-Fired Boiler Installation 3.6.4 Vent Terminations WARNING! Do not locate intake or exhaust terminations directly above a walkway; dripping of conden- sation can cause icing of the walking surface. No rain cap or Tee. required, Mechanical draft vent terminal Direct vent terminal Outside Plate clearance minimum 12 in. Cover Plate Less Fastener Centering than 10 ft. Support Plate Sealant 4 ft. min. 4 ft. min. Recommended 3 ft min. 12 in.
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MACH® Series Gas-Fired Boiler Installation 3. Insofar as is practical, close all building doors 3.6.6 Sealed Combustion Air/Venting System and windows and all doors between the space in The MACH Series Boilers are also certified for which the appliances remaining connected to the operation with a sealed combustion air and pressurized common venting system are located and other venting system. Such a system employs a sealed spaces of the building. Turn on clothes dryers combust
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MACH® Series Gas-Fired Boiler Installation Exhaust Vent Exhaust Vent (type of (Type of flue termination flue termination optional when roof venting.) optional when roof venting.) Air Inlet (tee mounted horizontally.) Roof Air Inlet (Type of flue Roof termination optional.) Sidewall Sidewall Inlet, Roof Vent Roof Inlet and Vent Air Inlet Exhaust Vent (Type of flue (Sidewall venting requires termination optional.) vertical tee termination.) Exhaust Ve
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MACH® Series Gas-Fired Boiler Installation Exhaust Vent 3.6.12 Intake Duct Terminations (Sidewall Venting Roof Requires Up Elbow Mounted) Round Air inlet (Down Elbow Mounted) 90° Elbow Sidewall C750/900/1050 Sidewall Inlet and Vent 3.6.9 Intake Duct Materials and Sizes: Material: PVC, CPVC (Schedule 40), single wall Sidewall galvanized steel, or other suitable materials. Air Inlet The intake duct must be sized for a maximum pressure (tee mounted drop o
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MACH® Series Gas-Fired Boiler Installation WARNING! Outside Plate All threaded connections must be made using a Cover Plate Centering Fastener pipe compound that is resistant to the action of Field Provided Support Plate Sealant liquefied petroleum gases. Do not use Teflon Inlet Screens tape on gas line threads. Remote Gas Shutoff Recommended (not supplied) Sealant Termination Natural Gas Supply By Installer 12" min. Union Intake Termination Details
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MACH® Series Gas-Fired Boiler Installation Pipe Capacity for Natural Gas Nominal Equivalent Pipe Length Maximum Capacity in Cubic Feet of Natural Gas per Hour Iron Pipe Internal Pressure Drop of 0.5 inch Water Column/Equivalent Length of Pipe (in feet) Size Diameter 90º Ell Tee (Inches) (Inches) (Feet) (Feet) 20 40 60 80 100 150 200 1/2 0.622 1.55 3.1 120 82 66 57 50 40 35 3/4 0.824 2.06 4.12 250 170 138 118 103 84 72 1 1.049 2.62 5.24 465 320 260 220 195 160 135 1
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MACH® Series Gas-Fired Boiler Installation 3.8.2 Boiler Inlet and Outlet Connections C750 C900 C1050 C450 C300 Condensate Proper flow rates may be achieved through a Trap (Piped to combination of primary and secondary flow loops. drain)* Multiple zones and pumps may result in different flow rates at different times. Consideration must be given to all possible conditions and their consequences. Piping With Refrigeration Machines Boiler Inlet and Outlet Co
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MACH® Series Gas-Fired Boiler Installation Drain Valve and Piping 3.8.3 Boiler Water Piping by Installer A drain valve is installed in the inlet (system return) Strainer header connection to the boiler. Prior to draining the To avoid possible contamination of the boiler with boiler for maintenance or testing, electrical power and dirt, rust or sediment from the system, a strainer near gas supply must be turned off to the boiler. The the boiler inlet is strongly recommended.
