Table Of Contents - Patterson-Kelley MACH C1500 Installation And Owner's Manual

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 .................................................2
2.4 Safety Labels .....................................................2
2.5 Safety Precautions ............................................2
2.5.2 Burn, Fire, and Explosion Hazards ..........2
2.5.3 Crush Hazards .........................................3
2.5.4 Chemical Hazards....................................4
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 and Placement ......................5
3.3.2 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 ..................................9
3.6.2 Flue Connection .......................................9
3.6.3 Required Clearances ...............................9
3.6.4 Vertical Vent Systems ............................10
3.6.5 Vent Terminations ..................................10
3.6.6. Direct Vent (Sealed Combustion) Systems
...................................................................11
3.6.7 Sidewall Venting with Sealed Combustion11
3.6.8 Intake Duct Materials and Sizes: ...........12
3.6.9 Sealing the Intake Duct..........................12
3.6.10 Intake Duct Connection to Boiler .........12
3.6.11 Venting for Multiple Boilers ..................12
3.6.12 Removing an Existing Boiler ................ 12
3.7 Gas Piping .......................................................13
3.7.1 Gas Supply Piping by Installer ............... 15
3.8 Boiler Water Piping..........................................15
3.8.1 Piping Design .........................................15
3.8.2 Boiler Inlet and Outlet Connections ....... 16
3.8.3 Boiler Water Piping by Installer.............. 17
3.8.4 Flushing and Filling ................................17
3.9 Burner and Ignition System .............................18
3.9.1 Inspection...............................................18
3.10 Pre-Start Check List ...................................... 18
3.11 Safety Checks ...............................................19
3.11.1 Test of Ignition Safety System ............. 19
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 Burner Setup................................... 24
3.12.3 Gas Pressure Adjustment .................... 25
3.12.4 Air Flow Adjustments ........................... 25
3.12.5 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 .............................. 28
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
5.1.3 Monthly (During Operation).................... 30

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