Patterson-Kelley MACH-05 User Manual
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 18301
Telephone: (877) 728-5351, Facsimile: (570) 476-7247
www.pkboilers.com
MACH® Series Gas-Fired Boiler
MACH® Series Gas-Fired Boiler Table of Contents
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 System10
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
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
MACH® Series Gas-Fired Boiler Table of Contents
5.1.3 Monthly (During Operation)....................30
5.1.4 Semi-Annually (every 6 months)............31
5.1.5 Annually .................................................31
5.2 Cleaning the Burner.........................................31
5.3 After All Repairs or Maintenance.....................31
5.4 Sequence of Operation....................................32
5.5 Troubleshooting...............................................32
5.5.1 Manual Reset Service Codes ................34
5.5.2 Auto-reset Service Codes......................35
6.0 PARTS/TECHNICAL SUPPORT.............. 36
6.1 Wiring Diagrams..............................................37
6.1.1 Terminal Block Assignments – High Voltage
Circuit (TB2)...............................................37
6.1.1a Terminal Block Assignments – Low Voltage
Circuit (TB1)...............................................38
6.1.2 Wiring Series C-300...............................39
!
WARNING
Improper use may
result in fire or injury.
Read instructions/safety
manual before installing,
c
1998 HCS, Inc. 800-748-0241
operating or servicing boiler.
Reorder No. 6020-V2WHPK
6.1.3 Wiring Series C-450...............................40
6.1.4 Wiring Series C-750/900/1050...............41
6.2 Boiler Parts List ...............................................42
6.2.1 Main Assembly.......................................42
6.2.2 Control Panel.........................................43
6.2.3 Display Panel.........................................44
6.2.4 C-300/450 Heat Engine .........................45
6.2.5 C-750/900/1050 Heat Engine ................46
6.2.6 C-300 Boiler Gas Train..........................47
6.2.7 C-450 Boiler Gas Train..........................48
6.2.8 C-750/900/1050 Boiler Gas Train..........49
7.0 LIMITED WARRANTY .............................50
8.0 APPENDIX ...............................................52
WARNING!
Chemicals, fuels, or other potentially hazardous
or toxic materials must not be stored in the same
room as the boiler.
WARNING!
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 fire or explosion and serious
injury, death, and/or property damage.
WARNING!
Installation and service must be performed by a
qualified installer or service agency who has been
trained on the Patterson-Kelley MACH Boiler.
What to do if you smell gas:
The same features which permit this boiler to achieve
high-efficiency performance make it unlike most other
boilers of this general size, so it is important to
understand how this boiler operates.
• Do not try to light any appliance.
• Do not touch any electrical switch.
• Do not use any phone in your building.
Immediately call your gas supplier from a
WARNING
neighbor's phone. Follow the gas supplier's
instructions.
• If you cannot reach your gas supplier call the fire
Do not store or use gasoline or other flammable
vapors or liquids in the vicinity of this or any other
department.
appliance.
MACH® Series Gas-Fired Boiler Safety
1.0 INTRODUCTION
The P-K MACH® Series
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.
Gas-Fired Boilers are fully
2.0 SAFETY
GENERAL
2.1
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.
• 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.
2.2
TRAINING
!
WARNING
Improper use may
result in fire or injury.
Read instructions/safety
manual before installing,
c
1998 HCS, Inc. 800-748-0241
operating or servicing boiler.
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
boiler, the use and locations of the controls, the
Series
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.
2.3
SAFETY 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.
Page 1
MACH® Series Gas-Fired Boiler Safety
2.4 SAFETY LABELS
NOTE
When opening leak test valves,
always follow instructions in
operation and safety manual.
c
1998 HCS, Inc. 800-748-0241
Improper use may
result in fire or injury.
Read instructions/safety
manual before installing,
c
1998 HCS, Inc. 800-748-0241
C 1998 HCS, Inc. 800-748-0241
operating or servicing boiler.
The safety labels shown above are affixed to your
boiler. Although the labels are of high quality, they
may become dislodged or unreadable over time.
Contact Patterson-Kelley toll-free at (877) 728-5351
for replacement labels.
2.5
SAFETY PRECAUTIONS
Provide a suitable location for the boiler, away from
normal personnel traffic, with adequate working space,
adequate clearances, proper ventilation and lighting,
with a structure sufficiently strong and rigid to support
the weight of the boiler, all piping, and accessories.
2.5.1 Electrical Hazards
C 1998 HCS, Inc. 800-748-0241
• Shock hazard! Properly lockout/tagout the
electrical service and all other energy sources
before working on or near the boiler.
• Shock hazard! Do not spray water directly on any
electrical components.
Reorder No. 8032-01NHPK
!
WARNING
Reorder No. 6020-V2WHPK
!
WARNING
Electrical hazard.
Follow lockout/tagout
procedure when
servicing this boiler.
Reorder No. 5025-V1WHPK
!
WARNING
Electrical hazard.
Follow lockout/tagout
procedure when
servicing this boiler.
Reorder No. 5025-V1WHPK
2.5.2 Burn, Fire, and Explosion Hazards
General Warning
c
1998 HCS, Inc. 800-748-0241
!
Improper use may
result in fire or injury.
Read instructions/safety
manual before installing,
operating or servicing boiler.
Hot Surface
WARNING
Reorder No. 6020-V2WHPK
NOTE
Make sure this union is
tight before closing cabinet
cover after servicing boiler.
c
1998 HCS, Inc. 800-748-0241
Reorder No. 8032-02NHAK
NOTE
When opening leak test valves,
always follow instructions in
operation and safety manual.
c
1998 HCS, Inc. 800-748-0241
• Burn, fire, and explosion hazards! Installation
must be in strict conformance to all applicable
codes and standards including NFPA 54, ANSI
Z223.1 and CAN/CGA B.149. Install all required
vent lines for gas devices. Refer to Section 3.7.1.
• Hazard from incorrect fuels! Possible fire,
explosion, overheating, and damage. Do not use
any fuels except the design fuels for the unit.
• Overfire hazards! High pressure in gas or propane
supply could result in overfiring of other devices
supplied from the same source.
• Fire and explosion hazards! Close the main gas
shutoff before servicing boiler.
• Fire and explosion hazards! Do not store or use
gasoline or other flammable vapors or liquids in
the vicinity of this or any other gas fired appliance.
• Burn hazard! Possible hot surfaces. Do not touch
gas vent during firing operation. Use only factory
recommended vent components.
• Burn hazard! Pipes, vents, and boiler components
could be hot. Do not touch piping or stack
surfaces during operation or immediately after
shutdown of the boiler.
Reorder No. 8032-01NHPK
Page 2
MACH® Series Gas-Fired Boiler Safety
• Burn hazard! Hot fluids. Use caution when
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.
• Gas leak hazard! Make sure the burner is installed
correctly and burner hood is securely fastened
following any maintenance performed on them.
These connections cannot be tested after the
burner is assembled.
• Gas leak hazard! All threaded gas connections
must be made using a pipe compound that is
resistant to liquefied petroleum. Do not use
Teflon™ tape on threaded gas piping.
• Gas leak hazard! Check entire gas train for leaks
after installation. If there is a smell of gas, shut
down the boiler and obtain immediate assistance
from trained service personnel and/or your local
fire department.
• Overfire hazard! Possible fire and explosion from
excess gas pressure. Make sure that gas inlet
pressure does not exceed 14 inches W.C. to the
regulator.
• Overfire hazard! Possible fire and explosion.
Possible malfunction of regulators and/or gas
safety shut off / control valves. Maintain all gas
train components in good condition. Do not alter
wiring connections. Annual inspection by factorytrained personnel for proper set-up and operation
is recommended.
2.5.3 Crush Hazards
General Warning
• Lifting hazards! Use properly rated lifting
equipment to lift and position the boiler. The load
is unbalanced. Test balance before lifting 3 ft.
above the floor. Do not allow personnel beneath
the lifted load. Refer to approximate weights in
the table below:
Boiler Size Weight in Pounds
300,000 Btu 354
450,000 Btu 440
750,000 Btu 650
900,000 Btu 700
1,050,000 Btu 750
• Bump hazard from overhead ductwork and piping.
Install components with adequate vertical
clearance.
2.5.4 Chemical Hazards
• Overfire and underfire hazards! Possible fire,
explosion, overheating, and component failure.
Do not attempt to adjust firing rate of the boiler.
The firing rate must be adjusted only by factory
trained personnel.
Page 3
General Warning
• Chemical hazards from cleaning products. Use
caution when cleaning the system. The use of
professional assistance is recommended. Use safe
procedures for the disposal of all cleaning
solutions.
• Combustion Condensate – a pH of approximately
4 to 5 can be expected. Use PVC or CPVC piping.
Collection and disposal must be in accordance
with all applicable regulations.
MACH® Series Gas-Fired Boiler Safety
2.5.5 Pressure Hazards
!
WARNING
Improper use may
result in fire or injury.
Read instructions/safety
manual before installing,
c
1998 HCS, Inc. 800-748-0241
operating or servicing boiler.
• Pressure hazard! Hot fluids. Install isolation
valves on boiler water inlet and outlet. Make sure
isolation valves are closed before servicing boiler.
• Pressure hazard! Hot fluids. Annually test safety
relief valve for proper operation. Do not operate
boiler with faulty relief valve.
2.5.6 Slip, Fall Hazards
!
WARNING
Improper use may
result in fire or injury.
Read instructions/safety
manual before installing,
c
1998 HCS, Inc. 800-748-0241
operating or servicing boiler.
• Tripping hazard! Do not install piping on floor
surfaces. Maintain clear path around boiler.
• Slip and fall hazard! Use drip pan to catch water
while draining the boiler. Maintain dry floor
surfaces.
• Slip and fall hazard! Do not locate intake or
exhaust terminations directly above a walkway;
dripping of condensation can cause icing of the
walking surface.
Page 4
MACH® Series Gas-Fired Boiler Installation
3.0 INSTALLATION
RECEIVING AND STORAGE
3.1
3.1.1 Initial Inspection
Upon receiving the boiler, inspect it for signs of
shipping damage. Since some damage may be hidden,
we recommend unpacking the boiler and removing the
top cover and inspecting the boiler.
Verify that the total number of pieces shown on the
packing slip agrees with those actually received.
Important: note any damage, suspected potential
damage, or shortage of materials on the freight bill
and immediately notify the carrier. File all claims
for shortage or damage with the carrier. Claims
for hidden damages must be filed with your carrier
within 7 days. The boiler carton is equipped with a
“Tip (N) Tell”. If "Tip (N) Tell” arrow point is
blue, that indicates that the package has been on its
side or tipped over in transit.
3.1.2 Storage Prior to Installation
If the boiler is not installed immediately, it must be
stored in a location adequately protected from the
weather, preferably indoors. If this is not possible,
then it should remain in the shipping container and be
covered by a tarpaulin or other waterproof covering.
Note: controls and other equipment that are
damaged or fail due to weather exposure are not
covered by warranty.
3.2
COMPLIANCE WITH CODES
The P-K MACH Series Boiler with standard
components and with many options complies with
American National Standard/CSA Standard ANSI
Z21.13/CSA 4.9, latest edition, Gas-Fired Low
Pressure Steam and Hot Water Boilers.
The heat exchanger is constructed and stamped in
accordance with ASME Boiler and Pressure Vessel
Code, Section IV for 50 psig maximum operating
pressure and/or 200º F maximum temperature.
Other codes or approvals which apply will be labeled
on the boiler.
Installation of the boiler must conform to all the
requirements of all national, state and local codes
established by the authorities having jurisdiction or,
in the absence of such requirements, in the U.S. to the
National Fuel Gas Code, ANSI Z223.1/NFPA 54,
latest edition. In Canada, the equipment shall be
installed in accordance with the current Installation
Code for Gas Burning Appliances and Equipment,
CAN/CGA-B.149, and applicable Provincial
Regulations for the class, which should be carefully
followed in all cases. Authorities having jurisdiction
should be consulted before installations are made.
Where required by local codes, the installation must
conform to American Society of Mechanical
Engineers Safety Code for Controls and Safety
Devices for Automatically Fired Boilers (ASME
CSD-1).
In the Commonwealth of Massachusetts (a) this unit
must be installed by a licensed pipe fitter / plumber,
(b) field installed gas cocks must be “T” handle type,
and (c) piping of condensate shall conform with the
State Plumbing Code.
3.3
SETUP
3.3.1 Foundation
Provide a firm, level foundation, preferably of
concrete.
Note: The boiler may be installed on a combustible
floor; however, the boiler must never be installed on
carpeting.
3.3.2 Placement
The boiler must be level to function properly. To
assist in leveling the boiler, the four (4) adjustable leg
bolts (1/2"- 13 NC) must be installed. The adjustable
legs are also necessary to provide adequate floor
Page 5
MACH® Series Gas-Fired Boiler Installation
clearance and prevent distortion of the cabinet,
(twisting, etc.) in addition to leveling.
Adjustable
Leg Bolts
Adjustable Legs for Leveling and Floor Clearance
3.3.3 Clearances
If the boiler is to be installed near combustible
surfaces, the minimum clearances shown in the table
below must be maintained.
Failure to provide for the service access clearances,
even with non-combustible surfaces, may cause future
problems servicing the boiler.
The boiler must be installed in a space large in
comparison to the boiler as described in Section 6.3 of
the National Fuel Gas Code, ANSI Z223.1, latest
edition.
No pipes,
ducts, etc. in
this area.
C
D
D
Minimum Clearances from Adjacent Walls, Ceiling, and
Dimensions (inches) Type of Surface
Combustible Surfaces 36 24 24 24
Non-combustible Surfaces 36 * 24 24**
A B C† D
Obstructions
† "C" Do not put pipes, ducts, etc. in this area above
the boiler.
CAUTION!
Bumping hazard from overhead ducts! Install all
components with adequate vertical clearances.
* Clearance depends upon vent configuration.
** Service access need be only on one side of a
boiler or row of boilers. Boilers may be installed
immediately adjacent to each other. However, P-K
recommends this clearance between each boiler
when there is insufficient access at the rear to allow
for service and adjustment.
A B
Page 6
ELECTRICAL CONNECTIONS
3.4
The boiler is wired for 120 volts, single phase, 60
hertz. The total operating amperage is indicated on
the rating nameplate. All MACH units require less
than 8 amps. Before starting the boiler, check to
ensure that the proper electrical service is connected
to the boiler.
MACH® Series Gas-Fired Boiler Installation
An external electrical disconnect (not supplied with
the boiler) with adequate overload protection is
required. The boiler must be grounded in accordance
with local codes or in the absence of such
requirements, in the U.S. with National Electrical
Codes, ANSI/NFPA No. 70 latest edition and in
Canada to the current Canadian Electrical Code, Part I,
CSA C22.1.
Note: A dedicated earth ground (green wire) is
required to avoid nuisance shutdowns. Do not ground
through the conduit. It is also important that proper
polarity be maintained.
Note: Refer to Terminal Block Assignments (Section
6.1.1).
120 Volt
Electrical Control
Junction Box
Low Voltage
Control Junction
Box
when burned, form acids which quickly attack the
boiler and the boiler stack. The result is improper
combustion and premature boiler failure.
Provisions for combustion and ventilation air must be
in accordance with Section 5.3, Air for Combustion
and Ventilation, of the National Fuel Gas Code,
ANSI Z223.1, latest edition, or applicable provisions
of the local building codes. In Canada, combustion
air openings shall comply with CSA B.149
Installation Code. The formula is 1 sq. in. per 1,000
Btu/hr of gas input not less than 100 sq. in. The
location shall be neither more than 18", nor less than
6" above the floor level.
The boiler room shall be provided with two openings
to ensure adequate combustion air and proper
ventilation. One opening should be 6 to 12 inches
above the floor and the other 6 to 12 inches below the
ceiling, preferably on opposite walls. The size of
each opening is determined by whether air is taken
from inside or outside the building. In Canada,
ventilation air openings shall be at least 10% of the
cross sectional area required for combustion air, but
not less than 10 square inches. It is to be located at
the highest practical point communicating with
outdoors.
WARNING!
Electrical Connections at Rear of Boiler
3.5 COMBUSTION AIR
Combustion air must be free from dust, lint, etc. The
presence of such materials in the air supplied to the
burner could cause nuisance "Low Air" shutdowns or
premature burner failure. The boiler should not be
operated during construction while the possibility of
drywall dust, demolition dust, etc. exists.
The combustion air supply must be completely free of
chemical fumes which may be corrosive when burned
in the boiler. Common chemicals which must be
avoided are fluorocarbons and other halogenated
compounds, most commonly present as refrigerants or
solvents, such as freon, trichlorethylene,
perchlorethylene, chlorine, etc. These chemicals,
Page 7
Under no circumstances shall the boiler room
ever be under a negative pressure. Particular
care should be taken when exhaust fans,
compressors, air-handling units or other
equipment may rob air from the boiler.
3.5.1 Air Inlet Requirements
If air is taken directly from outside the building, each
opening (minimum of two) should have a net free
area of 1 square inch for each 4,000 Btu per hour of
total boiler input. For instance, 112.5 square inches
are required for 450,000 Btu per hour input.
When air is taken from the outdoors through a
vertical duct, 1 square inch per 4,000 Btu per hour is
required. If a horizontal duct is used, 1 square inch
per 2,000 Btu per hour is required, i.e., 225 square
inches for 450,000 Btu per hour input.
MACH® Series Gas-Fired Boiler Installation
If air is taken from another interior space, each
opening should have a net free area of 1 square inch
for each 1,000 Btu per hour of boiler input (450 square
inches for a 450,000 Btu per hour.)
3.6
FLUE VENTING
This boiler requires a special vent system. This boiler
is not certified for use with Type "B" vent.
This boiler is Category IV (condensing – positive
pressure) as it is defined in ANSI Z21.13/CSA 4.9,
latest edition. The vent material must be listed
Category IV vent pipe (316L or AL29-4C Stainless
Steel) and comply with UL 1738 or UL103. In
Canada it must comply with ULC-636. The exhaust
vent can be run horizontally or vertically.
Vent installations shall be in accordance with Part 10,
Venting of Equipment, of the National Fuel Gas Code,
ANSI Z223.1 or CSA B.149 code, or applicable
provisions of the local building codes.
The venting system and the horizontal portions of the
venting system shall be supported to prevent sagging.
The vent must be sized according to the vent
manufacturer’s recommendations. Consult your vent
supplier for correct sizing and structural support
requirements. Design calculations should be based on
a maximum of 0.22" W.C. total frictional resistance in
the stack (measured at the boiler flue gas discharge),
with a stack temperature of 210° F (gross) and a CO
2
level of 9% (natural gas) or 10.4% (propane). These
values are to be used for vent sizing calculations.
The installation of a bird screen on the vent
termination is recommended. Consult your local vent
manufacturer for proper sizing.
3.6.1 Barometric Damper
WARNING!
Do not use a barometric damper with this
boiler. (This is a positive pressure system;
combustion gas may leak into the room.)
3.6.2 Flue Connection
The connection from the boiler to the vent should be
as direct as possible and the upward slope of any
horizontal breaching should be at least 1/4 inch per
linear foot. The 300 and 450 vent connection
incorporates a 4° slope toward the boiler to facilitate
pitching of the vent for condensate collection. This
boiler should not be connected into any portion of
another mechanical draft system operating under
positive pressure without consulting your local
venting representative. Provisions must be made for
supports to prevent contact of the vent with
combustible surfaces.
Note: If the vent is erected directly behind the boiler,
make sure that the weight of the vent is not
supported by the boiler vent collar. The collar is
not designed to support the weight of the vent.
Structural support and spacing from combustible
surfaces must be in accordance with the vent
manufacturer's requirements.
Sidewall
Pitch toward
boiler 1/4" per
foot minimum.
4 degree slope
toward boiler,
approx. ¾” per
foot.
Flue Connection at Boiler
3.6.3 Required Clearances
Provide clearances between combustion air intake,
exhaust vent, roof and wall surfaces, doors and
window, and snow line as shown in the following
diagrams. The exhaust vent termination must be 14
feet above grade when located adjacent to a public
walkway. It must also have a minimum 6 foot
horizontal and 6 foot vertical clearance (above or
below) any electric meters, gas meters, regulators, or
relief equipment.
Page 8
MACH® Series Gas-Fired Boiler Installation
WARNING!
Do not locate intake or exhaust terminations
directly above a walkway; dripping of condensation can cause icing of the walking surface.
Mechanical draft vent
Direct vent terminal
clearance minimum 12 in.
12 in.
min
Mechanical draft
vent terminal
4 ft.
min.
4 ft.
min.
12 in.
min.
terminal
12 in.
min.
Forced
air inlet
Reference: ANSI Z223.1 - 2002
Sidewall Installations
Combustion
Air Inlet
10' min.
4' min.
Flue Gas
Outlet
Grade
Less
than
10 ft.
3 ft min.
3.6.4 Vent Terminations
No rain cap
required,
or Tee.
Centering
Support Plate
Sealant
(see text below)
Outside Plate
Cover Plate
Fastener
Sealant
Recommended
Termination
12" min.
Vent Termination Details
The vent should extend at least three (3) feet above
the roof, or at least two (2) feet above the highest part
of any structure within ten (10) feet of the vent.
To prevent the possible re-circulation of flue gases,
your vent designer must take into consideration such
things as prevailing winds, eddy zones, building
configurations, etc. P-K can not be responsible for
the effects such adverse conditions may have on the
operation of the boilers. Dimensions listed above or
those illustrated are minimum, and may or may not be
sufficient for conditions at a specific job site.
4' min above
snow line
Rooftop Installations
Page 9
A tee must be of approved design and adequate
capacity.
3.6.5 Venting for Multiple Boilers
The venting instructions in this manual apply to a
single boiler.
Venting systems for multiple boilers must be
designed by qualified professionals and verified by
the stack manufacturer. The venting system must
prevent backflow of exhaust gas through idle
boilers which are not operating.
MACH® Series Gas-Fired Boiler Installation
3.6.6 Sealed Combustion Air/Venting System
The MACH Series Boilers are also certified for
operation with a sealed combustion air and pressurized
venting system. Such a system employs a sealed
combustion air intake duct leading from outdoors and
a sealed exhaust vent terminating outdoors. Air flow
through the system is maintained by the fan inside the
boiler assembly.
Vent Installation Details
Installation must conform to the vent manufacturer's
instructions in all respects including joining,
clearances, fastening, fire-stopping, and other matters.
Vent ductwork may be run horizontally or vertically if
so certified.
3.6.7 Removing an Existing Boiler
(from a common venting system)
When an existing boiler is removed from a common
venting system, the common venting system is likely
to be too large for proper venting of the appliances
remaining connected to it.
At the time of removal of an existing boiler, while the
other appliances remaining connected to the common
venting system are not in operation, the following
steps should be followed with each appliance
remaining connected to the common venting system
placed in operation:
1. Seal any unused openings in the common venting
system.
2. Visually inspect the venting system for proper size
and horizontal pitch and determine that there is no
blockage or restriction, leakage, corrosion or other
deficiency which could cause an unsafe condition.
3. Insofar as is practical, close all building doors
and windows and all doors between the space in
which the appliances remaining connected to the
common venting system are located and other
spaces of the building. Turn on clothes dryers
and any appliances not connected to the common
venting system. Turn on any exhaust fans, such
as range hoods and bathroom exhausts, so they
will operate at maximum speed. Do not operate a
summer exhaust fan. Close fireplace dampers.
4. Place the appliance being inspected in operation.
Follow the lighting instructions. Adjust the
thermostat so that the appliance will operate
continuously.
5. Test for spillage at the draft hood relief opening
after 5 minutes of main burner operation. Use the
flame of a match or candle or smoke from a
cigarette, cigar or pipe.
6. After it has been determined that each appliance
remaining connected to the common venting
system properly vents when tested as outlined
above, return doors, windows, exhaust fans,
fireplace dampers and any other gas-burning
appliance to their previous conditions of use.
Any improper operation of the common venting
system should be corrected so the installation
conforms with the National Fuel Gas Code, ANSI
Z223.1 and CSA B149 Installation Code. When
resizing any portion of the common venting system,
the common vent system should be resized to
approach the minimum size as determined using the
appropriate tables.
3.6.8 Intake/Exhaust Layout
Four basic configurations for the intake/exhaust may
be used. Refer to Section 3.6.3 for required
clearances for all terminations shown in the four
following figures.
Page 10
MACH® Series Gas-Fired Boiler Installation
Roof
Exhaust Vent (type of
flue termination
optional when roof
venting.)
Air Inlet (tee
mounted
horizontally.)
Sidewall
(Type of flue termination
optional when roof venting.)
(Type of flue
termination
optional.)
Exhaust Vent
Air Inlet
Roof
Sidewall Inlet, Roof Vent
Exhaust Vent
(Sidewall venting requires
vertical tee termination.)
termination optional.)
Air Inlet
(Type of flue
Roof Inlet and Vent
(Tee mounted horizontal.)
Air Inlet
Sidewall
Sidewall Inlet and Vent
Exhaust Vent
(Sidewall venting requires
vertical tee termination.)
Sidewall
Roof Inlet, Sidewall Vent
Basic Air Inlet/Vent Configurations
Page 11
MACH® Series Gas-Fired Boiler Installation
Exhaust Vent
(Sidewall
Venting
Requires Up
Elbow Mounted)
Air inlet
(Down Elbow
Mounted)
Sidewall
C750/900/1050 Sidewall Inlet and Vent
3.6.9 Intake Duct Materials and Sizes:
Material: PVC, CPVC (Schedule 40), single wall
galvanized steel, or other suitable materials.
The intake duct must be sized for a maximum pressure
drop of 0.22 inches W.C., for the SCFM as specified
below.
3.6.12 Intake Duct Terminations
Roof
Round
90° Elbow
Sidewall
Air Inlet
(tee mounted
horizontally)
Boiler Size Required SCFM
1050 245
900 210
750 175
450 105
300 70
The installation of a bird screen on the intake
termination is recommended.
3.6.10 Sealing the Intake Duct
Proper sealing of the intake ductwork is necessary to
prevent infiltration of air from conditioned space.
Joints in PVC or CPVC must be cemented. For
galvanized duct, wrap each joint and seam with
adhesive aluminum tape.
3.6.11 Intake Duct Connection to Boiler
Connect the air supply duct to the collar on the back of
the boiler. Fasten the duct to the collar with sheet
metal screws at 90º angles. Seal the joint.
Round
No rain cap -
Unrestricted
The roof intake termination must be an
unrestrictive type, as shown above.
Page 12
MACH® Series Gas-Fired Boiler Installation
Centering
Support Plate
Sealant
3.6.13 Vent Elbows
The turn from horizontal to vertical should be made
with two 45º ells or with one long radius 90º ell for
best operation. Do not use "short radius" ells.
3.7
Before making the gas hook-up, make sure the boiler
is being supplied with the type of fuel shown on the
boiler nameplate.
The boiler shall be installed such that the gas ignition
system components are protected from water
(dripping, spraying, rain, etc.) during appliance
operation and service (circulator replacement, control
replacement, etc.)
The boiler is factory fire-tested and adjusted for proper
combustion with natural gas supply pressure of 7”
W.C. Typical gas pressure supply for natural gas is
7" W.C. (11" W.C. for propane). The gas train
components are certified to handle a maximum inlet
pressure of 14" W.C. (1/2 psig.). If the available gas
pressure exceeds 14" W.C., a suitable additional
intermediate gas pressure regulator of the "lock up"
type must be provided to reduce the pressure to less
than 14" W.C.
Recommended
GAS PIPING
Outside Plate
Cover Plate
Fastener
Sealant
Termination
12" min.
Field Provided
Inlet Screens
Intake Termination Details
WARNING!
All threaded connections must be made using a
pipe compound that is resistant to the action of
liquefied petroleum gases. Do not use Teflon
tape on gas line threads.
Natural Gas
Supply
Drip Leg
Meter
(not supplied)
Remote Gas Shutoff
(not supplied)
By Installer
Union
Shutoff
(on boiler)
Gas Piping
In the Commonwealth of Massachusetts, the gas cock
must be a “T-handle type.”
Note: Install a sediment trap (drip leg) and a union
connection ahead of the primary manual shutoff valve
on the boiler. Gas piping should be installed in
accordance with National Fuel Gas Code, ANSI
Z223.1, latest edition, and any other local codes
which may apply; in Canada see CAN/CGA-B.149.
Note: See Pipe Capacity for Natural Gas chart on the
following page for required pipe size, based on
overall length of pipe from meter plus equivalent
length of all fittings. Approximate sizing may be
based on 1 cubic foot of natural gas per 1,000 Btu per
hour input, i.e., 500,000 Btu per hour requires about
500 cubic feet per hour. (See "Typical Boiler
Operating Conditions," Section 4.3, for more
information.)
Page 13
MACH® Series Gas-Fired Boiler Installation
Pipe Capacity for Natural Gas
Nominal
Iron Pipe
Size
(Inches)
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- 1/4 1.380 3.45 6.9 950 660 530 460 400 325 280
1- 1/2 1.610 4.02 8.04 1460 990 810 690 620 500 430
2 2.067 5.17 10.3 2750 1900 1520 1300 1150 950 800
2- 1/2 2.469 6.16 12.3 4350 3000 2400 2050 1850 1500 1280
3 3.068 7.67 15.3 7700 5300 4300 3700 3250 2650 2280
4 4.026 10.1 20.2 15800 10900 8800 7500 6700 5500 4600
Internal
Diameter
(Inches)
Equivalent Pipe Length
90º Ell
(Feet)
Tee
(Feet)
Maximum Capacity in Cubic Feet of Natural Gas per Hour
Pressure Drop of 0.5 inch Water Column/Equivalent Length of Pipe
(in feet)
20
40
60
80
100
150
3.7.1 Gas Supply Piping by Installer
3.8
BOILER WATER PIPING
200
The boiler and all gas piping connections should be
pressure-tested and must be checked for leaks before
being placed into service. Test with compressed air or
inert gas if possible.
The boiler must be disconnected at the boiler manual
shut-off valve (located at the end of the supplied gas
train) from the gas supply piping system during any
pressure testing of the system at pressures in excess of
1/2 psig (14" W.C.).
During any pressure testing of the gas supply piping
system at pressures equal to or less than 1/2 psig (14"
W.C.), the boiler should be isolated from the gas
supply piping system by closing the manual shut-off.
Some leak test solutions, including soap and water,
may cause corrosion. These solutions should be
rinsed-off with water after testing.
3.8.1 Piping Design
Water Flow in System
For proper water flow requirements see below.
Incorrect flow may result in eventual damage or
premature failure of the equipment.
Model Max Flow
GPM
Min Flow
GPM
DP ft. at
max flow
1050 105 52 12
900 90 45 12
750 75 37 12
450 45 22 8.5
300 30 15 8.5
Contact factory for minimum flow at other than
maximum firing rate.
Page 14
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