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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 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
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