Harsco Industrial MACH C1500GG Operating instructions

©2011 Harsco Industrial, Patterson-Kelley
Printed : 4/28/2011
MACH® GAS-FIRED BOILER
C1500GG & C2000GG
Dual Fuel Boiler
Natural Gas or Propane
Model #: ______ Serial #: ______________________
Start-up Date: _______________________
Harsco Industrial, Patterson-Kelley
100 Burson Street,
East Stroudsburg, PA 18301
Telephone: [phone]
Facsimile: [phone]
www.harscopk.com
MACH® C1500GG-C2000GG
Rev. 1.01 (4/28/11)
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 Harsco Industrial, Patterson-Kelley
C.S.A Design-Certified
Complies with ANSI Z21.13/CSA 4.9
Gas-Fired Low Pressure Steam and Hot Water
Boilers

MACH® Gas-Fired Boiler
Page 2
1.0 INTRODUCTION................................................................................................. 4
2.0 SAFETY.............................................................................................................. 4
2.1 General..........................................................................................................................4
2.2 Training .........................................................................................................................4
2.3 Safety Features.............................................................................................................5
2.4 Safety Labels ................................................................................................................5
2.5 Safety Precautions........................................................................................................6
3.0 INSTALLATION.................................................................................................. 8
3.1 Receiving and Storage..................................................................................................8
3.2 Compliance with Codes ................................................................................................8
3.3 Setup.............................................................................................................................9
3.4 Electrical Connections.................................................................................................10
3.5 Inlet Air and Exhaust Venting......................................................................................12
3.6 Gas Piping...................................................................................................................23
3.7 Boiler Water Piping .....................................................................................................25
3.8 Pre-Start Check List....................................................................................................29
3.9 Safety Checks.............................................................................................................29
3.10 Initial Adjustments.......................................................................................................31
3.11 Burner Adjustment ......................................................................................................34
4.0 OPERATION..................................................................................................... 37
4.1 General........................................................................................................................37
4.2 Normal Lighting and Shut-Down Procedures..............................................................37
4.3 Typical Boiler Utility Requirements.............................................................................38
5.0 MAINTENANCE................................................................................................ 39
5.1 Maintenance and Inspection Schedule.......................................................................39
5.2 Cleaning the Burner....................................................................................................41
5.3 After All Repairs or Maintenance ................................................................................41
5.4 Sequence of Operation...............................................................................................42
5.5 Troubleshooting ..........................................................................................................43
6.0 PARTS/TECHNICAL SUPPORT ...................................................................... 47
6.1 Wiring Diagrams..........................................................................................................47
6.2 Boiler Parts List...........................................................................................................51
7.0 LIMITED WARRANTY...................................................................................... 55
8.0 SUPPLEMENTAL INFORMATION................................................................... 56
8.1 MACH® Boiler Fire Test Report –Natural Gas ..........................................................56
8.2 MACH® Boiler Fire Test Report –Liquid Propane .....................................................57
8.3 Maintenance Log.........................................................................................................58
8.4 Mach®Boiler Altitude Derate Schedule ......................................................................59
8.5 MACH® Water Chemistry...........................................................................................60

MACH® Gas-Fired Boiler
Page 3
Reorder No. 6020-V2WHPK
Improper use may
result in fire or injury.
Read instructions/safety
manual before installing,
operating or servicing boiler.
c
!
WARNING
1998HCS, Inc. 800-748-0241
If the information in this manual is not followed exactly, a fire or explosion may result causing property
damage, personal injury or loss of life.
Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other
appliance.
Installation and service must be performed by a qualified installer, service agency, or the gas supplier.
It is essential to read, understand, and follow the recommendations of this
manual before installing, operating, or servicing this equipment.
Installation and service must be performed by a qualified and knowledgeable
individual who has been trained on the MACH®boiler. 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.
What to do if you smell gas:
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 neighbor's phone. Follow the gas supplier's instructions.
If you cannot reach your gas supplier, call the fire department.

MACH® Gas-Fired Boiler
Page 4
1.0INTRODUCTION
The MACH® Gas-Fired Boiler is fully modulating using a variable speed combustion blower, sophisticated
microprocessor controls, dual 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 MACH® 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). Some MACH® boilers are certified to use both fuels (although not
simultaneously). 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. Harsco Industrial, Patterson-Kelley cannot be responsible for the design or
operation of such systems and a qualified engineer or contractor must be consulted.
2.0 SAFETY
2.1 GENERAL
The MACH® gas-fired boiler must be:
Installed, operated, and serviced in accordance with instructions contained in this manual and other supplemental
MACH® boiler manuals.
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 and knowledgeable personnel in accordance with all applicable codes, laws,
and regulations.
NOTICE!: Each safety device must be maintained and checked per the recommended schedule; refer to
Section 5.1 of this manual.
2.2 TRAINING
Proper training is the best protection against accidents.
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.

MACH® Gas-Fired Boiler
Page 5
Operating and service personnel must be thoroughly familiar with the basic construction of the MACH® boiler
C1500GG or C2000GG, the use and locations of the controls, the 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 Technical Service toll free at [phone].
2.3 SAFETY FEATURES
It is the responsibility of the customer to maintain the safety features, such as but not limited to: guards, safety labels,
safety controls, interlocks, lockout devices, in place and operable.
2.4 SAFETY LABELS
The following words are used in this manual to de-note the degree of seriousness of the individual hazards.
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 Harsco Industrial, Patterson-Kelley toll-free at [phone] for
replacement labels.
NOTICE/NOTE - NOTICE is the preferred signal word to address practices not related to personal injury. The
safety alert symbol is not used with this signal word.
indicates a potentially hazardous situation which, if not avoided, may result in minor
or moderate injury. It may also be used to alert against unsafe practices.
indicates a potentially hazardous situation which, if not avoided, could result in death
or serious injury.
indicates an imminently hazardous situation which, if not avoided, will result in death
or serious injury. This signal word is to be limited to the most extreme situations.
Reorder No. 6020-V2WHPK
Improper use may
result in fire or injury.
Read instructions/safety
manual before installing,
operating or servicing boiler.
c
!
WARNING
1998 HCS, Inc. 800-748-0241

MACH® Gas-Fired Boiler
Page 6
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
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 this boiler or on any electrical
components.
Electrical hazard! Do not alter wiring connections.
2.5.2 Burn, Fire and Explosion Hazards
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/CSA B.149.1. 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 this
appliance or 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.
Burn hazard! Hot fluids. Use caution when servicing or draining the 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.
Excess pressure 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.
Fire and explosion hazard! Failure to maintain all gas train components may result in malfunction of regulators
and/or gas safety shut off / control valves. Annual inspection by factory-trained personnel for proper set-up and
operation is recommended.
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.
Hot Surface
Reorder No. 6020-V2WHPK
Improper use may
result in fire or injury.
Read instructions/safety
manual before installing,
operating or servicing boiler.
c
!
WARNING
1998 HCS, Inc. 800-748-0241
General Warning

MACH® Gas-Fired Boiler
Page 7
Gas may lose its odor. Proper gas sensing equipment and procedures should
be used for leak checks.
2.5.3 Crush Hazards
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:
Bump hazard from overhead ductwork and piping. Install components with adequate vertical
clearance.
2.5.4 Chemical Hazards
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 –an acidic pH of approximately 3.0 to 5.0 can be expected.
Use PVC, CPVC, or other corrosion resistant piping for drainage. Collection and disposal
must be in accordance with all applicable regulations. A condensate neutralization kit is
available. Please contact your local Harsco Industrial, Patterson-Kelley representative.
2.5.5 Pressure Hazards
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
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. (see section 3.6.3)
Fall hazard! Do not stand on any part of the boiler.
Catch hazard! Do not wear rings, jewelry, long hair, loose clothing while working on the boiler.
Boiler Size
Weight in Pounds
C1500GG
1200
C2000GG
1400
General Warning
General Warning
General Warning
General Warning

MACH® Gas-Fired Boiler
Page 8
3.0 INSTALLATION
Installation and service must be performed by a qualified installer, service
agency, or gas supplier.
3.1 RECEIVING AND STORAGE
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, removing the top, front, and side covers and inspect the boiler. Verify that the total
number of pieces shown on the packing slip agrees with those actually received.
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 and
freezing conditions, 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.
3.2 COMPLIANCE WITH CODES
The MACH® 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 100 psig maximum operating pressure and/or 200º F maximum temperature.
Installation of the boiler must comply with the requirements of all national, state and local codes established by the
authorities having jurisdiction. Authorities having jurisdiction should be consulted before installations are made.
Within the US, and in the absence of such local requirements, this boiler should be installed using 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/CSA-B149, latest edition and applicable Provincial Regulations for the class, which
should be carefully followed in all cases.
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, (c) piping of condensate shall conform to the State Plumbing Code, and
(d) refer to the Massachusetts supplement for further details.
NOTICE! 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.
NOTICE! Controls and other equipment that are damaged or fail due to weather exposure are not covered by
warranty.

MACH® Gas-Fired Boiler
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3.3 SETUP
3.3.1 Foundation
Provide a firm, level foundation, preferably of concrete.
NOTICE! The boiler may be installed on a combustible floor, however the boiler must never be installed
on carpeting.
3.3.2 Placement
The wheels provided with this boiler are for positioning purposes only. When
positioning this boiler, maintain positive control of it at all times. Do not attempt to move the boiler on
surfaces that are not level. Failure to heed this warning could result in personal injury or death.
Lifting the front of the boiler slightly will allow the boiler to be rolled off the shipping skid onto the concrete foundation.
Once in position, the wheel bolts may be removed allowing the wheels to recess up into the boiler. The base will sit
flat on the provided foundation. If the boiler is to be pulled out for maintenance, the wheels may be left attached.
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 prevent distortion of the cabinet, (twisting, etc.) in
addition to leveling.
Additionally there are three holes in the front and rear of the base that may be used for seismic anchoring.
3.3.3 Clearances
If the boiler is to be installed near combustible surfaces, the minimum clearances shown in the pictures and 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 the National Fuel Gas Code, ANSI Z223.1, latest edition.
Maintain a clearance from the vent to combustible surfaces of 18” or as specified in the vent manufacturer’s listed
installation instructions.
Minimum Clearances from Adjacent Walls, Ceiling, and Obstructions (shown above &below)
A
C
B
D
D
D

MACH® Gas-Fired Boiler
Page 10
† "C" Space required for pipes, ducts, etc. in this area above
the boiler.
* Clearance depends upon exhaust vent configuration.
** Service access is required on left side of boiler to facilitate
boiler maintenance. Minimum 2” clearance is required on
right side. Do not put pipes, ducts, vents, etc in this space.
Electrical conduit must be installed vertically so that the side
doors can be opened.
Bumping hazard from overhead ducts! Install all components with adequate
vertical clearances.
3.4 ELECTRICAL CONNECTIONS
The boiler is wired for 120 volts, single phase, 60 hertz.
The total operating amperage is indicated on the rating
nameplate. Each MACH® C1500GG-C2000GG boiler
requires less than 15 amps. Before starting the boiler,
check to ensure that the proper electrical service is
connected to the boiler.
An external electrical disconnect (not supplied with the
boiler) is required. The boiler electrical service must be
installed and 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 or, in Canada, to the Canadian Electrical Code,
Part I, CSA C22.1, latest edition. Conduit must be installed
vertically so that the side doors can be opened.
NOTICE! A dedicated earth ground (green wire) and neutral is required to avoid nuisance shutdowns.
Do not ground through the conduit. It is also important that proper polarity be maintained.
The electrical junction boxes are located at the front sides of the boiler. A detailed schematic of the connections is
shown in section 6.1.
3.4.1 High Voltage (TB2) Terminal Block
The boiler power circuit requires 120 VAC, 60 hertz, with a dedicated neutral and ground as labeled. Electrical
service must be rated for 8 amps minimum. Before starting the boiler, check to ensure that the proper voltage and
amperage are connected to the boiler and that the boiler is connected to a suitable fused disconnect switch or circuit
breaker. There must be less than 1.0V from Neutral (TB2-3) to Ground (TB2-8)
120VAC Switched Output- This contact closes when the boiler is switched on. This provides 120VAC 5Amp
service to TB2-10. The neutral for this circuit is provided on TB2-3. When the boiler is switched off, this terminal is
switched off as well.
3 Way Valve- This output is normally energized, keeping the three way valve providing heat to the building. The
Domestic Hot Water (DHW) call for heat de-energizes this circuit, causing the 3 way valve to self close, thereby
Type of Surface
Dimensions (inches)
A
B
C†
D
Combustible Surfaces
Minimum Clearances
18
18
18
18
Recommended Service
Clearances
30
12*
12
18**
TB1: Low Volt
Junction Box
TB2: 120 Volt
Junction Box
Customer Connections for the Boiler
Viewed from Front of Boiler.

MACH® Gas-Fired Boiler
Page 11
providing heat to the DHW loop. This output provides 120VAC 0.5Amp service to TB2-11. The neutral for this circuit
is provided on TB2-4.
DHW Pump Relay w/Delay Off - This output is enabled when there is a call for DHW. When the call for heat is
removed, the output remains enabled for a period of time. This output provides 120VAC 0.5Amp service to TB2-12.
The neutral for this circuit is provided on TB2-5.
Circ Pump Relay w/Delay Off - This output is enabled when there is a call for heat. When the call for heat is
removed, the output remains enabled for a period of time. This output provides 120VAC 0.5Amp service to TB2-13.
The neutral for this circuit is provided on TB2-6.
Damper Relay - This output is enabled when the call for heat is enabled. This output provides 120VAC service to
TB2-14. The neutral for this circuit is provided on TB2-7. This circuit is for pilot duty only.
Master Alarm Relay –This contact closes in the event of an alarm output from the boiler control, connecting TB2-
15 and TB2-16.
Flame Detected Relay –This contact closes whenever the boiler is firing, connecting TB2-17 and TB2-18.
3.4.2 Low Voltage (TB1) Terminal Block
Enable/Disable–TB1-1 and TB1-2 are used for enabling the boiler. Closing this circuit allows the boiler to run.
Opening this circuit prevents the boiler from running. This circuit is energized by the boiler. It has a 24VAC potential.
Devices connected to these terminals must be rated for 24VAC
External Interlock –TB1-3 and TB1-4 are used for attachment of an additional field safety device to the boiler
control circuit. Closing this circuit allows the boiler to run. Opening this circuit prevents the boiler from running. This
circuit is energized by the boiler with a 5V potential. Devices connected to these terminals must be rated for 5V.
Outdoor Temp Sensor –TB1-5 and TB1-6 are connected to the outdoor temperature sensor. The temperature
control must be programmed to run an outdoor air schedule. The outdoor air sensor and programming help are
available from the local Harsco Industrial, Patterson-Kelley Representative. This circuit is energized by the boiler with
a 5V potential. The temperature sensor must be a NTC having 12k@25°C.
DHW Stat/Sensor –TB1-7 and TB1-8 are connected to the DHW temperature sensor or thermostat. This circuit is
energized by the boiler with a 5V potential. The temperature sensor must be a NTC having 12k@25°C.
Header Temp Sensor –TB1-9 and TB1-10 are connected to the header temperature sensor. This circuit is
energized by the boiler with a 5V potential. The temperature sensor must be a NTC having 12k@25°C.
DHW Flow Switch –TB1-11 is energized by the boiler with a 5V potential. This circuit connects through a flow
switch on the domestic side of a domestic hot water system. The flow switch should close upon flow to provide a
closed circuit back to TB1-12.
Analog Input–Remote signal for controlling the boiler. The boiler can be operated in a remote setpoint or a remote
firing rate control mode. Input 0-10VDC signal on TB1-13 only. The 0V Analog Input is provided on TB1-14. The
temperature control must be programmed to run with the analog input.
MODBUS® –TB1-17 and TB1-18 are used for connecting a MODBUS® building management system. (See the
ENVI™ Control Advanced Users Guide for more information)
Cascade –TB1-19 and TB1-20 are used to connect between boilers that are part of a Master/Member Network. Up
to 24 boilers may be connected together. (See the ENVI™ Control Advanced Users Guide for more information)

MACH® Gas-Fired Boiler
Page 12
3.5 INLET AIR AND EXHAUST VENTING
3.5.1 Applicable Codes & Standards
CODES
United States:
NFPA 54/ANSI Z223.1 National Fuel Gas Code
NFPA/ANSI 211 Chimneys, Fireplaces, Vents and Solid Fuel Burning Appliances
Canada
CAN/CSA B149.1 Installation Codes for Gas Burning Equipment
STANDARDS
UL 1738 Venting Systems for Gas-Burning Appliances, Categories II, III, and IV
ULC S636-95 Standard for Type BH Venting Systems
Sheet Metal and Thermoplastic Duct Construction Manual
Air Conditioning Contractors National Association (SMACNA)
These codes and standards contain information for the venting of gas fired appliances, including, but not limited to
vent sizing, location, clearance to combustibles, and safe installation practices. The installation must comply with
both the above Federal Codes and with state, provincial and local codes.
Design and installation of venting systems should be done only by qualified and
knowledgeable venting systems personnel and in accordance with vent system manufacturer’s
installation instructions. Installing a boiler or vent system using improper installation methods or
materials can result in serious injury or death due to fire or asphyxiation.
Before connecting a boiler to a venting system, it must be determined whether
the boiler is to be installed in a conventional or Direct Vent configuration. In the US, provisions for
combustion and ventilation air must be in accordance with NFPA 54/ANSI Z223.1, National Fuel Gas
Code, latest edition, or applicable provisions of the local building codes. In Canada, combustion and
ventilation air openings shall comply with CAN/CSA B-149.1 Natural Gas and Propane Installation Code.
For correct installation of vent system, read all of these instructions and refer to
vent manufacturer’s instructions.
Failure to use a proper vent system (types and materials), as described in this manual will void the boiler
warranty and may result in rapid deterioration of the venting system, creating a health or life safety
hazard.
Faulty vent installation can allow toxic fumes to be released into living areas. This may cause property
damage, serious bodily injury or death.
3.5.1.1 Gas Vent Categories
Several codes and standards have categorized appliances in accordance with the flue gas temperature and pressure
produced by the appliance. Categories are defined as follows:
Category I An appliance that operates with a non-positive vent static pressure and with a vent temperature
that avoids excessive condensate production in the vent.
Category II An appliance that operates with a non-positive vent static pressure and with a vent temperature
that may cause excessive condensate production in the vent.
Category III An appliance that operates with a positive vent static pressure and with a vent temperature
that avoids excessive condensate production in the vent.

MACH® Gas-Fired Boiler
Page 13
Category IV An appliance that operates with a positive vent static pressure and with a vent temperature
that may cause excessive condensate production in the vent.
Direct Vent An appliance that is constructed and installed so that all air for combustion is derived directly
from outdoors and all flue gases are discharged to the outdoors.
3.5.1.2 Venting Materials for Flue/Exhaust Systems
The MACH®C1500GG and C2000GG boilers are dual-certified as both Category II and Category IV appliances,
which vent with a temperature that is likely to cause condensation in the vent. Refer to Section 3.5.3.2 for
requirements of Category II installations and Section 3.5.3.3 for requirements of Category IV installations. Any venting
system used with the MACH® boiler must comply with the applicable venting system as specified in the latest edition
of NFPA 54/ANSI Z223.1 in the US or the latest edition of CAN/CSA B-149.1 in Canada.
The venting materials listed below are intended for the venting of gas burning appliances only. Do not
use these venting materials for venting liquid or solid fuel (such as oil, kerosene, wood or coal)
appliances
Maintain clearances to combustibles as listed in the vent manufacturer’s installation instructions or as set
forth in the codes and standards listed in this section.
Do not use these vent pipes for incinerators of any sort.
This boiler is not certified for use with PVC nor CPVC venting. Use of PVC
or CPVC vent may result in vent failure and possible serious injury or death.
Table of Acceptable Materials for Venting Systems
Manufactured Venting
US and Canada
Factory Fabricated Metallic Vent Systems listed and labeled to UL1738 (Titled: Venting Systems for Gas-
Burning Appliances, Categories II, III, and IV)
Table of Applicable Vent Materials by MACH® Boiler Model
MACH® Boiler Model
AL29-4C
316L SS
CPVC
PVC
US C1500GG –C2000GG
X
X
No
No
CAN C1500GG –C2000GG
X
X
No
No
3.5.2 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, when burned, form acids which quickly attack the boiler and the boiler stack. The result is improper
combustion and premature boiler failure.
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. Note that this equipment might be in rooms other than the boiler
room.

MACH® Gas-Fired Boiler
Page 14
3.5.2.1 Air Inlet Requirements –United States (NFPA 54/ANSI Z223.1 & NFPA/ANSI 211)
When air is supplied from inside the building, the total required volume shall be the sum of the required volume for all
the appliances located in the mechanical room. Adjacent rooms furnished with fixed openings communicating directly
with the mechanical room are considered part of the required volume. The minimum volume is 50 ft3per 1000 Btu/hr
(4.8 m3/kW) of installed appliance input capacity.
Openings used to connect indoor spaces to obtain the required minimum volume shall be sized as follows:
When rooms are on the same floor, each opening shall have an area equal to 1 square inch for each 1000 Btu/hr
(2200 mm2/ kW) of installed appliance input capacity, but not less than 100 square inches. One opening should
commence less than 12 inches above the floor and the other less than 12 inches below the ceiling. The minimum
dimension of air openings shall be 3 inches.
When rooms are on different floors, each opening shall have an area equal to 2 square inches for each 1000
Btu/hr (4400 mm2/ kW) of installed appliance input capacity.
When combustion air is supplied from outside the building, the boiler room shall be provided with one or two openings
to ensure adequate combustion air and proper ventilation.
When using one permanent opening, the opening shall commence within 12 inches of the ceiling and shall
communicate directly with the outdoors or through a vertical or horizontal duct that communicates to the outdoors.
Minimum free area of the opening is 1 square inch for each 3000 Btu/hr (700 mm2/ kW) of installed appliance
input capacity, and
Not less than the sum of the areas of all vent connectors in the room.
When using two permanent openings, one opening shall commence within 12 inches above the floor and the other
within 12 inches below the ceiling, preferably on opposite walls. The openings shall communicate directly, or by way
of ducts, with free outdoor air. The minimum net free area of the openings shall be calculated in accordance with the
following:
When air is taken directly from outside the building, each opening (minimum of two, as outlined above), 1 square
inch for each 4,000 Btu per hour (550 mm2/kW) of total boiler input is required.
When air is taken from the outdoors through a vertical duct into the mechanical room, 1 square inch per 4,000 Btu
per hour (550 mm2/kW) of total boiler input is required.
When air is taken from the outdoors through a horizontal duct into the mechanical room, 1 square inch per 2,000
Btu per hour (1100 mm2/kW) of total boiler input is required.
NOTE:
1. The required size of openings for combustion and ventilation air shall be based on the net free area of the
opening.
2. Screens shall be not smaller than ¼”
3. Motorized louvers shall be interlocked with the appliance so that they are proven open prior to main burner
ignition and operation.
Table of US Minimum area of ventilation openings per boiler (sq inches)
MACH® Boiler
MODEL
AIR SOURCE
INDOOR AIR SUPPLY
OUTDOOR AIR SUPPLY
SAME
FLOOR
DIFF
FLOORS
ONE
OPENING
TWO OPENINGS
DIRECT
VERT
DUCT
HORIZ
DUCT
C1500GG
1500
3000
500
375
375
750
C2000GG
2000
4000
667
500
500
1000

MACH® Gas-Fired Boiler
Page 15
3.5.2.2 Air Inlet Requirements –Canada (CAN/CSA B149.1)
A. Ventilation of the space occupied by fuel burning appliance(s) or equipment shall be supplied by a ventilation
opening at the highest practicable point communicating with the outdoors. The total cross sectional area of the
ventilation opening must be either 10% of the net free area required for combustion air or 10 sq. in. (6500 mm2),
whichever is greater.
B. Use the following opening calculation for MACH ®or MODU-FIRE®FD boilers:
When combustion air is supplied for a forced draft burner by natural airflow from the outdoors and there is no draft
regulator or draft hood in the same space, there shall be a permanent opening with a cross sectional area not less
than 1 sq. in/ 30,000 Btu/Hr (70 mm2/kW) of the total rated input to the burner(s). This opening must not interfere
with the ventilation air opening defined in paragraph A.
C. Use the following opening calculation for P-K THERMIFIC®boilers or other natural draft or fan-assist appliances:
When combustion air is supplied for natural or fan-assisted burners by natural airflow from the outdoors, there
shall be a permanent opening with a cross sectional area not less than 1 sq. in/ 7000 Btu/Hr (321 mm2/kW) up to
and including 1,000,000 Btu/Hr plus 1 sq. in. / 14,000 Btu/Hr (155 mm2/kW) in excess 1,000,000 Btu/Hr. This
opening must be either located at or ducted to a point not more than 18 in. (450 mm) nor less than 6 in. (150 mm)
above floor level. This opening is in addition to the ventilation air opening defined in paragraph A.
D. When combustion air is supplied by natural airflow into a space containing both types of appliance described in
paragraphs B and C, the cross sectional area of the opening shall be not less than the sum of the cross sectional
areas for all appliances in the space as calculated by the applicable method . This opening is in addition to the
ventilation air opening defined in paragraph A.
E. When a duct is used to meet the requirement for combustion air supply, as described in paragraphs A through D,
above, the opening of the duct shall be located so there is no possibility of cold air affecting steam or water piping,
electrical equipment or mechanical equipment.
F. When combustion air is supplied by mechanical means, an airflow-sensing device must be installed. It must be
wired into the pre-ignition limit string to prevent the burner from starting or to stop an operating burner in case of
air supply failure.
G. When all combustion air is supplied through a make-up air heater, and the appliance is interlocked to the heater,
the requirements of paragraphs A through F do not apply.
NOTE:
1. The free area of a combustion air supply opening is calculated by deducting the blockage area of any fixed
louvers, grilles or screens from the total area of the opening.
2. Screens shall be not smaller than ¼”
3. Motorized louvers shall be interlocked with the appliance so that they are proven open prior to main burner
ignition and operation
Table of Canadian Minimum Area of Combustion and Ventilation Air Openings
MACH® Boiler
Required Combustion Air
Opening
Ventilation Air Opening
Model #
Input
(Btu/Hr)
in2
mm2
in2
mm2
C1500GG
1,500,000
50
32,258
10
6,452
C2000GG
2,000,000
67
43,226
10
6,452

MACH® Gas-Fired Boiler
Page 16
3.5.3 Flue Venting
This boiler is not certified for use with Type "B" vent nor with PVC/CPVC venting.
This boiler
3.5.3.1 VENT SIZING
The vent must be sized in accordance with the ASHRAE Systems and Equipment handbook, Chapter 30 or according
to the vent manufacturer’s recommendations. When using manufactured venting systems, consult your vent supplier
for correct sizing and structural support requirements.
Table of Vent Design Parameters
MACH® Boiler Model
Frictional
Resistance
Stack
Temperature
CO2Natural Gas
CO2LP Gas
C1500GG - C2000GG
0.22”
185°F
9.2%
10.5%
All boiler venting systems should be designed by a qualified venting professional
experienced in venting system design. The information contained herein should be used as a guide only
and is not intended to be used in lieu of qualified technical expertise.
3.5.3.2 CATEGORY II INSTALLATIONS
The MACH®C1500GG and C2000GG boilers are dual-certified for both Category II and Category IV operation.
Category II appliances operate with a non-positive vent static pressure and with a vent temperature that may cause
excessive condensate production in the vent. There are several requirements for reliable operation of the boilers
under Category II conditions:
1. A stainless steel vent adapter is required to mate the boiler exhaust connection and the vent pipe. See the table
below for the applicable part numbers.
2. A normally-closed motorized damper is required on the boiler’s air intake. See the table below for the applicable
part numbers.
3. The draft, measured inside the vent at the rear of the boiler, must not exceed -0.05” w.c. Excessive negative
draft will cause nuisance trips such as flame failures.
4. The vent system must be properly drained of condensate before returning to the boiler. Please see Section
3.5.3.6 for information on installing condensate drains in the exhaust vent.
All boiler venting systems should be designed by a qualified venting
professional experienced in venting system design. The information contained herein should
be used as a guide only and is not intended to be used in lieu of qualified technical expertise.

MACH® Gas-Fired Boiler
Page 17
Table of Required Stainless Steel Vent Adapters and Category II Motorized Dampers
The normally-closed motorized damper operates on 120 VAC and features an end limit switch wired into the boiler’s
external interlock circuit. Upon a call for heat, the boiler’s damper relay will energize and drive the damper open.
Once the damper reaches the fully-open position, the end limit switch makes contact and closes the external interlock
circuit allowing the boiler to fire. The diagram below shows the wiring necessary to install the normally-closed
motorized damper.
Boiler Size
Nominal
Stack Size
Stainless Vent
Adapter
Normally-Closed
Motorized Damper
A
B
C
D
C1500GG -
C2000GG
10"
2630000226
1004906945
10”
10”
13”
3.38”
Use caution if installing a barometric damper in the exhaust vent. The
vent pressure must be negative (Category II) at all times to prevent leakage of harmful flue
gases into the room. Leakage of flue gases can cause serious injury or death.

MACH® Gas-Fired Boiler
Page 18
3.5.3.3 CATEGORY IV INSTALLATIONS
If the vent installation is designed for Category IV conditions only (condensing –positive pressure) as it is defined in
ANSI Z21.13/CSA 4.9, latest edition. The vent material must be as listed in Table in section 3.5.1.2 and can be run
horizontally or vertically.
Vent installations shall be in accordance with NFPA54/ANSI Z223.1, the National Fuel Gas Code, or CAN/CSA-
B149.1, the Natural Gas and Propane Installation Code, or applicable provisions of the local building codes.
3.5.3.4 Required Clearances
Provide clearances between combustion air intake, exhaust vent, roof and wall surfaces, doors and window, and
snow line. Refer to Figure below: Termination Clearances –Forced Draft and Direct Vent Installations.
Reference: NFPA 54/ANSI Z223.1 National Fuel Gas Code
Do not locate intake or exhaust terminations directly above a walkway; dripping
of condensation can cause icing of the walking surface. Maintain a minimum clearance of 4 ft (1.22 m)
horizontally from any electric or gas meter, regulator or relief equipment.
Conventional Vent Systems Clearances
The following termination clearance requirements are for conventional, non-direct vent installations.
The vent system shall terminate at least 3 ft above a forced air inlet within 10 feet horizontally.
The vent system shall terminate at least 4 ft below, 4 ft horizontally from or 1 ft above any door, operable window
or gravity inlet into any building. The bottom of the vent terminal shall be at least 12 in. above grade or highest
expected snow line (if applicable).
Do not use a barometric damper if operating with a positive stack pressure
(Category IV). Harmful flue gases may leak into the room which can cause serious injury or death.

MACH® Gas-Fired Boiler
Page 19
Through the wall terminations shall not terminate over public walkways or over an area where condensate or
vapor could create a nuisance or hazard or could be detrimental to the operation of regulators, relief valves or
other equipment.
Direct Vent (Sealed Combustion) Systems Clearances
The vent terminal shall be located at least 12 in. from any air opening into a building. The bottom of the vent
terminal shall be at least 12 in. above grade. Both the vent and air intake terminals must be at least 12 in. above
the highest expected snow line.
Through the wall terminations shall not terminate over public walkways or over an area where condensate or
vapor could create a nuisance or hazard or could be detrimental to the operation of regulators, relief valves or
other equipment.
When multiple direct vent appliances are adjacent, the exhaust must terminate at least 10 feet horizontally or
three feet vertically from the air intake of another appliance.
Interior Component Clearances
All vent system components shall be installed so as to maintain the following required minimum clearances:
Combustible
Non-Combustibles
Unlisted single wall metal pipe
Do NOT Use
Do NOT Use
Single wall CPVC pipe
Do NOT Use
Do NOT Use
UL 1738 listed Category IV vent
Per manufacturer’s listing
Per manufacturer’s listing
NOTICE! 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. The CPVC or manufactured vent system shall be
supported in accordance with the manufacturer’s instructions. Horizontal vent sections shall be
supported in a manner to prevent sags or low spots where condensate can collect. Structural supports
must be connected to building elements of sufficient strength to withstand the weight of the vent system
and any bending forces imposed by the venting system.

MACH® Gas-Fired Boiler
Page 20
3.5.3.5 Flue Connection
The boiler vent should not be connected into any portion of another mechanical
draft system without consulting the vent manufacturer. The boiler shall not be connected to any part of a
vent system serving a Category I or II appliance, nor shall a Category I or II appliance be connected to
any part of the vent system serving this appliance. Improper interconnection of venting systems may
result in leakage of flue gases into occupied spaces.
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 complete exhaust with drain system is
shown in the figure below. The appliance
connector should incorporate provisions to
drain condensate formed in the vent system.
The connector shall include a drained boot tee,
a drained lateral tee or a horizontal or vertical
drain section.
NOTE! The condensate formed from
natural gas flue gases is acidic. The
condensate shall be drained in
accordance with local code requirements.
A condensate neutralizer may be required
by local code.