DuraVent PolyPro Flex User Manual

Installation Instructions

PolyPro Double-Wall Flex
Gas Vent System for Category II &
IV Gas-Burning Appliances

PolyPro

®

Flex

A MAJOR CAUSE OF VENT RELATED FIRES IS FAILURE

TO MAINTAIN REQUIRED CLEARANCES (AIR SPACES)
TO COMBUSTIBLE MATERIALS. IT IS OF THE UTMOST

IMPORTANCE THAT POLYPRO

® BE INSTALLED ONLY IN

ACCORDANCE WITH THESE INSTRUCTIONS.

• Assure unrestricted vent movement

IMPORTANT

Throughout this manual you will see

special attention boxes intended to

supplement the instructions and make

special notice of potential hazards.

In the judgement of M&G DuraVent,

these categories mean:

WARNING

Indicates a condition or hazard which

may cause severe personal injury, death

or major property damage.

CAUTION

Indicates a condition or hazard which

will or can cause minor personal injury

or property damage.

WARNING

Risk of carbon monoxide poisoning

or re due to joint separation or pipe

breakage.

• Examine all components for possible

shipping damage prior to installation;

• Read all instructions before beginning

the installation and follow these
instructions exactly as written.

• Proper joint assembly is essential for a

safe installation. Check the integrity of
ALL joints upon completion of assembly

• This venting system must be free to

expand and contract under normal
operation.

where required through walls, ceilings
and roof penetrations.

• This venting system must be supported

in accordance with these instructions.

• Do not mix pipe, ttings, or joining

methods from dierent vent system
manufacturers. Do not use adhesives of
any kind with this venting system.

Keep these instructions for future

reference.

Dear Customer, Installer, or End User:

We welcome any comments regarding
matters pertaining to our DuraVent products.
We welcome any ideas, input or complaints
to help improve our product oering. Send
your emails to:
[e-mail]

If you are searching for tech support or
product information, please phone us at
800-835-4429.
Or email us at:
[e-mail]

PolyPro® is one of M&G DuraVent's
GreenVent® line of products.

2

PolyPro Flex Gas Vent System

For the most up-to-date installation instructions, see www.duravent.com

CONTENTS

APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

MINIMUM CLEARANCE TO COMBUSTIBLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

GENERAL INSTRUCTION NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 4

INSTALLATION OF FLEX GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

MASONRY / SHEET ROCK ENCLOSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

B VENT / RELINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

PolyPro

®

Flex

3

APPLICATION / LISTING

For specic information on application,
equivalent length of ttings, listings, etc.,
please reference M&G Duravent's installation
instructions for rigid pipe (Document L273).

M&G Duravent's PolyPro vent pipe should not
be installed in areas where the temperature
could exceed 230 F / 110 C.

PERMITS

Check with your local Building Ocial, Fire
Ocial, or other authority having jurisdiction
regarding permits, restrictions, and
installation inspections in your area.

MINIMUM CLEARANCE TO
COMBUSTIBLES

Refer to Table A for minimum clearances
to combustible materials. Use the values
shown in this table unless the appliance
manufacturer species otherwise. If there
is a conict between the two, the greater
clearance shall apply. It is prohibited to place
any type of insulation around the venting
system within these clearances.

CAUTION

Installation applications and
terminations shown in these

instructions must be approved by

the manufacturer of the appliance to

which it is applied. Use only listed M&G

DuraVent terminations with PolyPro

Venting.

Table A

Minimum Clearance To Combustibles Table

VENT ORIENTATION

Horizontal Single Wall: 0" for ue temperatures up to 194*F (90*C).

Vertical Single Wall: 0"

IMPORTANT

The vent system must terminate in

accordance with local code requirements

and appropriate National Codes:
In the US: NFPA 54 / ANSI Z223.1

National Fuel Gas Code or the

International Fuel Gas Code.

In Canada: CAN/CGA-B149.1 Natural

Gas Installation Code or CAN/CGA-149.2

Propane Installation Code.

GENERAL INSTALLATION NOTES

Reference the Installation Instructions
provided with M&G Duravent's rigid pipe
(L273) for general instructions. PP Flex must

be enclosed, and used in conjunction with
rigid PP pipe to connect to an appliance.

• When used to conduct ue gases, PP ex

must not be installed at an angle greater
than 45 degrees from vertical. This will
ensure proper condensate ow back
towards the appliance outlet.

• PP Flex may be used to bring

combustion air into the appliance. In
these instances, pipe can be unenclosed
and oriented in a vertical or horizontal
position.

• PP ex must be treated carefully to

prevent damage when being installed
during low temperatures (<41°F, < 5 °C).
In colder weather, pre-warm ex prior
to installation. When relining, it may be
easier to insert ex from the bottom up

CLEARANCE

1/4" (6mm) for ue temperatures up to 230*F (110*C).

Flex: N/A- NOT ALLOWED

Flex: 0" (Must be enclosed)

4

rather the top down.

• Always use soapy water to lubricate

gaskets prior to joint assembly. Do
not use Petroleum based lubricants!

• Plastic venting systems shall not pass

through rated re separations.

ADDITIONAL INSTRUCTIONS FOR
TERMINATION

M&G Duravent's PP Flex terminations are
specically designed for use with high­eciency appliances that are known to
produce high volumes of uid due to
condensation of moisture within ue gases.
DO NOT modify these terminations.

IMPORTANT: Unless the appliance is designed
to address ow of condensates from the
vent system, a drain must be incorporated
within the vent to allow condensates and
rainwater to escape. This drain must include
a trap to prevent combustion gases from
entering living spaces. Be sure to check
the appliance manufacturer's installation
instructions closely in regards to condensate
management.

PP Flex pipe must always have gaskets
installed on both ends of any installation.

Gaskets are installed on the ex pipe, with the
gasket seating inside the ex pipe grooves
(Fig.1). Use soapy water to assist installation.

1. Cut PP ex pipe (knife, saw, etc) to
desired length. Special care should be taken
to ensure cut is square, and the edge is
deburred.

2. Place Flex Gasket over Flex pipe and install
in the rst whole groove nearest the end.

3. Open the locking tabs (x2) of the
appropriate ex tting to accept the ex pipe
(Fig.2)

4. Apply soapy water to the gasket, and push
pipe/gasket into appropriate ex tting,
seating pipe down until it bottoms out
(Fig.2).

Gasket in
fiRst
GRooVe

INSTALLATION OF FLEX GASKET:

PP flex PiPe

PP flex Gasket

flex aDaPteR

flex to coRRect

lenGth, clean eDGe

install Gasket, use

soaPy wateR

Figure 2, Installing Gasket / Flex Adapter

Figure 1, Mounting the Gasket

inseRt into

aDaPteR

lock PiPe to

aDaPteR

(click!)

5

5. Close locking tabs on ex adapter so
tabs seat in the ex pipe. Slight adjustment
of pipe may be needed to ensure proper
engagement.

that is lined with a clay or concrete liner,
check to see if a short portion of the tile is
sticking out of the top of the chimney. If so,
this short top portion must be broken o to
permit the termination's ashing to sit down
ush on the chimney's crown. It is best to do
this prior to beginning the installation.

1. Determine the required location of the
opening within the enclosure. Ensure the ue
access cut-out meets the minimum specied
size to allow manual assembly of connections
within the ue. With masonry chimneys, the
breech opening may have to be enlarged

FLEX CHIMNEY LINING KIT

RoPe

Figure 3, Flex Puller

FLEX PULLER

A ex puller is an optional component
available to help ease installation of PP
Flex through enclosures (Fig.3). The
2"(60mm) version is of dierent design than
3"-5"(80mm-130mm).

2" Dia: Unscrew ceramic holder from cone.
Install ceramic holder around PP Flex pipe,
and re-install into cone.
3"-5" Dia: Connected using bayonet style
connection with a rotating movement of 1/4
turn to lock in.

MASONRY / SHEET ROCK
ENCLOSURE:

Examine the chimney or enclosure
carefully for obstructions prior to starting
an installation. Any structural defects or
potential safety problems must be repaired
prior to relining, and the enclsoure should be
clean. If working with a masonry chimney

1. Wall Plate

2. Support Elbow

3. Flex Chimney Support

4. Flex Male Adapter

5. Clamp (or Tie)

6. Flex Coupler

7. Gasket

8. Flex Liner

9. Spacer

10. Support Bracket

11. Flex
Female Adapter

12. Flex Chimney
Cap Flashing

13. Termination
Pipe

6

1

13

12

11

10

7

9

8

7

5

4

3

2

6

to permit proper access. If this is the case,
patch up the opening after the installation
is completed using best practices. The slope
of the rigid connecting ue pipe must have a
minimum of 3° (equivalent 5cm/m) (5/8" per
foot).

2. Fix the Flex Chimney Support
(Fig.4) with 4 screws on the wall of the
enclosure.

6. Install PP Flex liner into the enclosure. A
second person is required to help feed the
exible liner into position (feeding either
from the top or bottom of the enclosure).
This will also help prevent damage from
occurring.

7. After installing the required length of liner,
remove the Flex Puller (if applicable)
8a. Position the Support Elbow on the Flex
Chimney Support (see 2 and 3, Fig.5)
8b. Secure the Support Elbow with the clamp
around the Flex Male Adapter and through
the slot of the Flex Chimney Support (see 1,
Fig.6).

1

2

1

3

Figure 4, Mounting Flex Chimney Support

3. The length of the exible liner can be
determined in two ways: use a rope with
a weight to measure the shaft length, add
16" (40cm) extra length for each bend. The
exible liner can be shortened with a saw or
scissors by cutting in a groove. The correct
length can also be determined after installing
the liner in the shaft and cutting it at the top
of the chimney, see Fig.8, dimension B.

4. Mount the Gasket into the ex pipe, and

attach to the appropriate coupler as detailed
above.

5. Mount the Spacers with a maximum
distance between them of 6 feet (2m).

Figure 5,
Installation
Support Elbow

Figure 6,
Securing
Support Elbow

9. Mount the Wall Plate on the wall of the
shaft (Fig.7). Pay attention to the correct
slope of 3°. The pipe of the Support Elbow
must be in the centre of the hole in the Wall
Plate.

10. The Support Elbow can be shortened if
required- For single wall, Dim A (Fig.7) must
have a minimum length of 1.6" (40mm).

11. At the top of the shaft, shorten the
exible liner to the required length and make
sure that dimension B in Fig.8 is between 1½

- 2½" (between 38 and 64 mm).

7

15. Install the Termination Pipe(see 1 ,

Fig.10). Assemble the storm collar portion of
the Flex Chimney Flashing (see 2, Fig.10).

16. Connect the appliance to the exible vent

=

=

=

system with M&G DuraVent rigid PolyPro vent
system.

=

1

A

Figure 7, Mounting the Wall Plate

13. Fit the Support Bracket (see 1, Fig.8)
over the liner and let it rest on the wall of the
shaft. Mount the Gasket as detailed above
(see Fig.1). Push the Flex Female Adapter on
the liner and close the latching tabs. Allow
the assembly to rest on the Support Bracket.

14. Seal the edge of the chimney shaft with
water-resistant sealant (see 1, Fig.9) and push
the Flex Chimney Flashing (see 2, Fig.9) on
the shaft and x it with four masonry anchors
(see 3, Fig.9).

B

1

3

2

1

Figure 9, Installing Vent Cap

1

2

Figure 8, Required Liner Length

8

Figure 10, Installing Termination Pieces

B VENT RELINE:

From within the room where the appliance is located, remove any existing horizontal or angled
sections of B Vent. PP Flex cannot be installed at an angle greater than 45 degrees from vertical.
The B Vent Adapter-Lower will t over the bottom of the existing B Vent's vertical stack at or
near the ceiling. Carefully inspect the B Vent to ensure integrity. Ensure any visible screws or
obstructions are removed. PP Rigid pipe must be used to complete install to the appliance-

Instructions- 2" (60mm) PP Flex in B Vent

1. Remove existing B Vent termination cap

2. Carefully feed ex down through B Vent so
approx 2' of ex extends beyond the bottom
of the B Vent (Flex puller or rope aid optional)

3. Cut to length the top of Flex pipe and
insert ex through B Vent Adapter- Upper, and
through the Termination Base.

4. Install the PP Flex Gasket and Flex Female
Adapter onto Flex pipe using instructions in
previous pages.

5. Lower the B Vent Adapter- Upper onto the
top of the existing B Vent and secure using
screws (x3) supplied with the hardware kit.

6. Attach the Termination Top to the
Termination Cap (clicks when engaged),
then insert the Flex Female Adapter into the

Termination Cap. Push the assembly onto the
Termination Base (clicks when engaged, see

Fig.12).

7. Push the completed assembly down onto
the B-Vent Adapter- Upper. When level, secure
with three screws provided.

8. At the bottom end, cut the PP Flex to
length 3" below the bottom of the vertical B
Vent still portruding from the ceiling.

9. Install the Flex Gasket
and Flex Male Adapter onto
the Flex pipe

10. Install B Vent Adapter-
Lower. (Flex Male Adapter
should protrude beyond
per Fig.13)

(click!)

11. Secure the B Vent
Adapter- Lower to the B

Vent using three screws
from the supplied
hardware.

Figure 12

Figure 11- (2" Flex / B Vent)

teRMination toP

teRMination caP

flex feMale aDaPteR

2" (60MM) flex Gasket

2" (60MM) flex

teRMination Base

MountinG haRDwaRe

B Vent aDaPteR- uPPeR

B Vent PiPe

2" (60MM) flex Gasket

flex Male aDaPteR

MountinG haRDwaRe

B Vent aDaPteR- loweR

9

B Vent

aDaPteR-

loweR

flex Male

aDaPteR

B Vent PiPe

MountinG
haRDwaRe

flex

feMale

aDaPteR

B Vent

aDaPteR-

uPPeR

B Vent

PiPe

c suPPoRt
BRacket

Figure 13

Instructions- 3" (80mm) PP Flex in B Vent

1. Remove existing B Vent termination cap

2. Carefully feed ex down through B Vent so
approx 2' of ex extends beyond the bottom
of the B Vent (Flex puller or rope aid optional)

3. Cut to length the top of Flex pipe and
insert ex through B Vent Adapter- Upper

4. Install PP Flex Gasket and Flex Female
Adapter onto Flex pipe per instructions
detailed above

5. Lower B Vent Adapter- Upper to the top
of the B Vent and secure with screws (x3)
supplied

6. Install C Support Bracket as shown in Fig.14
and lower Flex Female Adapter into B Vent

Adapter- Upper

7. Attach Termination Top to Termination Cap
(clicks when engaged), insert 3" Rigid Pipe
into Termination Cap, and attach Termination
Insert into Termination Cap (clicks). Then
connect Termination Insert to Termination
Transition (click).

8. Line up inner pipe connections and push
termination assembly down onto B Vent
Adapter- Upper and secure with screws (x3)
provided

9. Cut Flex to length 3" below the bottom of
the B Vent

10. Install Flex Gasket and Flex Male Adapter
on Flex

11. Install B Vent Adapter- Lower. (Flex Male
Adapter should protrude beyond per Fig.13)

12. Secure B Vent Adapter- Lower to B Vent
with hardware provided

Figure 14

teRMination toP

teRMination caP

3" (80MM) RiGiD PiPe

teRMination inseRt

teRMination tRansition

c suPPoRt BRacket

B Vent aDaPteR- uPPeR

flex feMale aDaPteR

3" (80MM) flex Gasket
3" (80MM) flex

B Vent PiPe

3" (80MM) flex Gasket

flex Male aDaPteR

MountinG haRDwaRe
B Vent aDaPteR- loweR

Figure 15- (3" Flex / B Vent)

10

11

POLYPRO WARRANTY

M&G DuraVent, Inc. (“DuraVent”) provides this warranty for PolyPro® for ten years. Subject to the limitations set fort h below, DuraVent
warrants that its products will be free from defects in material or manufacturing, if properly installed, maintained and use d. DuraVent
product s are fully warranted if installe d only by a professional installer. This Warrant y is transferable from t he original homeowner to the
buyer of the home within the warranted ten years. This warranty does not cover normal wear and tear, smoke damage or damage caused
by chimney res, ac ts of God, or any product that was: (1) purchased other than from an authorized DuraVent dealer, retailer or distributor;
(2) modied or altered; (3) improperly serviced, inspec ted or cleaned; or (4) subject to negligence or any use not in accordance with the
installation ins tructions included with the product as deter mined by DuraVent.

Installation ins tructions are available online at w ww.duravent.com under Support/Literature and through our Cus tomer Service Department
800-835- 4429 or customerser [e-mail].

DuraVent provides the following warranties for PolyPro: One Hundred Percent (100%) MSRP 10 years from the date of purchase.

All warranty obligations of DuraVent shall be limited to repair or replacement of the defective pro duct pursuant to the terms and conditions
applicable to each pro duct line. These remedies shall constitute DuraVent’s sole obligation and sole remedy under this warranty. This
warranty provides no cash surrender value. The terms and conditions of this warranty may not be modie d, altered or waived by any action,
inaction or representation, whether or al or in writing, except upon the ex press, written author ity of an executive ocer of DuraVent.

This product is intended for venting only category IV appliances burning Nat ural Gas, Propane and Oil. All other fuels are not covered under
this warranty.

LIMITATIONS ON POLYPRO INTERNET SALES: Not withstanding any other terms or conditions of this PolyPro Warrant y, DuraVent provides no
warranty f or PolyPro® if it is not installed by a qualied professional installer.

DuraVent must be notied and given the opportunity to inspect defective product prior to replacement under the terms of this limited
lifetime warranty. All warranty claims must be submitted with pro of of purchase. Labor and installation costs are not covered under this
warranty. To obtain warranty service contac t: DuraVent Warranty Ser vice, 877 Cotting Ct., Vacaville CA 9568 8, or call 800-835-4429.

WHERE LAWFUL, DURAVENT DISCLAIMS ALL OTHER WARRANTIES, INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF
MERCHANTABILITY AND FIT NESS FOR A PARTICULAR PURPOSE. IN NO EVENT WILL DURAVENT BE LIABLE FOR INCIDENTAL, CONSEQUENTIAL,
PUNITIVE OR SPECIAL DAMAGES O R DIRECT OR INDIRECT LOSS OF ANY KIND, INCLUDING BUT N OT LIMITED TO PROPERTY DAMAGE AND
PERSONAL INJURY. DURAVENT’S ENTIRE LIABILITY IS LIMITED TO THE PURCHASE PRICE OF THIS PRODUCT. SOME STATES DO NOT ALLOW
LIMITATIONS ON IMPLIED WARRANTIES, OR THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE
LIMITATIONS AND EXCLUSIONS MAY NOT APPLY TO YOU. THIS LIMITED WARRANTY GIVE S YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO
HAVE OTHER RIGHTS THAT VARY FROM STATE TO STATE.

For the most up-to-date installation instructions, se e www. duravent.com

REV 3.22.2012

Customer Service Support 800-835-4429 707-446-4740 FAX www.duravent.com

PolyPro® and GreenVent® are registered trademarks of M&G DuraVent, Inc.
All rights reserved, ©2012 M&G DuraVent is a member of M&G Group.

9/2012 l272