LAARS NTV600 User Manual

Addendum to Instructions
Vent and Air Intake Lengths for use with
Laars Neotherm NTH600 & NTV600 Appliances
FOR YOUR SAFETY: This product must be installed and serviced by a professional service technician, qualified in hot water boiler installation and maintenance. Improper installation and/or operation could create carbon monoxide gas in flue gases which could cause serious injury, property damage, or death. Improper installation and/or operation will void the warranty. For indoor installations, as an additional measure of safety, Laars strongly recommends installation of suitable Carbon Monoxide detectors in the vicinity of this appliance and in any adjacent occupied spaces.
This Addendum applies to the following Document:
Models Affected Size Part No. Doc. No.
NeoTherm (NTH, NTV) 600 H2335500G Doc. 1218G
Change to Table 2. (page 11):
Description of Change: In the interest of continuing
product improvement and maintaining product reliability and safety, Laars has revised the allowable exhaust vent and combustion air intake lengths for the NTH600 and NTV600 boilers as follows:
4" diameter PVC, CPVC or stainless material is allowed in lengths up to 40 equivalent feet for each intake and vent section.
6" diameter PVC, CPVC or stainless material is allowed in lengths up to 100 equivalent feet for each intake and vent section with the following considerations:
For any combination of vent and intake lengths up to 40 equivalent feet, any even or uneven combination of length is allowed.
For overall lengths greater than 40 equivalent feet, the exhaust may be up to 20 feet greater than the intake length.
Example 1: If the exhaust is 40 equivalent feet, then the intake length can be zero, and as long as 40 equivalent feet.
Example 2: If the exhaust is 90 equivalent feet, then the intake length can be as little as 70 equivalent feet, and as long as 100 equivalent feet.
Example 3: If the exhaust is 50 equivalent feet, then the intake length can be as little as 30 equivalent feet, and as long as 100 equivalent feet.
INTAKE / EXHAUST
STANDARD MAX EQUIV. OPTIONAL MAX EQUIV.
SIZE VENT FT. M VENT FT. M
80 2" 40 6.1 3" 100 30.5 105 2" 40 6.1 3" 100 30.5 150 3" 100 30.5 n/a
199/210 3" 100 30.5 n/a
285 4" 100 30 n/a — 399 4" 100 30 n/a — 500 4" 100 30 n/a
*600* 4" 40 6.1 6" 100 30
750 4" 40 6.1 6" 100 30 850 4" 40 6.1 6" 100 30
Installations in the U.S. require exhaust vent pipe that is a combination of PVC & CPVC complying with ANSI/ASTM D1785 F441 or stainless steel complying with UL1738. Installations in Canada require exhaust vent pipe that is certified to ULC S636.
Intake (air) pipe must be PVC or CPVC that complies with ANSI/ASTM D1785 F441, ABS that complies with ANSI/ASTM D1527 or galvanized material.
Installer must comply fully with manufacturer's installation instructions, including use of minimum exhaust length CPVC, to maintain ANSI Z21.13 safety certification.
Closet and alcove installations do not allow the use of PVC under any circumstances
To calculate max equivalent length, measure the linear feet of the pipe, and add 5 feet (1.5m) for each elbow used.
For any combination of vent and intake lengths up to 40 equivalent feet,
*
any even or uneven combination of length is allowed. For overall lengths greater than 40 equivalent feet, the exhaust may be up to 20 feet greater than the intake length.
Table 2. Vent / Air Pipe Sizes.
Litho in U.S.A. © Laars Heating Systems 1109 H2350600-
Addendum to Instructions
Polypropylene Vent Material for use with
Laars NeoTherm and Mascot II Appliances
FOR YOUR SAFETY: This product must be installed and serviced by a professional service technician, qualified
in hot water boiler installation and maintenance. Improper installation and/or operation could create carbon monoxide gas in flue gases which could cause serious injury, property damage, or death. Improper installation and/ or operation will void the warranty. For indoor installations, as an additional measure of safety, Laars strongly recommends installation of suitable Carbon Monoxide detectors in the vicinity of this appliance and in any adjacent occupied spaces.
This Addendum applies to the following:
Models Affected Sizes Part No. Doc. No.
NeoTherm (NTH, NTV) 80-850 H2335500 1218
Mascot II (LMH, LMC) 125 H2338100A 1230
Description of Change: The use of polypropylene vent material has been accepted by CSA for use with exhaust and combustion on NeoTherm and Mascot II appliances. The polypropylene component manufacturer shall have ULC­S636 approval with a recognized listing agency for all components used in the venting system. All components used must be from the same manufacturer and designed for use with exhaust temperatures at or below 195°F (90°C).
Please reference the current edition of the appliance installation and operation instructions for proper vent sizing. Only approved pipe diameters, lengths, and, arrangements associated with the specific model size allowed.
The installer shall refer to the polypropylene component manufacturer's approved installation and application instructions for their specific assembly requirements.
800.900.9276 • Fax 800.559.1583 (Customer Service, Service Advisors)
20 Industrial Way, Rochester, NH 03867 • 603.335.6300 • Fax 603.335.3355 (Applications Engineering)
1869 Sismet Road, Mississauga, Ontario, Canada L4W 1W8 • 905.238.0100 • Fax 905.366.0130
www.Laars.com Litho in U.S.A. © Laars Heating Systems 1106
H2348400-
Installation and Operation Instructions Document 1218G
Installation and Operation Instructions for
®
NeoTherm
Modulating Boiler Model NTH
Sizes 080–850 MBTU/h
Water Heater Model NTV
Sizes 150–850 MBTU/h
FOR YOUR SAFETY: This product must be installed and serviced by a professional service technician, qualified in hot water boiler and heater installation and maintenance. Improper installation and/or operation could create carbon monoxide gas in flue gases which could cause serious injury, property damage, or death. Improper installation and/or operation will void the warranty.
WARNING
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 and liquids in the vicinity of this or any other appliance.
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 nearby phone. Follow the gas supplier's instructions.
• If you cannot reach your gas supplier, call the fire department.
Installation and service must be performed by a qualified installer, service agency, or gas supplier.
Assurez-vous de bien suivres les instructions données dans cette notice pour réduire au minimum le risque d’incendie ou d’explosion ou pour éviter tout dommage matériel, toute blessure ou la mort.
Ne pas entreposer ni utiliser d’essence ni d’autres vapeurs ou liquides inflammables dans le voisinage de cet appareil ou de tout autre appareil.
QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:
• Ne pas tenter d’allumer d’appareils.
• Ne touchez à aucun interrupteur. Ne pas vous servir des téléphones dansle bâtiment où vous vous trouvez.
• Appelez immédiatement votre fournisseur de gaz depuis un voisin. Suivez les instructions du fournisseur.
• Si vous ne pouvez rejoindre le fournisseur de gaz, appelez le sservice des incendies.
L’installation et l’entretien doivent être assurés par un installateur ou un service d’entretien qualifié ou par le fournisseur de gaz.
AVERTISSEMENT
H2335500G
Page 2
LAARS Heating Systems
TABLE OF CONTENTS
SECTION 1. General Information
1.1 Introduction...................................................... 4
1.2 Model Identification ......................................... 4
1.3 Appliance Overview......................................... 4
1.4 Warranty.......................................................... 9
1.5 Unpacking ....................................................... 9
1.6 Dimensions...................................................... 9
SECTION 2. Locating the Appliance
2.1 Locating the Appliance .................................. 11
2.2 Locating Appliance for Correct Vent Distance
from Outside Wall or Roof Termination ......... 11
Section 3. Venting and Combustion Air
3.1 Combustion Air .............................................. 12
3.1.1 Combustion Air From Room.......................... 12
3.1.2 Ducted Combustion Air ................................. 12
3.2 Venting .......................................................... 13
3.2.1 Venting Requirements Unique to Canada..... 14
3.3 Locating Vent & Combustion Air Terminals ... 14
3.3.1 Side Wall Vent Terminal................................ 14
3.3.2 Side Wall Combustion Air Terminal............... 15
3.3.3 Vertical Vent Terminal ................................... 15
3.3.4 Vertical Combustion Air Terminal .................. 15
3.3.5 Installations in the Commonwealth of
Massachusetts .............................................. 15
3.4 Common Vent Test ....................................... 17
Section 4. Gas Supply and Piping
4.1 Gas Supply and Piping .................................. 18
Section 5. Pump Requirements
5.1 NeoTherm Boiler Flow and
Head Requirements ...................................... 19
5.2 NeoTherm Water Heater
Flow and Head Requirements....................... 19
Section 6A. Water Connections -
6A.1 NTH System Piping: Hot Supply Connections . 20
6A.2 NTH Cold Water Make-Up ............................ 20
6A.3 Freeze Protection .......................................... 21
6A.4 NTH Suggested Piping Schematics .............. 21
6A.5 Recognized Chemicals.................................. 21
NTH Boiler
Section 6B. Water Connections -
6B.1 NTV Water Quality ........................................ 29
6B.2 Piping Requirements ..................................... 29
6B.3 Cold Water Make-Up..................................... 30
6B.4 Freeze Protection .......................................... 30
6B.5 NTV Suggested Piping Schematics............... 30
6B.6 NTV Suggested Pumps ................................. 30
NTV Water Heater
Section 7. Electrical Connections
7.1 Main Power ................................................... 32
7.2 Pump Connections ........................................ 33
7.3 24 Vac Transformer with Integral
Circuit Breaker............................................... 33
7.4 Hydronic Call for Heat ................................... 33
7.5 Outdoor Air Temperature Sensor .................. 33
7.6 Domestic Hot Water Connection ................... 33
7.7 System Sensor
(lead lag/cascading operation only)............... 33
7.8 External Control Connections........................ 33
7.9 Optional Field Connections ........................... 33
7.10 Lead lag/ Cascading Wiring Connections ..... 33
7.11 Wiring Diagrams ............................................ 35
Section 8. NeoTherm Control Setup and Operation
8.1 Display Navigation......................................... 37
8.2 Ignition Control - Sequence of Events ........... 37
8.3 Modulation Control ........................................ 38
8.4 Pump Control ................................................ 38
8.5 Anti-Short Cycle (ASC).................................. 38
8.5 High Limit ...................................................... 38
8.7 Outlet Water Temperature............................. 38
8.8 Inlet Water Temperature ............................... 38
8.9 Heat Exchanger Temperature Rise ............... 38
8.10 Stack Temperature........................................ 38
8.11 Domestic Hot Water Temperature................. 38
8.12 Lead Lag/Cascading ..................................... 38
8.12.1 Lead Lag Setpoint ......................................... 39
8.12.2 Lead Lag Master/Slave Selection.................. 39
8.12.3 Lead Lag Address ......................................... 39
8.12.4 Lead Lag Hysteresis...................................... 39
8.12.5 Lead Lag Base Load Setting ......................... 39
8.13 Boiler Pump Interrupt .................................... 39
NeoTherm Boilers and Water Heaters
Page 3
SECTION 9. Modes of Operation
9.1 Hydronic Heating Demand ............................ 40
9.2 Hydronic Heating with Outdoor Reset ........... 40
9.3 Hydronic Heating with Domestic Hot
Water (DHW) Priority..................................... 40
9.4 Hydronic Heating Using External
Modulation Control ........................................ 40
9.5 Hydronic Heating Using Local Lead-Lag/
Cascading Feature........................................ 41
9.6 Hydronic Heating Using Local Lead-Lag/ Cascading Feature with Indirect Hot Water... 41
9.7 Warm Weather Shutdown ............................. 41
9.8 Domestic Hot Water Demand (NTV only)...... 41
9.9 Domestic Hot Water Heating Using
External Modulation Control .......................... 42
9.10 Domestic Hot Water Heating Using Local
Lead-Lag/Cascading Feature........................ 42
Section 10. Operating Instructions
10.1 Filling the Boiler System ................................ 43
10.2 Operating the Burner and Set Up .................. 43
10.2.1 Burner Operation........................................... 43
10.2.2 Boiler Setup and Adjustment......................... 44
10.3 Shutting Down NeoTherm ............................. 44
10.4 To Restart NeoTherm.................................... 44
SECTION 11. Maintenance
11.1 System Maintenance ..................................... 46
11.2 Appliance Maintenance and Component
Description .................................................... 46
11.2.1 Burner............................................................ 46
11.2.2 Modulating Gas Valve / Venturi ..................... 46
11.2.3 Appliance Control .......................................... 46
11.2.4 Ignitor Assembly............................................ 47
11.2.5 Flame Sensor ................................................ 47
11.2.6 Transformer with Integral Circuit Breaker...... 48
11.2.7 Blower ........................................................... 48
11.2.8 Heat Exchanger Coils.................................... 48
11.2.9 Gas Pressure Switches (optional) ................. 49
11.2.10 Gas Conversion ............................................. 49
Section 12. Trouble Shooting
12.1 Sequence of Operation ................................. 49
12.2 Short Cycling ................................................. 49
12.3 Error Codes ................................................... 49
Section 13. Replacement Parts
13.1 General Information....................................... 52
13.2 Parts List ....................................................... 52
Page 4
LAARS Heating Systems
SECTION 1. General Information
WARNING
NeoTherm units must be installed in accordance with the procedures detailed in this manual, or the LAARS Heating Systems warranty will be voided. The installation must conform to the requirements of the local jurisdiction having authority, and, in the United States, to the latest edition of the National Fuel Gas Code, ANSI Z223.1/NFPA54. In Canada, the installation must conform to the latest edition of CSA B149.1 Natural Gas and Propane Gas Installation Code, and/or local codes. Where required by the authority having jurisdiction, the installation of NeoTherm boilers must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1. Any modifications to the boiler, its gas controls, or wiring may void the warranty. If field conditions require modifications, consult the factory representative before initiating such modifications.
1.1 Introduction
This manual provides information necessary for the installation, operation, and maintenance of LAARS Heating Systems NeoTherm appliances. Read it carefully before installation.
All application and installation procedures should be reviewed completely before proceeding with the installation. Consult the LAARS Heating Systems factory, or local factory representative, with any problems or questions regarding this equipment. Experience has shown that most operating problems are caused by improper installation.
NeoTherm is protected against over pressurization. A pressure relief valve is included with each NeoTherm. Some NeoTherms may require that the PRV be installed prior to filling the system. Refer to Figures 1-7 for PRV locations.
IMPORTANT: The inlet gas pressure to the appliance must not exceed 13" W.C. (3.2kPa).
All installations must be made in accordance with
1) American National Standard Z223.1/NFPA54-Latest Edition “National Fuel Gas Code” or 2) CSA B149.1 “Natural Gas and Propane Installation Code” and with the requirement of the local utility or other authorities having jurisdiction. Such applicable requirements take precedence over the general instructions contained herein.
All electrical wiring is to be done in accordance with the local codes, or in the absence of local codes, with: 1) The National Electrical Code ANSI/NFPA No. 70-latest Edition, or 2) CSA STD. C22.1 “Canadian Electrical Code - Part 1”. This appliance must be electrically grounded in accordance with these codes.
1.2 Model Identification
Consult the rating plate on the unit. The following information describes the model number structure.
(1-2) Model Series Designation
N T = NeoTherm
(3) Usage
H = Hydronic V = Volume Water
(4-6) Size
0 8 0 = 80,000 BTU/hr input 1 0 5 = 105,000 BTU/hr input 1 5 0 = 150,000 BTU/hr input 1 9 9 = 199,000 BTU/hr input 2 1 0 = 210,000 BTU/hr input 2 8 5 = 285,000 BTU/hr input 3 9 9 = 399,000 BTU/hr input 5 0 0 = 500,000 BTU/hr input 6 0 0 = 600,000 BTU/hr input 7 5 0 = 750,000 BTU/hr input 8 5 0 = 850,000 BTU/hr input
(7) Fuel
N = Natural Gas P = LP Gas
(8) Options Code
X = Standard Unit J = CSD-1, FM, GAP, IL Code
(9) Pump Options
N = Pump included X = No pump (configuration available for all sizes)
(10) Revision
2 = Second version
(80-500 only)
(size 500-850 only)
1.3 Appliance Overview
See Figures 1 through 7.
Model Nomenclature
12 3 456 7 8 9 10 NT H 2
SERIES
N T
USAGE
H - HYDRONIC V - VOLUME
WATER
SIZE
MBTU/h
0 8 0 1 0 5 1 5 0 1 9 9 2 1 0 2 8 5 3 9 9 5 0 0 6 0 0 7 5 0 8 5 0
FUEL
N - NATURAL P - PROPANE
OPTIONS CODE
X - STANDARD J - CSD-1,
FM, GAP,
(500-850 only)
IL
PUMP OPTIONS
N - PUMP INCL.
(80-500 only)
X - NO PUMP
REVISION
2 - SECOND
NeoTherm Boilers and Water Heaters
Page 5
Figure 1. Location of Components, Sizes 80–105.
Figure 2. Location of Components, Sizes 150-210.
Page 6
LAARS Heating Systems
Figure 3. Location of Components, Size 285.
Figure 4. Location of Components, Size 399.
NeoTherm Boilers and Water Heaters
Page 7
Figure 5. Location of Components, Size 500.
Figure 6. Location of Components, Size 600.
Page 8
LAARS Heating Systems
Figure 7. Location of Components, Sizes 750 and 850.
NeoTherm Boilers and Water Heaters
Page 9
1.4 Warranty
LAARS Heating Systems’ NeoTherm appliances
are covered by a limited warranty. The owner should complete the warranty registration at www.Laars.com.
All warranty claims must be made to an authorized LAARS Heating Systems representative. Claims must include the serial number and model (this information can be found on the rating plate), installation date, and name of the installer. Shipping costs are not included in the warranty coverage.
Some accessory items may be shipped in separate packages. Verify receipt of all packages listed on the packing slip. Inspect everything for damage immediately upon delivery, and advise the carrier of any shortages or damage. Any such claims should be filed with the carrier. The carrier, not the shipper, is
responsible for shortages and damage to the shipment whether visible or concealed.
1.5 Unpacking
The NeoTherm is shipped in a single crate with the following standard components packed with the appliance (see Figure 8):
A. exhaust vent terminal
(US only)
B. air intake terminal
C. temperature/pressure gauge kit
D. circulator pump/wire harness
(units with pump)
E. CPVC exhaust pipe section (80-500) (US only)
F. outdoor/system sensor kit
G. flow switch kit
(399-850)
H. alternate size vent/terminal screens
J. exhaust vent adapter CPVC/ST ST
(750-850)
K. 4x6 PVC adapter with 4x7 PVC pipe section
(750-850) (not to be used on exhaust in Canada)
1. Remove all packing and tie-down materials.
2. Check contents of the carton against items shown.
1.6 Dimensions
Dimensions are shown in Figure 9.
Figure 8. Contents of Shipping Package.
Page 10
LAARS Heating Systems
W L H AIR INLET VENT
SIZE IN CM IN CM IN CM IN CM IN CM
80 25 64 19½ 49 38¼ 97 2 5.1 2 5.1 105 25 64 19½ 49 38¼ 97 2 5.1 2 5.1 150 25 64 19½ 49 38¼ 97 3 7.6 3 7.6
199/210 25 64 26¾ 68 38¼ 97 3 7.6 3 7.6
285 25 64 26¾ 68 38¼ 97 11 11 399 25 64 31½ 80 38¼ 97 11 11 500 25 64 37¾ 96 38¼ 97 11 11 600 25 64 37¾ 96 38¼ 97 11 11 750 25 64 51 130 38¼ 97 11 17 850 25 64 55¼ 130 38¼ 97 11 17
Dimensions are nominal and are shown in inches, cm.
NeoTherm is shipped with adapters for the air and vent that accept
*
standard pipe of the proper size and type.
AB CD E F G J K MN
SIZE IN CM IN CM IN CM IN CM IN CM IN CM IN CM IN CM IN CM IN CM IN CM
80 NTH 13½ 34 24 18¼ 46 19 10¾ 28 11¾ 30 13¾ 35 21 53 10¾ 27 15¼ 39 13 33 105 NTH 13½ 34 8 21 18¼ 46 6 16 10¾ 28 11¾ 30 14¼ 36 21 53 22 15¼ 39 13 33 150 NTH 13¼ 34 14 18¼ 46 8 10¾ 28 19 14¼ 36 19½ 49 19 15¼ 39 13 33 150 NTV 13¼ 34 14 19 48 8 10¾ 28 19 14¼ 36 19½ 49 19 15¼ 39 13 33 210 NTH 20½ 52 14 18¼ 46 8 17¾ 45 19 14¼ 36 19½ 49 11¾ 30 15¼ 39 13 33 199 NTV 20½ 52 14 19 48 8 17¾ 45 19 14¼ 36 19½ 49 11¾ 30 15¼ 39 13 33 285 NTH 20¼ 52 19 19¼ 49 16 11¼ 29 13½ 34 14 36 15 38 17 43 18¾ 48 13 33 285 NTV 20¼ 52 19 19¾ 50 16 11¼ 29 13½ 34 14 36 15 38 17 43 18¾ 48 13 33 399 NTH 25 64 13 19¼ 49 11 14¾ 37 18½ 47 19¼ 49 16½ 42 21¾ 55 18¾ 48 13 33 399 NTV 25 64 13 19¾ 50 11 14¾ 37 18½ 47 19¼ 49 16½ 42 21¾ 55 18¾ 48 13 33 500 NTH 30¼ 77 13 19½ 50 11 15¼ 38 20 51 20½ 52 19 48 26 66 18¾ 48 13 33 500 NTV 30¼ 77 13 19¾ 50 11 15¼ 38 20 51 20½ 52 19 48 26 66 18¾ 48 13 33 600 (both) 29¾ 76 5 13 19½ 50 11 15 38 20 51 3 8 19 48 26 66 18¾ 48 21 750 (both) 35½ 90 6 15 19½ 50 13 19 48 40½ 103 8 19 48 30¾ 78 18¾ 48 21
(both) 39¾ 101 6 15 19½ 50 13 19 48 44¾ 114 9 19 48 35 89 18¾ 48 21
850
Figure 9. Dimensional Drawing, Sizes 80-500.
NeoTherm Boilers and Water Heaters
SECTION 2. Locating the Appliance
Page 11
2.1 Locating the Appliance
NeoTherm is for indoor installations only.
The appliance should be located to provide clearances on all sides for maintenance and inspection. It should not be located in an area where leakage of any connections will result in damage to the area adjacent to the appliance or to lower floors of the structure.
When such a location is not available, it is recommended that a suitable drain pan, adequately drained, be installed under the appliance.
The appliance is design certified by CSA­International for installation on combustible flooring; in basements; in closets, utility rooms or alcoves.
NeoTherm Boilers must never be installed on carpeting. The location for the appliance should be
chosen with regard to the vent pipe lengths and external plumbing and on a level surface. The unit shall be installed such that the gas ignition system components are protected from water (dripping, spraying, rain, etc.) during operation and service (circulator replacement, control replacement, etc.). When vented vertically, the NeoTherm must be located as close as practical to the vertical section of the vent. If the vent terminal and/or combustion air terminal terminate through a wall, and there is potential for snow accumulation in the local area, both terminals should be installed at an appropriate level above grade or the maximum expected snow line.
The dimensions and requirements that are shown in Table 1 should be met when choosing the locations for the appliance.
2.2 Locating Appliance for Correct Vent
Distance from Outside Wall or
Roof Termination
The forced draft combustion air blower in the appliance has sufficient power to vent properly when the guidelines in Table 2 are followed.
NOTE: When located on the same wall, the NeoTherm combustion air intake terminal must be installed a minimum of 12" below the exhaust terminal.Models 399­850 also require a minimum horizontal distance from intake to exhaust terminal of 36".
For concentric vent terminal kit (optional), follow installation instructions included with the kit.
APPLIANCE SURFACE INCHES CM
Left Side 1 2.5 Right Side 12 31 Top 24 61 Back 6 15 Closet, Front (285-500) 6 15 Alcove, Front (285-500) 24 61 Front (600-850) 24 61 Vent
Certified by CSA for zero clearance to
STANDARD MAX EQUIV. OPTIONAL MAX EQUIV.
SIZE VENT FT. M VENT FT. M
80 2" 40 6.1 3" 100 30.5 105 2" 40 6.1 3" 100 30.5 150 3" 100 30.5 n/a
199/210 3" 100 30.5 n/a
285 4" 100 30 n/a — 399 4" 100 30 n/a — 500 4" 100 30 n/a — 600 4" 100 30 n/a — 750 4" 40 6.1 6" 100 30 850 4" 40 6.1 6" 100 30
Installations in the U.S. require exhaust vent pipe that is a combination of PVC & CPVC complying with ANSI/ASTM D1785 F441 or stainless steel complying with UL1738. Installations in Canada require exhaust vent pipe that is certified to ULC S636.
Intake (air) pipe must be PVC or CPVC that complies with ANSI/ASTM D1785 F441, ABS that complies with ANSI/ASTM D1527 or
galvanized material.
Installer must comply fully with manufacturer's installation instructions, including use of minimum exhaust length CPVC, to maintain ANSI Z21.13 safety certification.
Closet and alcove installations do not allow the use of PVC under any circumstances
To calculate max equivalent length, measure the linear feet of the pipe, and add 5 feet (1.5m) for each elbow used.
SUGGESTED SERVICE ACCESS CLEARANCE
combustible materials on all sides.
Table 1. Clearances.
INTAKE / EXHAUST
Table 2. Vent / Air Pipe Sizes.
Page 12
LAARS Heating Systems
SECTION 3. Venting and Combustion Air
3.1 Combustion Air
NeoTherm boilers and water heaters must have provisions for combustion and ventilation air in accordance with the applicable requirements for Combustion Air Supply and Ventilation in the National Fuel Gas Code, ANSI Z223 1; or in Canada, the Natural Gas and Propane Installation Code, CSA B149.1. All applicable provisions of local building codes must also be adhered to.
A NeoTherm unit can take combustion air from the space in which it is installed, or the combustion air can be ducted directly to the unit. Ventilation air must be provided in either case.
3.1.1 Combustion Air From Room
In the United States, the most common requirements specify that the space shall communicate with the outdoors in accordance with method 1 or 2, which follow. Where ducts are used, they shall be of the same cross-sectional area as the free area of the openings to which they connect.
HORIZONTAL INTAKE AND EXHAUST PVC VENT TERMINAL KITS
2" PVC 3" PVC 4" PVC 6" PVC
SIZE
105 included optional optional optional n/a n/a 150 n/a n/a included optional n/a n/a
199/ 210 n/a n/a included optional n/a n/a
285 n/a n/a optional optional included n/a 399 n/a n/a n/a n/a included n/a 500 n/a n/a n/a n/a included n/a 600 n/a n/a n/a n/a included optional 750 n/a n/a n/a n/a n/a included 850 n/a n/a n/a n/a n/a included
Concentric vent terminal = 10 ft. pipe length.
Standard Concentric Standard Concentric Standard Standard
CA006000 CA005900 239-44069-01
80 included optional optional optional n/a n/a
Table 3a. PVC Vent Terminal Kits.
Method 1: Two permanent openings, one
commencing within 12" (300mm) of the top and one commencing within 12" (300mm) of the bottom, of the enclosure shall be provided. The openings shall communicate directly, or by ducts, with the outdoors or spaces that freely communicate with the outdoors. When directly communicating with the outdoors, or when communicating to the outdoors through vertical ducts, each opening shall have a minimum free area of 1 square inch per 4000 Btu/hr (550 square mm/kW) of total input rating of all equipment in the enclosure. When communicating to the outdoors through horizontal ducts, each opening shall have a minimum free area of not less than 1 square inch per 2000 Btu/hr (1100 square mm/kW) of total input rating of all equipment in the enclosure.
Method 2: One permanent opening, commencing
within 12" (300mm) of the top of the enclosure, shall be permitted. The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces that directly communicate with the outdoors and shall have a minimum free area of 1 square inch per 3000 Btu/hr (734 square mm/kW) of the total input rating of all equipment located in the enclosure. This opening must not be less than the sum of the areas of all vent connectors in the confined space.
Other methods of introducing combustion and ventilation air are acceptable, providing they conform to the requirements in the applicable codes listed above.
In Canada, consult local building and safety codes or, in absence of such requirements, follow CAN/CGA B149.
3.1.2 Ducted Combustion Air
The combustion air can be taken through the wall, or through the roof. When taken from the wall, it must be taken from out-of-doors by means of the LAARS horizontal wall terminal, shown in Table(s) 3. See Table 2 to select the appropriate diameter air pipe. When taken from the roof, a field-supplied rain cap or an elbow arrangement must be used to prevent entry of rain water (see Figure10).
SIZE Boiler Flue Intake Air Boiler Intermediate Flue Intake Air Boiler Flue Intake Air
399-600 F303759 750-850
MATERIAL UNITED STATES CANADA
ABS ANSI/ASTM D1527
PVC, sch 40 ANSI/ASTM D1785 or D2665
CPVC, sch 40 ANSI/ASTM F441
Single wall galv. steel 26 gauge
PRO TECH (FasNSeal) HEAT FAB (Saf-T-Vent) Z FLEX (Z-Vent)
Adapter Termination Termination Adapter Adapter Termination Termination Adapter Termination Termination
F303759
(intake only)
FSBS4 FSAIH04
FSRC4(R.C) 303888 5400CI 2SVSRCX04
FSBS6
FSAIH04
303888 Table 3b. Approved Stainless Steel Terminations and Adapters.
Table 4. Required Combustion Air Pipe Material.
KB285600 9454BUREZ-1*
INSTALLATION STANDARDS
9492
9414TERM 2SVSLA04
Air pipe material must be chosen
based upon the intended application of the boiler.
2SVSTP04
2SVSTEX0490
NeoTherm Boilers and Water Heaters
Page 13
Use ABS, PVC, CPVC or galvanized pipe for the combustion air intake (see Table 4), sized per Table 2. Route the intake to the boiler as directly as possible. Seal all joints. Provide adequate hangers. The unit must not support the weight of the combustion air intake pipe. Maximum linear pipe length allowed is shown in Table 2. Subtract 5 allowable linear ft. (1.5m) for every elbow used.
The connection for the intake air pipe is at the top of the unit (see Figure 9a or Figure 9b).
In addition to air needed for combustion, air shall also be supplied for ventilation, including air required for comfort and proper working conditions for personnel.
3.2 Venting
WARNING
Failure to use CPVC or stainless steel venting for the first 20" (285-600) / 30" (80-210) of vent material or for any part of the venting that is installed inside a closet may lead to property damage, personal injury or death. The proper length of this material is supplied with boiler. Boilers in U.S. may use pipe included with boiler.
WARNING
Failure to use the appropriate vent material, installation techniques, glues/sealants could lead to vent failure causing property damage, personal injury or death.
The unit’s vent can terminate through the roof, or
through an outside wall.
When using PVC/CPVC for vent material, venting must be connected to the CPVC section included with NeoTherm sizes 80-600. The CPVC vent section included with the NeoTherm may be broken by CPVC fittings if necessary, but never reduced in total length. See Table 2 to select the appropriate vent pipe diameter. Vent pipe must pitch upward, toward the vent terminal, not less than 1/4" per foot, so that condensate will run back to the NeoTherm to drain. Route vent pipe to the heater as directly as possible. Seal all joints and provide adequate hangers as required in the venting system manufacturer’s Installation Instructions. Horizontal portions of the venting system must be supported to prevent sagging and may not have any low sections that could trap condensate. The unit must not support the weight of the vent pipe. Please see Table 2 for proper diameter vs. length allowed.
IMPORTANT NOTE ABOUT COMMON VENTING: A single vent that is shared by multiple NeoTherm units MUST be engineered by a competent venting specialist, and involves the selection of draft inducing equipment, hardware and controls to properly balance flue gas pressures. Do not common vent NeoTherm
WARNING
All venting must be installed according to this manual and any other applicable local codes, including but not limited to, ANSI Z223.1/NFPA 54, CSA B149.1, CSAB149.2 and ULC-S636. Failure to follow this manual and applicable codes may lead to property damage, severe injury, or death.
The flue temperature of the NeoTherm changes dramatically with changes in operating water temperature. Therefore, it is necessary to assess the application of the boiler to determine the required certified vent class. If the NeoTherm is installed in an application where the ambient temperature is elevated, and/or installed in a closet/alcove, CPVC or stainless steel material is required. If the system temperatures are unknown at the time of installation, class IIB or higher venting material is recommended.
The NeoTherm is a Category IV appliance and may be installed with PVC and CPVC that complies with ANSI/ASTM D1785 F441, or a stainless steel venting system that complies with UL 1738 Standard (see Table 5).
Figure 10. Combustion Air and Vent Through Roof.
INSTALLATION STANDARDS
MATERIAL UNITED STATES CANADA
Stainless Steel UL 1738
PVC, sch 40 ANSI/ASTM D178 venting material. The venting material must be chosen
CPVC, sch 40 ANSI/ASTM F441
Table 5. Required Exhaust Vent Material.
Venting must be ULC-S636 certified for use as
based upon the intended application of the boiler.
Page 14
LAARS Heating Systems
units unless the vent system meets this requirement. NeoTherm units are never permitted to share a vent with Category I appliances.
A condensate drain trap is built into NeoTherm.
Connect a 3/4" PVC pipe between the drain connection and a floor drain (or condensate pump if a floor drain is not accessible).
The condensate drain must be installed so as to prevent accumulation of condensate. When a con­densate pump is not used, the tubing must continuously slope downward toward the drain with no spiraling.
Consult local codes for disposal method.
Caution
Condensate is mildly acidic (pH some floor drains and/or pipes, particularly those that are metal. Ensure that the drain, drainpipe, and anything that will come in contact with the condensate can withstand the acidity, or neutralize the condensate before disposal. Damage caused by
failure to install a neutralizer kit or to adequately treat condensate will not be the manufacturer’s responsibility.
..
.5), and may harm
..
3.2.1 Venting Requirements Unique to Canada
NeoTherm boilers and water heaters are Vent Category IV appliances. Per the requirements of CAN/ CSA-B149.1, only BH vent systems can be connected to these units and such vent systems, either ULC S636 certified stainless steel or other ULC S636 certified BH vent (eg. plastics) must be installed per the vent manufacturer's certified installation instructions.
As a result, two items listed in the Unpacking section (Figure 8) are
not included with NeoTherm
units for Canada (underlined):
A. exhaust vent terminal (not included)
B. air intake terminal
C. temperature/pressure gauge kit
D. circulator pump/wire harness (units with pump)
E. CPVC exhaust pipe section (80-500) (not incl.)
F. outdoor/system sensor kit
G. flow switch kit (399-850)
H. alternate size vent/terminal screens
J. exhaust vent adapter CPVC/ST ST (750-850)
It is the responsibility of the appropriately licensed technician installing this NeoTherm unit to use ULC S636 certified vent material consistent with the requirements as described in the Venting and Combustion Air section.
IMPORTANT! It is also the responsibility of the installer to ensure that a flue gas sampling port is installed in the vent system. This flue gas sampling port must be installed near the flue connection of the NeoTherm unit: within 2 feet of the flue connection. There is no flue gas sampling port internal to the
NeoTherm, so one must be installed in the vent system external to the NeoTherm unit. A flue gas sampling port available as a component of the ULC S636 certified vent system is preferred. However, if one is not available with the certified vent system, Laars suggests using a tee with the branch connection sized to allow for insertion of a flue gas analyzer probe. The branch connection must be resealable with a cap or other by other means to ensure the vent system remains sealed
(Figure 11).
Consideration must be given to the placement and orientation of the flue gas sampling port to ensure that condensate is free to flow back into the NeoTherm unit and not collect anywhere in the vent system - including in the flue gas sampling port.
An exhaust vent terminal must be installed. If an exhaust vent terminal is not available with the certified vent system, Laars suggests the use of a coupler fitting from the certified vent system into which the vent terminal screen, included with the NeoTherm and shown in the Unpacking section of the NeoTherm Installation & Operating Instructions, be installed. Be sure to install and terminate both vent and combustion air pipes per the Venting and Combustion Air section of the NeoTherm instructions.
3.3 Locating Vent & Combustion Air
Terminals
3.3.1 Side Wall Vent Terminal
The appropriate Laars side wall vent terminal must be used. The terminal must be located in accordance with ANSI Z223.1/NFPA 54 and applicable local codes. In Canada, the installation must be in accordance with CSA B149.1 or .2 and local applicable codes. Consider the following when installing the terminal:
Figure 11. Test Port.
NeoTherm Boilers and Water Heaters
Page 15
1. Figure 12 shows the requirements for mechanical vent terminal clearances for the U.S. and Canada.
2. Vent terminals for condensing appliances or appliances with condensing vents are not permitted to terminate above a public walkway, or over an area where condensate or vapor could create a nuisance or hazard.
3. Locate the vent terminal so that vent gases cannot be drawn into air conditioning system inlets.
4. Locate the vent terminal so that vent gases cannot enter the building through doors, windows, gravity inlets or other openings. Whenever possible, avoid locations under windows or near doors.
5. Locate the vent terminal so that it cannot be
blocked by snow. The installer may determine that a vent terminal must be higher than the minimum shown in codes, depending upon local conditions.
6. Locate the terminal so the vent exhaust does not settle on building surfaces or other nearby objects. Vent products may damage surfaces or objects.
7. If the boiler or water heater uses ducted combustion air from an intake terminal located on the same wall, see Figures 12-14 for proper spacing and orientation.
If the vent termination is located in an area
exposed to high winds, an optional PVC tee (the same diameter as the vent pipe) may be used. The tee'd vent termination offers greater protection from wind related operating issues.
3.3.2 Side Wall Combustion Air Terminal
The LAARS side wall combustion air terminal, or
concentric terminal (see Table 3), must be used when the heater takes air from a side wall. Contact Laars for AL29-4C termination fittings. Consider the following when installing the terminal (see Figures 12-14):
1. Do not locate the air inlet terminal near a source of corrosive chemical fumes (e.g., cleaning fluid, chlorine compounds, etc.)
2. Locate the terminal so that it will not be subject to damage by accident or vandalism. It must be at least 7 feet (2.1m) above a public walkway.
3. Locate the combustion air terminal so that it cannot be blocked by snow. The National Fuel Gas Code requires that it be at least 12 inches (30cm) above grade, but the installer may determine it should be higher, depending upon local conditions.
4. If the NeoTherm is side-wall vented to the same wall, locate the vent terminal at least 1 foot (0.3m) above the combustion air terminal.
5. For concentric vent, follow instructions
included with vent kit.
6. Multiple vent kits should be installed such that the horizontal distance between outlet group and inlet group is 36" (90cm) (see Figure 13).
7. Vent outlet for models 80-285 must be no lower than the center of the air inlet, and must be at least
12" (30cm) away from the air inlet. Vent outlets for models 399-850 must be at least 12" above the top of the air inlet, and must be at least 36" (90cm) horizontally from the air inlet (see Figure 14).
3.3.3 Vertical Vent Terminal
When the unit is vented through the roof, the vent must extend at least 3 feet (0.9m) above the point at which it penetrates the roof. It must extend at least 2 feet (0.6m) higher than any portion of a building within a horizontal distance of 10 feet (3.0m), and high enough above the roof line to prevent blockage from snow. The vent terminal included with the NeoTherm can be used in both vertical and horizontal applications. When the combustion air is taken from the roof, the combustion air must terminate at least 12" (30cm) below the vent terminal (see Figure 11).
3.3.4 Vertical Combustion Air Terminal
When combustion air is taken from the roof, a field-supplied rain cap or an elbow arrangement must be used to prevent entry of rain water (see Figure 11). The opening on the end of the terminal must be at least 12" (30cm) above the point at which it penetrates the roof, and high enough above the roof line to prevent blockage from snow. When the vent terminates on the roof, the combustion air must terminate at least 12" (30cm) below the vent terminal.
3.3.5 Installations in the Commonwealth of Massachusetts
In Massachusetts the following items are required if the side-wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches. From Massachusetts Rules and regulations 248 CMR 5.08
1. Installation of Carbon Monoxide Detectors
At the time of installation of the side wall vented gas fueled appliance, the installing plumber or gas­fitter shall observe that a hard-wired carbon monox­ide detector with an alarm battery back-up is instal­led on the floor level where the gas appliance is to be installed. In addition, the installing plumber or gasfitter shall observe that a battery operated or hard-wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side-wall hori­zontally vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for in­stallation of hard-wired carbon monoxide detectors. a. In the event that the side-wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard-wired carbon monoxide with alarm and battery back-up may be installed on the next adjacent floor level. b. In the event that the requirements of the subdivi­sion cannot be met at the time of completion of installation, the owner shall have a period of thirty
Page 16
U.S. Installations (see note 1) Canadian Installations (see note 2)
A= Clearance above grade, veranda, porch, 12 inches (30 cm) 12 inches (30 cm)
deck, or balcony See note 6 See note 6
B= Clearance to window or door that may be Direct vent only: 12 inches (30cm); 36 inches (91 cm)
opened Other than Direct vent: 4 ft (1.2m) below or to
side of opening; 1 ft (30cm) above opening
C= Clearance to permanently closed window See note 4 See note 5 D= Vertical clearance to ventilated soffit located
above the terminal within a horizontal See note 4 See note 5 distance of 2 feet (61cm) from the center line of the terminal
E= Clearance to unventilated soffit See note 4 See note 5 F= Clearance to outside corner See note 4 See note 5 G= Clearance to inside corner See note 4 See note 5 H= Clearance to each side of center line 3 feet (91 cm) within a height 15 feet
extended above meter/regulator assembly See note 4 above the meter/regulator assembly
I= Clearance to service regulator vent outlet See note 4 3 feet (91 cm) J= Clearance to nonmechanical air supply Direct vent only: 12" (30cm) 80-285; 36" (91cm)
inlet to building or the combustion air inlet 399-850. Other than Direct vent: 4 ft (1.2m) below 36 inches (91 cm) to any other appliance or to side of opening; 1 ft (30cm) above opening
K= Clearance to a mechanical air supply inlet 3 feet (91 cm) above if within 10 feet (3 m) 6 feet (1.83 m)
horizontally
L= Clearance above paved sidewalk or paved Vent termination not allowed in this location Vent termination not allowed in this
driveway located on public property for category IV appliances. location for category IV appliances.
M= Clearance under veranda, porch, deck, See note 4 12 inches (30 cm) (see note 3)
or balcony
Notes:
1. In accordance with the current ANSI Z223.1 / NFPA 54 National Fuel Gas Code.
2. In accordance with the current CAN/CGA-B149 Installation Codes.
LAARS Heating Systems
3. Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.
4. For clearances not specified in ANSI Z223.1 / NFPA 54, clearance is in accordance with local installation codes and the requirements of the gas supplier.
5. For clearances not specified in CAN/CGA-B149, clearance is in accordance with local installation codes and the requirements of the gas supplier.
6. IMPORTANT: terminal must be placed such that it remains a minimum 12" above expected snow line. Local codes may have more specific requirements, and must be consulted.
Figure 12. Combustion Air and Vent Through Side Wall.
*When vent terminal is less than 10 feet (3m) horizontally from a forced air inlet, the terminal must be at least 3 feet (0.9m) above the air inlet.
NeoTherm Boilers and Water Heaters
Figure 13. Multiple Side-Wall Terminals, Air and Vent.
(30) days to comply with the above requirements, provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm be installed.
2. Approved Carbon Monoxide Detectors
Each carbon monoxide detector shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.
3. Signage
A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for horizontally vented gas fueled heating appliance or
Page 17
equipment. The sign shall read, in print no less than one-half (1/2) inch in size: "GAS VENT DI­RECTLY BELOW, KEEP CLEAR OF ALL OBSTRUCTIONS".
4. Inspection
The state or local gas inspector of the side-wall horizontally vented gas fueled appliance shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a) 1-4.
3.4 Common Vent Test
NOTE: This section does not describe a method for
common venting NeoTherm units. It describes what must be done when a unit is removed from a common vent system. NeoTherm units require special vent systems and fans for common vent. Contact the factory if you have questions about common venting NeoTherm units.
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, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not 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 there is no blockage or restriction, leakage, corrosion and other
Figure 14. Minimum Venting Distance.
Page 18
LAARS Heating Systems
deficiencies which could cause an unsafe condition.
3. Insofar as it 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 appliance 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 in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so 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.
7. Any improper operation of the common venting system should be corrected so that the installation conforms to the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CSA B149.1, Installation Codes. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as deter­mined using the appropriate tables and guidelines in the National Fuel Gas Code, ANSI Z223.1 NFPA 54 and/or CSA B149.1, Installation Codes.
SECTION 4. Gas Supply and Piping
4.1 Gas Supply and Piping
Gas piping should be supported by suitable
hangers or floor stands, not the appliance.
Review the following instructions before
proceeding with the installation.
1. Verify that the appliance is fitted for the proper type of gas by checking the rating plate. NeoTherm will function properly without the use of high altitude modification at elevations up to 10,000 feet (3050 m).
2. The maximum inlet gas pressure must not exceed 13" W.C. (3.2kPa). The minimum inlet gas pressure is 4" W.C. (1.0kPa).
3. Refer to Tables 6A, 6B, 6C and 6D to size piping.
4. Run gas supply line in accordance with all applicable codes.
5. Locate and install manual shutoff valves in accordance with state and local requirements.
6. A sediment trap must be provided upstream of the gas controls.
7. All threaded joints should be coated with piping compound resistant to action of liquefied petroleum gas.
8. The appliance and its individual shutoff valve must be disconnected from the gas supply piping during any pressure testing of that system at test pressures in excess of 1/2 PSIG (3.45kPa).
9. The unit must be isolated from the gas supply system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 PSIG (3.45kPa).
10. The appliance and its gas connection must be leak tested before placing it in operation.
11. Purge all air from gas lines.
WARNING:
Open flame can cause gas to ignite and result in property damage, severe injury, or loss of life.
NOTE: The NeoTherm appliance and all other gas appliances sharing the gas supply line must be firing at maximum capacity to properly measure the inlet supply pressure. The pressure can be measured at the supply pressure port on the gas valve. Low gas pressure could be an indication of an undersized gas meter, undersized gas supply lines and/or an obstructed gas supply line. Some NeoTherm units are equipped with low and high gas pressure switches that are integrally vent limited. These types of devices do not require venting to atmosphere.
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