Lennox GWM-050IE, GWM-075IE, GWM-100IE, GWM-150IE, GWM-200IE Installation Instructions Manual
INSTALLATION
PRODUCT LITERATURE
Lennox Industries Inc.
Dallas, Texas
INSTRUCTIONS
GWM-050IE, GWM-075IE,
GWM-100IE, GWM-150IE,
GWM-200IE
WALL MOUNTED GAS
BOILER
RETAIN THESE INSTRUCTIONS FOR
FUTURE REFERENCE
These instructions must be affi xed
on or adjacent to the boiler .
WARNING
Improper installation, adjustment, alteration,
service, or maintenance could result in death
or serious injury. Refer to this manual for
assistance. For additional information consult
a qualifi ed installer, service agency, or the gas
supplier.
WALL MOUNTED GAS-FIRED HOT WATER
BOILERS
These Gas-Fired Water boilers are low pressure,
stainless steel boilers Design Certifi ed by CSA
(Canadian Standards Association) for use with
Natural and Propane Gases. They are constructed
and hydrostatically tested for a maximum working
pressure of 50 psi (pounds per square inch) in
accordance with A.S.M.E. (American Society
of Mechanical Engineers) Boiler and Pressure
Vessel Code Section IV Standards for Heating
Boilers.
PN# 240009475, Rev. A [07/2012]
FIGURE 1-1 Dimensions
DIMENSIONS
(D)
Wall Hanging
Bracket
(D)
Vent Connector
Safety Relief
Valve
Connection
(¾ NPT)
Combustion Air
(A)
(B)
Models
Width (A)
Height (B)
Depth (C)
Bracket (D)
Water
Connections
Gas
Connection
Condensate Drain
Connection (H)
Weight
Vent Connector/
Combustion Air
Table 1 : Physical Data
050/075/100 150/200
20"
(508mm)
31"
(787mm)
14"
(356mm)
28"
(711mm)
Location
(I)
Size (E) 1-1/4" NPT
Location
(J)
Size (G)
Shipping
Unit
2"
(51mm)
4-1/2"
(114mm)
1/2"
NPT
3/4" NPT
111 lb
(50 kg)
91 lb
(41 kg)
2"
(51mm)
23"
(584mm)
42"
(1092mm)
16.0"
(406mm)
40"
(1016mm)
2"
(51mm)
1-1/4" NPT
4-1/2"
(114mm)
3/4"
NPT
3/4" NPT
~182 lb
(83 kg)
~157 lb
(71 kg)
3"
(76mm)
(C)
(I)
(J)
Supply Water (E)
Gas Connection (G)
Return Water (E)
Condensate Drain Connection (H)
2
TABLE OF CONTENTS
1 - Introduction ............................................................................................................................... 4
2 - Important Safety Information ....................................................................................................5
3 - Component Listing ..................................................................................................................... 6
4 - Locating Boiler ...........................................................................................................................9
5 - Hydronic Piping ........................................................................................................................ 11
5.2 Special Conditions ................................................................................................................... 11
5.3 Safety Relief Valve and Air Vent .... ............................................................................................11
5.4 Trim Piping ............................................................................................................................. 12
5.5 System Piping ......................................................................................................................... 12
6 - Combustion Air And Vent Piping ...............................................................................................17
6.2 Removal of Existing Boiler From Common Vent System..................................................................17
6.3 Materials ............................................................................................................................... 17
6.4 Pipe Installation ...................................................................................................................... 18
6.5 Termination ............................................................................................................................ 18
6.6 Condensate Piping ................................................................................................................... 24
7 - Gas Supply Piping ....................................................................................................................25
8 - Electrical Connections ..............................................................................................................27
8.3 Line Voltage Connections .......................................................................................................... 27
8.4 External Connections ............................................................................................................... 27
9 - Start Up Procedure ...................................................................................................................29
9.6 CSD-1 Compliance Test.............................................................................................................32
10 - Operating Instructions ............................................................................................................34
11 - General Maintenance And Cleaning........................................................................................ 35
12 - Ratings And Capacities ........................................................................................................... 38
13 - Troubleshooting .....................................................................................................................39
14 - Wiring Diagram ...................................................................................................................... 53
15 - Glossary ................................................................................................................................. 55
Appendix A - Control Module .........................................................................................................57
1.1 Introduction ........................................................................................................................... 57
1.2 Operation ............................................................................................................................... 57
1.3 Status Indication ..................................................................................................................... 57
1.4 Sequence of Operation ............................................................................................................. 58
1.5 Theory of Operation................................................................................................................. 60
Information and specifi cations outlined in this manual in effect at the
time of printing of this manual. Manufacturer reserves the right to
discontinue, change specifi cations or system design at any time without
notice and without incurring any obligation, whatsoever.
3
1 - INTRODUCTION
1.1 Designated Use
• Hot water heating boiler.
• Indoor installation.
• Closet or alcove installation.
• Direct vent boiler.
• For use with natural gas or liquefi ed petroleum gases
(LP/propane).
1.2 The unit MUST NOT:
• Directly heat potable water. Indirect heating is acceptable.
• Heat water with non-hydronic heating system chemicals
present (example, swimming pool water).
• Exceed 50 psig (344 kPa) system pressure.
• Exceed 195°F (90.5°C) system design temperature.
1.3 Operational Features
• Modulating: 20-100%.
• Integral Dual Limit.
• Integral Low Water Cutoff (with test button).
• Outdoor Temperature Reset.
• Integral Multiple Boiler Control.
4
!
This is the safety alert symbol. Symbol alerts you to
potential personal injury hazards. Obey all safety messages
following this symbol to avoid possible injury or death.
2.2
Become familiar with symbols identifying
potential hazards.
2 - IMPORTANT SAFETY INFORMATION
2.1 General
Boiler installation shall be completed by qualifi ed agency.
See glossary for additional information.
WARNING
!
Fire, explosion, asphyxiation and electrical shock
hazard. Improper installation could result in death
or serious injury. Read this manual and understand
all requirements before beginning installation.
2.2
Become familiar with symbols identifying
potential hazards.
This is the safety alert symbol. Symbol alerts you to
potential personal injury hazards. Obey all safety messages
following this symbol to avoid possible injury or death.
!
DANGER
Indicates a hazardous situation which, if not avoided,
WILL result in death or serious injury
2.3 Installation shall conform to requirements of
authority having jurisdiction or in absence of such
requirements:
•
United States
• National Fuel Gas Code, ANSI Z223.1/NFPA 54
• National Electrical Code, NFPA 70.
• Canada
• Natural Gas and Propane Installation Code,
CAN/CSA B149.1.
• Canadian Electrical Code, Part I, Safety Standard
for Electrical Installations, CSA C22.1
2.4 Where required by authority having jurisdiction,
installation shall conform to Standard for Controls
and Safety Devices for Automatically Fired Boilers,
ANSI/ASME CSD-1.
Additional manual reset low water cutoff may be required.
2.5 Requirements for Commonwealth of
Massachusetts:
Boiler installation must conform to Commonwealth of
Massachusetts code 248 CMR which includes but is not
limited to:
• Installation by licensed plumber or gas fi tter.
.
!
WARNING
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
!
CAUTION
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
NOTICE
Used to address practices not related to personal
injury.
5
Return Water From Heating System (In)
(see
page 8)
-
Connection supplied at bottom of boiler.
Low Voltage Terminal Strip
(see page 8) -
Connection of all low voltage wiring, including
thermostat. See section
8.
Heat Exchanger Pump
Gas Shutoff Valve
- Fuel supply isolation
during servicing. See section 7
Combustion Air Blower
- Delivers
proper quantity of combustion air, receives fuel from
gas valve, mixes air and fuel sending mixture to burner
for combustion.
Gas (Control) Valve
- Delivers
proper quantity of fuel to Combustion Air Blower.
See section 7.
High Temperature Supply Switch
Low Water Cutoff
Senses inadequate
quantity of water. Turns off boiler before damage can
occur.
8
Gas Connection
- See section 7.
Control Module
3 - COMPONENT LISTING
3.1 Component Listing
1.
User Interface (see Appendix A) - Displays
information regarding boiler condition. Allows
adjustment of boiler operating parameters. NOTE: Does
not replace thermostat used to control central heating
space.
2.
Combustion Air Inlet (2"/3" ) (see page 7 & 8)
3.
Return Water From Heating System (In)
page 8)
4.
Low Voltage Terminal Strip
Connection of all low voltage wiring, including
thermostat. See section
5.
Igniter (see page 8)
6.
Flame Sensor (see page 8)
7.
Sight Glass (see page 8) - Permits observation of
burner fl ame.
-
Connection supplied at bottom of boiler.
(see page 8) -
8.
(see
20.
Gas (Control) Valve (see page 8)
proper quantity of fuel to Combustion Air Blower.
See section 7.
21.
High Temperature Supply Switch (see page 8)
22.
Low Water Cutoff (see page 8) --
quantity of water. Turns off boiler before damage can
occur.
23.
Safety Relief Valve (see pages 7 & 8) - Factory
supplied, Field installed. See section 5.
24.
High Voltage Junction Box (see page 8) - For
connection of 120V components. See section
25.
Vent Connector (see pages 7 & 8) - See section 6.
26.
Gas Connection (see page 8)
27.
Wall Hanging Support Bracket (see page 7) -
Integral to boiler. Allows wall mounting when used
with supplied wall mounting bracket. See section 4.
- Delivers
Senses inadequate
8.
- See section 7.
8.
Burner (see page 36)
9.
Heat Exchanger (see page 8)
10.
Condensate Collector (see page 8)
11.
Return Temperature Sensor (not shown)
12.
Drain Valve (see page 12)
13.
Heat Exchanger Ball Valve (see page 8)
14.
Supply Water Outlet to Heating System (Out)
(see pages 8) - Connections supplied for connecting
from bottom of boiler. See section 5.
15.
Vent Temperature Sensor (see page 8)
16.
Condensate Drain (see page 8) - Boiler produces
a liquid (condensate) as a by-product of combustion.
Condensate must be piped to appropriate drain. See
section 6.
17.
Heat Exchanger Pump (see page 8)
28.
Air Vent (see page 7 & 8)
29.
Control Module (see page 8)
30.
Transformer (see page 8) - Supplies 24V power to low
water cutoff.
31.
Pressure Test Port - (see page 8)
32.
Combustion Analysis Test Port - (see page 8)
33.
Return Water Sensor (see page 8)
34.
User Interface - (see page 8)
18.
Gas Shutoff Valve (see page 8)
during servicing. See section 7
19.
Combustion Air Blower (see page 8)
proper quantity of combustion air, receives fuel from
gas valve, mixes air and fuel sending mixture to burner
for combustion.
- Fuel supply isolation
- Delivers
6
3 - COMPONENT LISTING
SAFETY RELIEF VALVE
AIR VENT
WALL
SUPPORT
FIGURE 3-1 Boiler Components (Viewed from Back of Boiler)
VENT CONNECTOR
COMBUSTION
AIR INLET
WALL HANGING
SUPPORT
BRACKET
AIR VENT
SAFETY RELIEF VALVE
NOTE:
See Section 5-3
For Safety Relief
Valve Piping
Instructions
FIGURE 3-2 Jacket Latch (Viewed from front of boiler)
Jacket Latch
Lift Jacket Up,
Engage Jacket With
Chassis
Push Down
7
3 - COMPONENT LISTING
GAS SHUTOFF
VALVE
COMBUSTION
AIR
BLOWER
GAS (CONTROL)
VALVE
LOW WATER
CUTOFF
AIR VENT
HEAT EXCHANGER
PUMP
RETURN WATER
FROM HEATING
SYSTEM (IN)
(OUT)
LOW VOLTAGE
TERMINAL STRIP
GAS CONNECTION
COMBUSTION
ANALYSIS TEST
PORT
HIGH VOLTAGE
JUNCTION BOX
HEAT EXCHANGER
BALL VALVE
See Section5
SAFETY RELIEF VALVE SAFETY RELIEF VALVE
AIR INLET
struio
ns
HEAT
EXCHANGER
IGNITER
SIGHT
GLASS
CONDENSATE
DRAIN
USER INTERFACE
FIGURE 3-3 Boiler Components (View from Front of Boiler)
AIR VENT
HIGH TEMPERATURE
SUPPLY SWITCH
LOW WATER
CUTOFF
SAFETY RELIEF VALVE
VENT CONNECTOR
NOTE:
See Section 5
For Piping
Instructions
COMBUSTION
AIR INLET
IGNITER
FLAME
SENSOR
GAS (CONTROL)
VALVE
COMBUSTION
AIR
BLOWER
GAS SHUTOFF
VALVE
(SHOWN IN OPEN
POSITION)
HEAT EXCHANGER
PUMP
COMBUSTION
ANALYSIS TEST
PORT
VENT
TEMPERATURE
SENSOR
CONDENSATE
COLLECTOR
SIGHT
GLASS
PRESSURE
TEST PORT
USER INTERFACE
CONTROL
MODULE
Fuse and
Holder
HEAT
EXCHANGER
TRANSFORMER
RETURN WATER
SENSOR (Located
behind piping)
LOW VOLTAGE
TERMINAL STRIP
HIGH VOLTAGE
JUNCTION BOX
SUPPLY WATER TO
HEATING SYSTEM
(OUT)
HEAT EXCHANGER
BALL VALVE
8
GAS CONNECTION
CONDENSATE
DRAIN
RETURN WATER
FROM HEATING
SYSTEM (IN)
4 - LOCATING BOILER
Model
Top (A)
Left Side (B)
Right Side (C)
Front (D)
Back (E)
Bottom (F)
Combustion Air/Vent
piping
Hot Water Piping
4.1 Boiler Location Considerations
• Ambient room temperature always above 32°F (0°C) to
prevent freezing of liquid condensate.
• Approved for installation in closets.
• Protect gas ignition system components from water
(dripping, spraying, rain, etc.) during operation and
service (circulator replacement, condensate trap, control
replacement, etc.).
• Wall mounting.
• Wall must be plumb and capable of supporting boiler
weight plus 60 lbs (28 kg). See Table 1.
• Wall mounting. See section 4.2.
• Access to outdoors to meet minimum and maximum
pipe lengths for combustion air and vent piping. See
section 6.
• Disposal of condensate. See section 6.
• Drainage of water (or water - antifreeze solution) during
boiler service or from safety relief valve discharge. See
section 5.
• Access to system water piping, gas supply, and electrical
service. See sections 5, 7 and 8.
FIGURE 4-1 Clearance to Combustible Materials
A
B
F
FLOOR
E
A
C
F
A
• Clearances to combustible materials and service
clearances. See Table 2 and fi gure 4-1.
• Multiple Boilers can be wall mounted, placed side by
side, or back to back.
TABLE 2: BOILER CLEARANCES
Dimension
Model
Top (A)
Left Side (B)
Right Side (C)
Front (D)
Back (E)
Bottom (F)
Combustion Air/Vent
Hot Water Piping
(1)
Required distances measured from boiler.
(2)
Service, proper operation clearance recommendation.
piping
Combustible
Materials
050/075/100/
150/200
0" (0 cm) 14" (36 cm)
0" (0 cm) 0" (0 cm)
0" (0 cm) 0" (0 cm)
0" (0 cm) 6" (16 cm)
0" (0 cm) 0" (0 cm)
0" (0 cm) 12" (32 cm)
0" (0 cm)
½" (1.3 cm) 6" (16 cm)
D
E
F
F
FLOOR
(1)
Service
050/075/100/
150/200
6" (16 cm)
(1)(2)
9
4 - LOCATING BOILER
!
4.2 Pre-pipe supply and return water connections with
FIGURE 4-2 Wall Mount Bracket Engaged with Bracket on Boiler
Center brackets. Avoid
overhang on sides of wall
mount bracket.
factory fi ttings before wall mounting.
4.3 Wall Mounting
Mount boiler on wall using wall mounting bracket included
with unit.
• Structure must be capable of supporting boiler weight
• Wall mount bracket has 4 slots allowing mounting on
• Boiler includes (4) 3/8" x 3" lag screws and (4) washers
• Attach wall mount bracket level on wall.
plus 60 lbs (28 kg). See Table 1, page 2.
two (2) wall studs spaced at 11½" to 16½" on center.
See fi gure 4-2.
for attaching wall mount bracket to wood studs. Field
source appropriate fasteners for other wall constructions
(masonry, concrete).
4 Slots for attaching Wall
Mount Bracket to Studs
• Boiler must engage with wall mount bracket.
• Avoid overhang on sides of wall mount bracket. Verify
boiler bracket is centered on wall bracket. See fi gure
4-2.
!
CAUTION
Boiler weight exceeds 75 pounds (34 kg). Do not
lift boiler onto wall without assistance.
10
5 - HYDRONIC PIPING
5.1 General
• Install piping in accordance with authority having jurisdiction.
NOTICE
Use two (2) wrenches when tightening and fi tting
to pipe boiler's threaded fi ttings. Boiler's internal
piping can be damaged if subjected to excessive
torque.
• Support system piping and safety relief valve discharge
piping. Boiler's internal piping and wall mount bracket can
be damaged if subjected to excessive weight.
• Size central heating pump (and domestic hot water pump,
if used) for system requirements only. Heat exchanger
pump compensates for pressure drop through boiler
internal piping and heat exchanger.
• Thoroughly clean and fl ush system before connecting to
boiler.
5.2 Special Conditions
• System piping exposed to freezing conditions: Use
inhibited proplyene glycol solutions certifi ed by fl uid
manufacturer for use with closed water heating system.
Do not use automotive or ethylene glycol.
!
WARNING
• Poison hazard. Ethylene glycol is toxic. Do not
use ethylene glycol.
• Never use automotive or standard glycol antifreeze,
even ethylene glycol made for hydronic systems.
• Ethylene glycol can attack gaskets and seals used
in hydronic systems.
• Use only inhibited proplyene glycol solutions
certifi ed by fl uid manufacturer as acceptable for
use with closed water heating system.
• Thoroughly clean and fl ush any system that used
glycol before installing new Boiler.
• Provide user with Material Safety Data Sheet
(MSDS) on fl uid used.
NOTICE
Do not expose boiler and condensate piping to
freezing temperatures.
• Boiler installed above radiation level (or as required by
authority having jurisdiction). Integral low water cutoff
provided in boiler. See page 6.
• Boiler used in connection with refrigeration system.
Install piping in parallel with boiler, with appropriate
valves to prevent chilled medium from entering boiler.
• System piping connected to heating coils located in air
handling unit exposed to refrigerated air circulation.
Install fl ow control valves or other automatic means to
prevent gravity circulation of boiler water during cooling
cycle.
5.3 Safety Relief Valve and Air Vent
NOTICE
Boiler rated at 50 psig (345 kPa) maximum
allowable working pressure. Boiler provided with
30 psig (206 kPa) safety relief valve. Field source
safety relief valve for system pressures greater than
30 psig (206 kPa). Temperature Pressure Gauge
and Air Vent satisfactory for 30-50 psig (206-345
kPa) operation.
FIGURE 5-1 Safety Relief Valve & Air Vent (View from
front of boiler)
Safety Relief
Valve
Air Vent
3/4"F x 3/4"M
NPT Tee
3/4 NPT
3/4" x 1/4" NPT
90° Elbow
3/4" NPT
Close Nipple
• Install safety relief valve and air vent using pipe fi ttings
provided with boiler. See fi gure 5-1
• Install safety relief valve with spindle in vertical position.
• Do not install shutoff valve between boiler and safety
relief valve.
Position Air Vent and Safety Relief Valve
to provide space for discharge piping.
11
5 - HYDRONIC PIPING
!
WARNING
Burn and scald hazard. Safety relief valve could
discharge steam or hot water during operation.
Install discharge piping per these instructions.
FIGURE 5-2 Safety Relief Valve Discharge Piping
Safety Relief Valve
• Install discharge piping from safety relief valve. See
fi gure 5-2.
• Use ¾" or larger pipe.
• Use pipe suitable for temperatures of 375°F (191°C)
or greater.
• Individual boiler discharge piping shall be independent
of other discharge piping.
• Size and arrange discharge piping to avoid reducing
safety relief valve relieving capacity below minimum
relief valve capacity stated on rating plate.
• Run pipe as short and straight as possible to location
protecting user from scalding and properly drain
piping.
• Install union, if used, close to safety relief valve outlet.
• Install elbow(s), if used, close to safety relief valve
outlet and downstream of union (if used).
• Terminate pipe with plain end (not threaded).
5.4 Trim Piping
• Temperature - Pressure Gauge. Install temperature
pressure gauge using nipple, tee and bushing provided
with boiler. See fi gure 5-3.
Check Local Codes
For Maximum
Distance To Floor
FIGURE 5-3 Temperature Pressure Gauge and Drain
Valve Installations
5.5 System Piping
Gas Supply
• Drain Valve. Install drain valve using nipple, tee and
bushing provided with boiler. See fi gure 5-3.
• Systems with automatic fi ll valves require back fl ow
prevention device.
• Single boiler system. See fi gures 5-4, 5-5, 5-6, 5-7 for
general guidance. Additional considerations:
• Control system designed for single central heating
pump. Installer responsible for integration of
multiple central heating pumps.
• Control system allows domestic hot water
prioritization. Function could be lost if central
heating pump not directly connected to control
system.
• Multiple boiler system. See fi gure 5-8 for general
guidance. Additional considerations:
• Control system requires equivalent water
temperatures entering each boiler to properly
sequence and adjust system supply temperature.
• Install multi boiler sensor kit. See "Parts, Kits &
Optional Accessories" manual for part number.
Temperature Pressure
Gauge shown at
System Supply
Connection
Drain Valve shown
at System Return
Connection to Boiler
12
5 - HYDRONIC PIPING
NOTICE
Illustrations are meant to show system piping
concept only. Installer responsible for all equipment
and detailing required by authority having
jurisdiction.
FIGURE 5-4 System Piping
Safety Relief Valve
Piping Legend
Check Local Codes
For Maximum
Distance To Floor
System
Supply
FLOOR
System
Return
13
5 - HYDRONIC PIPING
5-5 TWO-PIPE ZONED SYSTEM WITH VALVES
DHW
Pump
CH/System
Pump
5-6 TWO-PIPE ZONED SYSTEM WITH PUMPS
DHW
Pump
Heat exchanger
ball valve open
(as shipped)
3/8"/10mm
Open End
Wrench
Zone
Pump
Heat exchanger
ball valve open
(as shipped)
3/8"/10mm
Open End
Wrench
14
5 - HYDRONIC PIPING
5-7A SINGLE BOILER USING PRIMARY/SECONDAY PUMPING
12"/305mm Max. apart
12"/305mm
Max. apart
Existing closely spaced tees
in primary system loop
CH/System
Pump
Heat exchanger
ball valves closed
5-7B SINGLE BOILER USING PRIMARY/SECONDAY PUMPING
Limit length
to
5'/1.6 m
3/8"/10mm Open
End Wrench
12"/305mm Max. apart
12"/305mm
Max. apart
CH/System
Pump
Heat exchanger
ball valve open
Existing closely spaced tees
in primary system loop
Limit length
to
5'/1.6 m
3/8"/10mm Open
End Wrench
15
5 - HYDRONIC PIPING
5-8 TYPICAL MULTIPLE BOILER PIPING - (See Multiple Boiler Guide)
DHW
CH/
System
Pump
Pump
12"/305mm Max. apart
System
T emperature
Sensor
Size common piping
according to
maximum heat
capacity of
entire system
Up to 16
boilers
All heat exchanger
ball valves closed
3/8"/10mm Open
End Wrench
(See Multiple Boiler Guide)
16
6 - COMBUSTION AIR AND VENT PIPING
6.1 General
This boiler requires a dedicated direct vent system.
Install combustion air and vent piping in accordance
with these instructions, authority having jurisdiction,
and:
• USA - National Fuel Gas Code, ANSI 223.1/NFPA 54.
• Canada - Natural Gas and Propane Installation Code,
CAN/CSA B149.1
Vent connections serving appliances vented by natural draft
shall not be connected into any portion of mechanical draft
systems operating under positive pressure.
Install vent system in accordance with these instructions.
6.2 Removal of Existing Boiler From Common
Vent System
When existing boiler is removed from common venting
system, common venting system is likely to be too large for
proper venting of appliances remaining connected to it.
After removal of existing boiler, following steps shall
be followed with each appliance remaining connected to
common venting system placed in operation, while other
appliances remaining connected to common venting system
are not in operation:
• Seal any unused openings in common venting system.
• Visually inspect venting system for proper size and
horizontal pitch. Determine there is no blockage or
restrictions, leakage, corrosion and other defi ciencies
which could cause an unsafe condition.
• When practical, close all building doors, windows, and
all doors between space in which appliances remaining
connected to common venting system are located and
other spaces of building. Turn on clothes dryer and any
appliance not connected to common venting system.
Turn on exhaust fans, such as range hoods and bathroom exhaust so they will operate at maximum speed.
Do not operate summer exhaust fan. Close fi replace
dampers.
• Any improper operation of common venting system
should be corrected so installation conforms with National
Fuel Code, ANSI Z223.1/NFPA 54 and/or Natural Gas
and Propane Installation Code, CAN/CSA B149.1. When
re-sizing any portion of common venting system, common venting system should be re-sized to approach
minimum size as determined using appropriate tables in
Chapter 13 of the National Fuel Gas Code, ANSI Z223.1/
NFPA 54 and/or Natural Gas and Propane Installation
Code, CAN/CSA B149.1.
6.3 Materials
• See Table 3
Table 3 - Combustion air and vent pipe fi ttings
must conform with the following:
Item Material Standards
PVC schedule 40 ANSI/ASTM D1785
PVC - DWV ANSI/ASTM D2665
CPVC schedule 40
Vent Pipe
and Fittings
Pipe
Cement/
Primer
• IPEX is approved vent manufacturer in Canada listed
to ULC-S636.
• IPEX System 636 Cements and Primers are approved
in Canada listed to ULC-S636.
SDR-21 & SDR-26 PVC ANSI/ASTM D2241
ABS-DWV ANSI/ASTM D2661
Schedule 40 ANSI/ASTM F628
PVC ANSI/ASTM D2564
CPVC ANSI/ASTM F493
Schedule 40 ABS ANSI/ASTM D2235
DO NOT USE CELLULAR (FOAM) CORE PIPE
ANSI/ASTM D1784/
F441
• Turn on appliance being inspected. Follow lighting
instructions. Adjust thermostat so appliances will operate
continuously.
• Test for spillage at draft hood relief opening after 5
minutes of main burner operation. Use fl ame of match or
candle, smoke from cigarette, cigar or pipe.
• Determine each appliance remaining connected to
common venting system properly vents when tested
as outlined above. Then return doors, windows,
exhaust fans and any other gas-burning appliance to
their previous condition of use.
!
WARNING
Use of cellular core PVC for venting fl ue gas could
result in death, serious injury.
17
6 - COMBUSTION AIR AND VENT PIPING
6.4 Pipe Installation
• Minimum and maximum combustion air and vent pipe
lengths listed in Table (4). Pipe length counted from
combustion air connector to termination.
• Install fi eld-sourced 2" to 3" transition, if used, in vertical
section at combustion air inlet and vent connector.
• 90° elbows equivalent to 5.0 ft (1.6 m). 45° elbows
equivalent to 3.5 ft (1.1 m). 2" to 3" transition has no
equivalent length.
• Slope vent pipes minimum 1/4" per foot (21 mm/m)
back toward boiler. Support horizontal sections to
prevent sags capable of accumulating condensate.
• Support piping in accordance with pipe manufacturer's
instruction and authority having jurisdiction. In absence
of manufacturer's instruction use pipe hooks, pipe
straps, brackets, or hangers of adequate and strength
located at intervals of 4 ft (1.2m) or less. Allow for
expansion/contraction of pipe.
• Combustion air and vent piping must be air tight and
water tight.
• Certifi ed vent system components must NOT be inter-
changed with other vent systems or unlisted pipe/fi ttings.
• Canadian installations only. All venting material, primer
and glue must be listed to ULC S636.
6.5 Termination
• Terminate combustion air and vent pipes with fi ttings or
concentric vent kit.
• See "Parts, Kits and Optional Accessories" manual
for concentric vent kit part numbers.
• Use horizontal pipe for vent and 90° elbow for
combustion air termination when using fi ttings.
• Terminate combustion air and vent pipes in same
atmospheric pressure zone through exterior sidewall or
roof.
• Locate combustion air termination as far as possible
from swimming pool, swimming pool pump house, and
other sources of airborne chlorine.
• Locate combustion air and vent terminals as required by
authority having jurisdiction.
!
WARNING
Vent extending through exterior wall shall not
terminate adjacent to wall or below building
extensions such as eaves, balconies, parapets or
decks. Failure to comply could result in death or
serious injury.
• Canadian installations only. First 3 ft (0.9 m) of
plastic vent pipe from vent connector must be readily
accessible for visual inspection.
Table 4 - Combustion Air and Vent Piping Length
Combustion Air and Vent Pipe Equivalent Length
2” Pipe 3” Pipe
Model 050 075/100 075/100 150/200
Min.
Max.
6 ft.
(1.8 m)
100 ft.
(30.5 m)
6 ft.
(1.8 m)
50ft.
(15.2 m)
1 - 90° elbow = 5 ft (1.6 m)
1 - 45° elbow = 3.5 ft (1.1 m)
1- 2" x 3" adapter = 0 ft (0 m)
Note: Concentric Vent Kit=5 ft (1.6m) equivalent length
6 ft.
(1.8 m)
100 ft.
(30.5 m)
6 ft.
(1.8 m)
100 ft.
(30.5 m)
For Example: Boiler can be installed on outside wall and vented with
1-90° elbow and 1 ft (0.30 m) of vent pipe.
18
6 - COMBUSTION AIR AND VENT PIPING
FIGURE 6-1
8" (21 cm)
Minimum
Vent Combustion
12" (30 cm)
Minimum above
anticipated snow line
FIGURE 6-2
12" (30 cm)
Minimum
3" (8 cm)
Maximum
Air
15" (38 cm)
Maximum
Roof Line
Roof
Terminations
3" (8 cm) Maximum horizontal
separation between combustion air
intake and vent of same appliance.
8" (21 cm) Minimum vertical
separation between combustion
air intake and vent of different
appliances.
15" (38 cm) Maximum horizontal
length of vent.
Maximum vent/intake between
different appliances 12" (30cm).
Maximum allowable total vertical
vent length with outside exposure is
10 ft.(3.05m).
Abandoned unused masonry
chimney may be used as chaseway for combustion air and vent.
Both combustion air and vent pipe
must exit above top of chimney with
clearances as shown in Figure 6-1.
12" (30 cm)
Minimum from
overhang
See snow & ice
page 22
FIGURE 6-3
3" (8 cm)
Minimum
separation
12" (30 cm) Separation
between bottom of
combustion air intake and
bottom of vent
Vent
Combustion Air
12" (30cm)
Minimum
separation
Side Wall
Terminations
3" (8 cm) Minimum horizontal
separation between combustion air
intake and vent terminations.
8" (21 cm) Minimum vertical
separation between combustion air
intake and vent terminations.
12" (30 cm) Separation between
bottom of combustion air intake and
bottom of vent.
Multiple terminations as shown in
6-1, 6-2, and 6-3 must be a minimum
of 12” (30 cm) horizontally between
vent of one termination and air intake
of next appliance.
Maximum allowable total outside
exposure vent length equals 10 ft.
(3.05m).
Maintain a pitch of 1/2" per ft.
(42mm/m) outside exposure back to
boiler to ensure proper condensate
drainage for horizontal runs.
See snow & ice
page 23
Combustion Air
Vent
19
6 - COMBUSTION AIR AND VENT PIPING
FIGURE 6-4
Combustion
Air
1" (2.54cm)
Maximum
1"(2.54cm)
Maximum
Vent
FIGURE 6-7
FIGURE 6-5
1" (2.54cm)
Maximum
* See Note
Below
Combustion
Air
Roof overhang
12" (30cm) Minimum
36"(0.9m) Minimum
Maintain 12"(30cm)
Vent
clearance above
clearance above highest
highest anticipated
anticipated snow level or
snow level or grade
Maintain 12"
grade
*Must be less than 4" or greater than 24" Horizontal distance between end bells of each air intake to prevent fl ue
gas recirculation.
Note: Securing strap must
be fi eld installed to prevent
movement of termination
kit in side wall
OD 3½" (
OD 4½" (11.4cm) - 3" (7.6cm) kit
Combustion Air
Elbow fi eld
supplied
** Note Overall length may be modifi ed by cutting or
extending both combustion air and vent pipes. 12" is
minimum allowable length and 60" is maximum allowable
length for this dimension. SDR-26 PVC (D2241) only may
be used for extending pipes. Do not use Schedule 40 PVC
or use couplings to extend pipes. Dimension will change if
intake/vent pipes are lengthened or shortened.
8.9cm)
- *2" (
5.0cm)
kit
**See
Note
*2 or 3" (5.0 or 7.6cm) Diameter
PVC intake/combustion air
*2" (
5.0cm)
Diameter = 41" Length (1.0m))
46-3/4" (1.2 m)
3" (7.6cm) Diameter = 47" Length (1.2m)
Combustion Air
Vent
1"(2.54cm)
Maximum
* Note: 2" For use with models 050/075/100.
3" For use with models 075/100/150/200
20
6 - COMBUSTION AIR AND VENT PIPING
Concentric
Vent Roof
Terminations
Glue inner vent pipe to prevent
recirculation.
Maintain 12" (30 cm) US ((18"(46
cm) Canada)) minimum clearance
above highest anticipated snow
level. Maximum of 24"(0.61m)
above roof.
Support must be fi eld installed to
secure termination kit to structure.
Elbow, roof boot/fl ashing fi eld
supplied.
Allowed Wall/Roof thickness 1/2"-30"
(1.2 - 76cm).
Vertical concentric vent system can be
installed in unused masonry chimney.
Contact Technical Support for
questions regarding installation or use.
FIGURE 6-6
Combustion Air
Roof boot/fl ashing
(fi eld supplied)
Note: Support must
be fi eld installed to
secure termination
kit to structure
Vent
Vent
Maintain 12"(30cm)
clearance above highest
anticipated snow level
24" above roof
Support
(fi eld supplied)
Combustion Air
21
6 - COMBUSTION AIR AND VENT PIPING
Forced Air
Inlet
12"
(30.5cm m)
Minimum
Less than
10' (3 m)
Minimum
Termination must
be 12" (30.5 cm)
from or below doors,
windows or gravity
inlet.
Termination
Termination
3' (0.9 m)
[If located
within 10' (3 m)
of forced air
inlet]
Doors &
Windows
Condensate
Forced Air
Inlet
Combustion air and vent termination
must be 12" (300 mm) from or below
doors, windows or gravity inlet.
Vent gas may condense, forming
moisture, may be corrosive. Protect
building materials at vent from exhaust
of vent gas.
Terminate venting system 3’ (0.9 m)
above and 10' (3.0 m) from any forced
air inlet (except boiler’s combustion
air inlet).
3' (0.9 m)
Minimum
Grade, Snow
& Ice
"L"
Corner
Terminate vent system bottom,
minimum 12" (300 mm) above highest
anticipated snow level. Canada 18"
above anticipated snow level.
Avoid locations where snow may drift
and block vent and combustion air. Ice
or snow may cause boiler to shut down
if vent or combustion air becomes
obstructed.
Vent termination shall NO T be installed
closer than 3' (0.9 m) from inside
corner of “L” shaped structure.
22
Loading...