Lochinvar C 402 - 2072 User Manual
WARNING: If the information in these instructions is not
followed exactly, a fire or explosion may result causing property
damage, personal injury or death.
-- 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 near by 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 the gas supplier.
CFX-CHX-I-O Rev A
Installation & Operation Manual
Models: 402 - 2072
WARNING:
This manual supplies information for the
installation, operation, and servicing of the
appliance. It is strongly recommended that this
manual and the Copper-fin II Service Manual be
reviewed completely before proceeding with an
installation. Perform steps in the order given.
Failure to comply could result in severe personal
injury, death, or substantial property damage.
Save this manual for future reference.
Contents
HAZARD DEFINITIONS ..................................................... 2
PLEASE READ BEFORE PROCEEDING ......................... 3
SAFETY INFORMATION ................................................... 4
THE COPPER-FIN II -- HOW IT WORKS ...................... 5-7
RATINGS ........................................................................... 8
1. DETERMINE UNIT LOCATION
Location of Unit .................................................................. 9
Recommended Service Clearances .................................. 9
Non-Combustible / Combustible Flooring ........................ 10
Combustion Air Options .............................................. 10-13
2. VENTING
Before You Begin ............................................................. 13
Vent System Options ....................................................... 14
General Venting Information ............................................ 15
Conventional Negative Draft Venting .......................... 16-18
Vertical DirectAire Venting .......................................... 19-21
Sidewall Venting .......................................................... 22-24
Horizontal DirectAire Venting ........................................... 25
Direct Venting .............................................................. 26-29
Outdoor Installation .......................................................... 30
3. GAS CONNECTIONS
Connecting to Gas Supply ............................................... 31
Gas Pressure Test ........................................................... 31
Checking Manifold Gas Pressure .................................... 31
Combination Gas Valves .................................................. 32
Checking Gas Supply Pressure ....................................... 33
4. WATER CONNECTIONS
Inlet & Outlet Connections ............................................... 34
Relief Valve ...................................................................... 35
Heating Boiler Installations .......................................... 35-36
Low Temperature Return Water Systems ........................ 36
Low Temperature Bypass Requirements ......................... 36
Three Way Valves in System ........................................... 37
Radiant Floor and Snow Melt Heating Systems .............. 37
Typical Heating Boiler Installations .................................. 38
Installation with a Chilled Water System .......................... 38
Primary/Secondary Piping of a Single Boiler .............. 39
Primary/Secondary Piping of Multiple Boilers ............ 40
Boiler w/Low Temperature Bypass Piping .................. 41
Primary/Secondary Piping with Buffer Tank ............... 42
5. ELECTRICAL CONNECTIONS
Boiler Operating Control Module ...................................... 43
Line Voltage Connections ................................................ 44
Low Voltage Connections ................................................ 44
Wiring of the Cascade ...................................................... 45
Low Voltage Field Wiring Connections ............................ 46
6. STARTUP
Check/Control Water Chemistry ....................................... 47
Freeze Protection (when used) ........................................ 47
Fill and Test Water System .............................................. 47
Purge Air from Water System .......................................... 47
Check for Gas Leaks ....................................................... 47
Check Thermostat Circuit(s) ............................................ 48
Check Vent and Air Piping ............................................... 48
Placing the Boiler in Operation ........................................ 48
Start the Boiler ................................................................. 48
If Boiler Does Not Start Correctly ..................................... 48
Set Space heating Operation (boiler only) ....................... 48
Operating Instructions ...................................................... 49
Set DHW Operation ......................................................... 50
7. OPERATING INFORMATION
General ........................................................................ 51-53
Cascade ...................................................................... 53-54
Sequence of Operation ............................................... 55-56
Copper-fin II Control Module ............................................ 56
Access Modes ............................................................ 57
Saving Parameters ..................................................... 57
Status Display Screens ............................................... 58-61
8. DOMESTIC WATER HEATERS
Initial Setup of Maximum Water Flow .............................. 62
Water Chemistry............................................................... 63
Typical Water Heater Piping w/Storage Tank(s) ......... 64-65
Multiple Water Heater Piping w/Storage Tank(s) ........ 66-67
Pump Operation ............................................................... 68
Minimum Water Temperatures (domestic hot water) ....... 69
9. MAINTENANCE ......................................................71-75
10. CONNECTION DIAGRAM ................................... 76-77
11. LADDER DIAGRAM .............................................. 78-79
Revision Notes .................................................. Back Cover
Hazard definitions
The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk
levels or to important information concerning the life of the product.
DANGER
WARNING
CAUTION
CAUTION
NOTICE
2
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury.
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not
avoided, may result in property damage.
NOTICE indicates special instructions on installation, operation, or maintenance that are important but
not related to personal injury or property damage.
Please read before proceeding
Special instructions
Installation & Operation Manual
NOTICE
WARNING
WARNING
This is a gas appliance and should be installed
by a licensed electrician and/or certified gas
supplier. Service must be performed by a
qualified service installer, service agency or
the gas supplier.
If the information in these instructions is
not followed exactly, a fire or explosion may
result causing property damage, personal
injury, or death.
This appliance MUST NOT be installed in
any location where gasoline or flammable
vapors are likely to be present, unless the
installation is such to eliminate the probable
ignition of gasoline or flammable vapors.
Improper installation, adjustment,
alteration, service or maintenance can
cause injury or property damage. Refer
to this manual for assistance or additional
information, consult a qualified installer,
service agency or the gas supplier.
Checking equipment –
Upon receiving equipment, check for signs of shipping damage.
Pay particular attention to parts accompanying the appliances
which may show signs of being hit or otherwise being
mishandled. Verify total number of pieces shown on packing
slip with those actually received. In case there is damage or a
shortage, immediately notify the carrier.
Do not use this appliance if any part has been under water.
The possible damage to a flooded appliance can be extensive
and present numerous safety hazards. Any appliance that has
been under water must be replaced.
NOTICE
REMOVAL OF COMBUSTION CHAMBER LINING OR
BASE PANELS:
Avoid breathing dust and contact with skin
and eyes.
• Use NIOSH certified dust respirator (N95).
This type of respirator is based on the OSHA
requirements for cristobalite at the time this
document was written. Other types of
respirators may be needed depending on the job
site conditions. Current NIOSH recommendations
can be found on the NIOSH website at
http://www.cdc.gov/niosh/homepage.html.
NIOSH approved respirators, manufacturers, and
phone numbers are also listed on this website.
The ceramic fiber material used in this
appliance is an irritant; when handling or
replacing the ceramic materials it is advisable
that the installer follow these safety guides.
Apply enough water to the combustion chamber
lining to prevent airborne dust.
Remove the combustion chamber lining from the
appliance and place it in a plastic bag for disposal.
• NIOSH stated First Aid:
Eye: Irrigate immediately.
Breathing: Fresh air.
WARNING
The combustion chamber insulation in this
appliance contains ceramic fiber material.
Ceramic fibers can be converted to cristobalite
in very high temperature applications.
The International Agency for Research on
Cancer (IARC) has concluded, “Crystalline
silica in the form of quartz or cristobalite
from occupational sources is carcinogenic
to humans (Group 1).” Normal operating
temperatures in this appliance are below the
level to convert ceramic fibers to cristobalite.
Abnormal operating conditions would have
to be created to convert the ceramic fibers in
this appliance to cristobalite.
The ceramic fiber material used in this
appliance is an irritant; when handling
or replacing the ceramic materials it is
advisable that the installer follow these safety
guidelines.
Warranty –
Factory warranty (shipped with unit) does not apply to units
improperly installed or improperly operated.
Experience has shown that improper installation or system
design, rather than faulty equipment, is the cause of most
operating problems.
1. Excessive water hardness causing a lime/scale build-up in
the copper tube is not the fault of the equipment and is
not covered under the manufacturer’s warranty (see
Water Treatment and Water Chemistry).
2. Excessive pitting and erosion on the inside of the copper
tube may be caused by too much water velocity through
the tubes and is not covered by the manufacturer’s
warranty (see Boiler Flow Rates and Temperature Rise for
flow requirements).
• Wear long-sleeved, loose fitting clothing, gloves,
and eye protection.
33
Please read before proceeding
Safety information
Installation & Operation Manual
Owner warning –
The information contained in this manual is intended for use
by qualified professional installers, service technicians, or gas
suppliers.
NOTICE
A gas appliance that draws combustion air from the equipment
room where it is installed must have a supply of fresh air
circulating around it during burner operation for proper gas
combustion and proper venting.
WARNING
Consult and follow all local Building and
Fire Regulations and other Safety Codes that
apply to this installation. Consult local gas
utility company to authorize and inspect all
gas and flue connections.
Should overheating occur or the gas supply
fail to shut off, do not turn off or disconnect
the electrical supply to the pump. Instead,
shut off the gas supply at a location external
to the appliance.
Prevention of freezing –
Heat exchangers and headers damaged by freezing are not
covered by warranty.
See Section 7, Operating Information - Freeze Protection for
more information.
Codes –
The equipment shall be installed in accordance with those
installation regulations in force in the local area where the
installation is to be made. These shall be carefully followed in all
cases. Authorities having jurisdiction shall be consulted before
installations are made. In the absence of such requirements, the
installation shall conform to the latest edition of the National
Fuel Gas Code, ANSI Z223.1. Where required by the authority
having jurisdiction, the installation must conform to American
Society of Mechanical Engineers Safety Code for Controls and
Safety Devices for Automatically Fired Boilers, ASME CSD-1.
All boilers conform to the latest edition of the ASME Boiler
and Pressure Vessel Code, Section IV. Where required by the
authority having jurisdiction, the installation must comply with
the Canadian Gas Association Code, CAN/CGA-B149.1 and/
or B149.2 and/or local codes. This appliance meets the safe
lighting performance criteria with the gas manifold and control
assembly provided, as specified in the ANSI standards for gasfired hot water boilers, ANSI Z21.13 and gas water heaters,
ANSI Z21.10.3.
WARNING
1. This unit is only for use with the type of gas indicated on the
rating plate.
2. If you smell gas
• shut off gas supply
• do not try to light any appliance
• do not touch any electrical switch; do not use any phone
in your building
• immediately call your gas supplier from a neighbor’s
phone. Follow the gas supplier’s instructions
• if you cannot reach your gas supplier, call the fire
department
3. Boilers and water heaters are heat producing appliances. To
avoid damage or injury, do not store materials against the
appliance or the vent-air intake system. Use proper care
to avoid unnecessary contact (especially children) with the
appliance and vent-air intake components.
4. Never cover your unit, lean anything against it, store trash
or debris near it, stand on it or in any way block the flow of
fresh air to your unit.
5. UNDER NO CIRCUMSTANCES MUST FLAMMABLE
MATERIALS SUCH AS GASOLINE OR PAINT THINNER
BE USED OR STORED IN THE VICINITY OF THIS
APPLIANCE, VENT-AIR INTAKE SYSTEM OR ANY
LOCATION FROM WHICH FUMES COULD REACH
THE APPLIANCE OR VENT-AIR INTAKE SYSTEM.
6. Appliance surfaces become hot during operation. Be careful
not to touch hot surfaces. Keep all adults, children, and
animals away from operation of the hot unit. Severe burns
can occur.
7. You must take adequate care to prevent scald injury when
storing water at elevated temperatures for domestic use.
8. This unit must have an adequate supply of fresh air during
operation for proper gas combustion and venting.
9. Make sure all exhaust venting is properly installed and
maintained. Improper venting of this unit could lead to
increased levels of carbon monoxide.
10. Do not use this boiler if any part has been under water.
Immediately call a qualified service technician to replace
the boiler. The possible damage to a flooded boiler can
be extensive and present numerous safety hazards. Any
appliance that has been under water must be replaced.
11. Do not alter this unit in any way. Any change to this unit or
its controls can be dangerous.
To minimize the possibility of serious
personal injury, fire or damage to your
unit, never violate the following safety
rules.
4
The Copper-fin II - How it works...
Installation & Operation Manual
1. Heat exchanger
The heat exchanger allows system water to flow through specially
designed tubes for maximum heat transfer. The glass lined
headers and copper fined tubing are encased in a jacket that
contains the combustion process.
2. Heat exchanger access cover
The heat exchanger access cover is a galvanized steel door which
allows access for service, maintenance, and removal of the
heat exchanger from inside the combustion chamber.
3. Blower
The blower pulls in and injects air into the individual burners
along with gas from the gas manifold where the mix is burned inside
the combustion chamber.
4. Gas valve
The gas valves (reference) have a dual purpose; changing the gas
supply pressure to manifold pressure, and the reference side of the
gas valve is designed to allow chamber pressure to change the
volume of gas through the valve and measured as net manifold
pressure. This is not a design to compensate for gas supply
pressure issues.
5. System / tank temperature sensor (not shown)
When connected, this sensor can be used as a system sensor or a
tank sensor.
6. Outlet/limit temperature sensor
This sensor monitors the outlet water temperature. If
selected as the controlling sensor and a system supply
sensor is not connected, the appliance will maintain
set point by adjusting the firing rate of the unit according to
this sensor.
7. Inlet temperature sensor
This sensor monitors inlet water temperature. If selected as
the controlling sensor and a system return sensor
is not connected, the appliance will maintain set point
by adjusting the firing rate of the unit according to this
sensor.
8. Temperature and pressure gauge (boilers only)
The temperature and pressure gauge monitors the outlet
temperature of the appliance as well as the system water
pressure.
9. Electronic display
The electronic display consists of 6 buttons and a two-line
16-character liquid crystal display used to monitor the
operation of the heater as well as enter and view the
programming of the main control board.
10. Burner
The burner is a ported stainless steel construction which uses a gas
air mix to operate at a fixed input. Banks of burners turn on
or off to vary the firing rate.
11. Water outlet (system supply)
The water outlet is a 2 or 2 1/2" (depending on model) pipe
connection that supplies water to the system with connections
for a flow switch (see #26), a relief valve (see #23), and a
temperature and pressure gauge (boilers only) (see #8).
12. Water inlet (system return)
The water inlet is a 2 or 2 1/2" (depending on model) pipe
connection that receives water from the system and delivers it to
the heat exchanger.
13. Gas supply pipe
The gas supply pipe on this appliance is 1 1/4 or 2" (depending on
model) diameter NPT. Please reference the National Fuel Gas
Code charts for connection details.
14. SMART SYSTEM Control Module
The SMART System Control Module is the main control for the
appliance. This module contains the programming that
operates the blower, gas valve, and pumps in addition to other
programmable features.
15. Air intake
Fresh air for combustion is drawn through a filter provided at the
air intake, located at either the rear or right side of the appliance.
16. Line voltage terminal strip
The line voltage terminal strip provides a location to connect
all of the line voltage (120 VAC) contact points to the unit.
17. Low voltage connection board(s)
The low voltage connection board provides a location to connect
all of the low voltage devices to the appliance. This is where most
of the external safety controls are connected.
18. Front doors - upper and lower
The front doors provide access to the gas train as well as the
blower, burners and other key components for service and
maintenance.
19. Hot surface igniter (HSI)
The hot surface igniter is a device that is used to ignite the
air/gas mixture as well as monitor the performance of the flame
during operation. This device acts as a flame sense electrode.
20. Flame inspection window (sight glass)
The flame inspection windows, located on either side of the
appliance, allow for visual inspection of the burners and flame
during operation.
21. Gas shut off valve (downstream test cock) (boiler only)
The downstream test cock is provided in the gas train to ensure
complete shut off of the gas to the burner in case of
maintenance, inspection, or testing of the valve.
22. Manual reset high limit sensor
This device monitors the outlet water temperature to ensure
safe operation. If the temperature exceeds its setting (field
adjustable), it will break the control circuit, shutting the
appliance down. Manual reset is performed through the display.
23. Relief valve
The relief valve is a safety device that ensures the maximum
pressure of the appliance is not exceeded. Boilers operate on
pressure only and are shipped from the factory at a rating of
50 PSI. Water heaters operate on temperature and pressure and
are shipped standard as 150 PSI and 210°F (98.9°C).
24. Power switch
The power switch is used to engage and disengage power to the
appliance on the 120 VAC circuit.
25. Air pressure switch
The air pressure switch is a safety device which ensures proper
blower operation. The air pressure switch is wired in series with
the low voltage control circuit in such a way that if the fan does not
engage or shuts down prematurely the device will break the
control circuit and the unit will shut down.
26. Flow switch
The flow switch is a safety device that ensures flow through the
heat exchanger during operation. This appliance is low mass and
should never be operated without flow. The flow switch makes
contact when flow is detected and allows the unit to operate. If
flow is discontinued during operation for any reason the flow
switch will break the control circuit and the unit will shut down.
27. Drain port(s)
The drain ports are located underneath the front header.
28. Manual shutoff valve (not shown)
Manual valve used to isolate the unit from the gas supply.
5
The Copper-fin II - How it works...
18
13
27
18
15
23
26
4
25
24
16
14
3
17
10
19
21
2
7
12
8
6
22
11
20
1
9
Installation & Operation Manual
13
27
18
Models 402 - 752 Front View
18
15
23
26
Models 402 - 752 Rear View
14
17
16
24
10
19
21
Models 402 - 752 Right Side (inside unit)
6
22
25
11
Models 402 - 752 Left Side (inside unit)
12
20
Installation & Operation Manual
18
13
27
18
15
26
23
8
3
4
2
21
19
10
24
16
25
17
14
6
22
7
9
1
20
12
11
8
The Copper-fin II - How it works... (continued)
13
27
18
18
Models 992 - 2072 Front View
15
26
23
Models 992 - 2072 Rear View
14
25
17
16
24
10
Models 992 - 2072 Right Side (inside unit)
19
21
11
Models 992 - 2072 Left Side (inside unit)
22
12
20
7
Ratings
Installation & Operation Manual
Copper-fin II
I=B=R Rating
Model Number
Note: Change “N” to
“L” for L.P. gas models.
CFN0402 250 399 339 295
CFN0502 250 500 425 370
CFN0652 250 650 553 481
CFN0752 250 750 638 555
CFN0992 360 990 842 732
CFN1262 360 1260 1071 931
CFN1442 360 1440 1224 1064
CFN1802 360 1800 1530 1330
CFN2072 630 2070 1760 1530
CHN0402 250 399 339 295
CHN0502 250 500 425 370
CHN0652 250 650 553 481
CHN0752 250 750 638 555
CHN0992 360 990 842 732
CHN1262 360 1260 1071 931
CHN1442 360 1440 1224 1064
CHN1802 360 1800 1530 1330
CHN2072 630 2070 1760 1530
Min Max
Input
MBH
(Note 4)
Gross
Output
MBH
(Note 1)
Net
I=B=R
Ratings
Water,
MBH
(Note 2)
Other Specifications
Appliance
Water
Content
Gallons
1.6 2" 1-1/4" 6"
1.7 2" 1-1/4" 6"
2.0 2" 1-1/4" 8"
2.1 2" 1-1/4" 8"
2.2 2-1/2" 2" 10"
2.6 2-1/2" 2" 12"
2.9 2-1/2" 2" 12"
3.3 2-1/2" 2" 12"/14"
3.6 2-1/2" 2" 12"/14"
1.6 2" 1-1/4" 6"
1.7 2" 1-1/4" 6"
2.0 2" 1-1/4" 8"
2.1 2" 1-1/4" 8"
2.2 2-1/2" 2" 10"
2.6 2-1/2" 2" 12"
2.9 2-1/2" 2" 12"
3.3 2-1/2" 2" 12"/14"
3.6 2-1/2" 2" 12"/14"
Water
Connections
Gas
Connections
Air / Vent
Sizes
(Note 3)
NOTICE
Maximum allowed working pressure is located on the rating plate.
Notes:
1. The ratings are based on standard test procedures prescribed
by the United States Department of Energy.
2. Net I=B=R ratings are based on net installed radiation of
sufficient quantity for the requirements of the building
and nothing need be added for normal piping and pickup.
Ratings are based on a piping and pickup allowance of 1.15.
8
3. Copper-fin II’s require special gas venting. Use only the
vent materials and methods specified in the Copper-fin II
Installation and Operation Manual.
4. The Copper-fin II is orificed for operation up to 2000
feet altitude, and including up to 4,500 feet, with no field
adjustments. The appliance will de-rate by 4% for each
1000 feet above sea level up to 4,500 feet. Consult the
factory for installations above 4,500 feet elevation.
1 Determine unit location
Location of unit
This unit meets the safe lighting performance criteria with the
gas manifold and control assembly provided, as specified in
the ANSI standards for gas-fired units, ANSI Z21.13/CSA 4.9
and ANSI Z21.10.3/CSA 4.3 - latest edition.
1. Maintain all clearances from combustible construction
when locating appliance. See Clearances from Combustible
Construction, this page.
2. Locate the appliance so that if water connections should
leak, water damage will not occur. When such locations
cannot be avoided, it is recommended that a suitable
drain pan, adequately drained, be installed under the unit.
The pan must not restrict combustion airflow. Under no
circumstances is the manufacturer to be held responsible
for water damage in connection with this unit, or any of its
components.
3. The appliance must be installed so that the ignition
system components are protected from water (dripping,
spraying, rain, etc.,) during appliance operation and service
(circulator replacement, control replacement, etc.,).
4. Appliances located in a residential garage and in adjacent
spaces that open to the garage and are not part of the living
space of a dwelling unit must be installed so that all burners
and burner ignition devices have a minimum clearance of
not less than 18" (46 cm) above the floor. The appliance
must be located or protected so that it is not subject to
physical damage by a moving vehicle.
5. DO NOT install this appliance in any location where
gasoline or flammable vapors are likely to be present.
6. The appliance must be installed on a level floor.
7. Combustible floor installation:
a. Models 402 - 752 require an approved floor kit for
installation on combustible flooring (reference Table
1A).
b. Models 992 - 2072 are approved for installation
on combustible flooring without a floor kit. Note:
Concrete block over wood flooring is not considered
non-combustible.
8. DO NOT install this appliance directly on carpeting or
other combustible material.
9. Maintain required clearances from combustible surfaces,
reference the Indoor Clearances from Combustible
Construction Section, this page.
10. For outdoor models, you must install an optional vent
cap. Instructions for mounting the vent cap are included
in the venting section of this manual. Do not install
outdoor models directly on the ground. You must install
the outdoor unit on a concrete, brick, block, or other
non-combustible pad. Outdoor models have additional
special location and clearance requirements. See Outdoor
Installation Venting, page 30. A wind proof cabinet
protects the unit from weather.
Indoor clearances from combustible
construction
Maintain minimum specified clearances for adequate
operation. Allow sufficient space for servicing pipe
connections, pump and other auxiliary equipment, as well
as the unit. See rating plate for specific service clearance
requirements.
Installation & Operation Manual
Right Side 3" (7.5 cm)
Rear 3" (7.5 cm) (3" min. from any surface)*
Left Side 6" (15 cm) (24" (0.61 m) suggested for
service)
Front Alcove* (30" (0.76m) suggested for service)
Top 3" (7.5 cm)
Flue 1" (25.4 mm)
Hot Water Pipes 1" (25.4 mm)
*An Alcove is a closet without a door. Thirty-six inches (36")
to rear required for outdoor installation.
Note: No additional clearance is needed on the right side of the
unit for the observation port. An observation port is located on
both the right and left side of the unit.
Figure 1-1_Indoor clearances from combustible construction
3"
MIN
TOP
3"
MIN
RIGHT SIDE
6"
MIN
LEFT SIDE
NOTICE
3"
MIN
REAR
30"
MIN
FRONT
Clearances from combustible construction
are noted on the appliance rating plate.
TABLE - 1A
COMBUSTIBLE FLOOR KITS
Model Kit Number
402 CFK3301
502 CFK3302
652 CFK3303
752 CFK3304
Freeze protection
Although these units are CSA International design-certifi ed for
outdoor installations, such installations are not recommended
in areas where the danger of freezing exists. You must provide
proper freeze protection for outdoor installations, units installed
in unheated mechanical rooms or where temperatures may
drop to the freezing point or lower. If freeze protection is not
provided for the system, a low ambient temperature alarm is
recommended for the mechanical room. Damage to the unit by
freezing is non-warrantable.
9
1 Determine unit location
Anytime the inlet temperature drops below 45°F, the
control turns on the pump contact. If the inlet temperature is
below 37°F, and the unit is in the ON Mode, the fi rst stage will
fi re.
Location
Locate indoor boilers and water heaters in a room having a temperature safely above freezing [32°F (0°C)].
Installation & Operation Manual
CAUTION
A mechanical room operating under a negative
draft pressure may experience a down draft
in the flue of a boiler when it is not firing.
The cold outside air pulled down the flue
may freeze a heat exchanger. This condition
must be corrected to provide adequate freeze
protection.
Hydronic systems anti-freeze
Freeze protection for a heating boiler or hot water supply boiler
using an indirect coil can be provided by using hydronic system
antifreeze. Follow the appliance manufacturers instructions. Do
not use undiluted or automotive type antifreeze (see page 47).
Outdoor boiler installation
Adequate hydronic system antifreeze must be used. A snow
screen should be installed to prevent snow and ice accumulation
around the unit or its venting system.
Combustion and ventilation air
Provisions for combustion and ventilation air must be in
accordance with Air for Combustion and Ventilation, of the
latest edition of the National Fuel Gas Code, ANSI Z223.1,
in Canada, the latest edition of CAN/CGA-B149 Installation
Code for Gas Burning Appliances and Equipment, or applicable
provisions of the local building codes.
Provide properly-sized openings to the equipment room to
assure adequate combustion air and proper ventilation when
the unit is installed with conventional venting or sidewall
venting.
Combustion air options
CAUTION
This unit has four combustion air options.
1. Outside Combustion Air, No Ducts
You can direct outside combustion air to this unit using either
one or two permanent openings (see FIG. 1-2).
Under no circumstances should the
equipment room ever be under a
negative pressure. Particular care
should be taken where exhaust fans,
attic fans, clothes dryers, compressors,
air handling units, etc., may take away
air from the unit.
Figure 1-2_Outside Combustion Air - Single Opening
Two Openings
The combustion air opening must have a minimum free area of
one square inch per 4000 Btu/hr input (5.5 cm2 per kW). You
must locate this opening within 12" (30 cm) of the bottom of the
enclosure (see FIG. 1-3).
The ventilation air opening must have a minimum free area of
one square inch per 4000 Btu/hr input (5.5 cm2 per kW). You
must locate this opening within 12" (30 cm) of the top of the
enclosure.
Figure 1-3_Outside Combustion Air - Two Openings
2. Outside Combustion Air, Using Ducts
You can direct outside combustion air to this unit using two air
ducts to deliver the air to the boiler room (see FIG. 1-5).
Each of the two openings must have a minimum free area of one
square inch per 2000 Btu input (11cm2 per kW).
3. Combustion Air from Interior Space
You can direct combustion air to this unit using air from an
adjoining interior space. You must provide two openings from
the boiler room to the adjoining room (see FIG. 1-4).
Each of the two openings must have a net free area of one square
inch per 1000 Btu input (22cm2 per kW), but not less than 100
square inches (645cm2).
One Opening
The opening must have a minimum free area of one square
inch per 3000 Btu input (7 cm2 per kW). You must locate this
opening within 12" (30 cm) of the top of the enclosure.
10
Figure 1-4_Combustion Air from Interior Space
1 Determine unit location (continued)
All dimensions are based on net free area in square inches.
Metal louvers or screens reduce the free area of a combustion air
opening a minimum of approximately 25%. Check with louver
manufacturers for exact net free area of louvers. Where two
openings are provided, one must be within 12" (30 cm) of the
ceiling and one must be within 12" (30 cm) of the floor of the
equipment room. Each opening must have a minimum net free
area as specified in TABLE 1C, page 11. Single openings shall be
installed within 12" (30 cm) of the ceiling.
Installation & Operation Manual
Figure 1-5_Outside Combustion Air Through Ducts
4. Outside Combustion Air - Using Direct Venting
With this option, you can connect combustion air vent piping
directly to the unit. See the information under Direct Venting
starting on page 26 for specific information regarding this
option.
TABLE - 1C
MINIMUM RECOMMENDED COMBUSTION
AIR SUPPLY TO EQUIPMENT ROOM
*Outside Air from
Model
Number
402
502
652
752
992
1262
1442
1802
2072
2 Openings Directly from
Outdoors
Top
Opening, in
100
(645 cm2)
125
(806 cm2)
163
(1052 cm2)
188
(1213 cm2)
248
(1600 cm2)
315
(2032cm2)
360
(2323cm2)
450
(2903cm2)
518
(3342cm2)
Bottom
2
Opening, in
(645 cm2)
(806 cm2)
(1052 cm2)
(1213 cm2)
(1600 cm2)
(2032cm2)
(2323cm2)
(2903cm2)
(3342cm2)
100
125
163
188
248
315
360
450
518
*Outside Air from
1 Opening Directly
from Outdoors, in
2
133
(858 cm2)
167
(1077 cm2)
217
(1400 cm2)
250
(1613 cm2)
330
(2129 cm2)
420
(2710 cm2)
480
(3097 cm2)
600
(3871 cm2)
690
(4452 cm2)
2
CAUTION
The combustion air supply must be
completely free of any flammable vapors
that may ignite or chemical fumes which
may be corrosive to the appliance. Common
corrosive chemical fumes which must be
avoided are fluorocarbons and other
halogenated compounds, most commonly
present as refrigerants or solvents, such as
Freon, trichlorethylene, perchlorethylene,
chlorine, etc. These chemicals, when
burned, form acids which quickly attack
the heat exchanger finned tubes, headers,
flue collectors, and the vent system. The
result is improper combustion and a nonwarrantable, premature unit failure.
Inside Air from
2 Ducts Delivered from
Outdoors
Top
Opening, in
2
Opening, in
Bottom
200
(1291 cm2)
(1291 cm2)
250
(1613 cm2)
(1613 cm2)
325
(2097 cm2)
(2097 cm2)
375
(2420 cm2)
(2420 cm2)
495
(3194 cm2)
(3194 cm2)
630
(4065 cm2)
(4065 cm2)
720
(4646 cm2)
(4646 cm2)
900
(5807 cm2)
(5807 cm2)
1035
(6678 cm2)
(6678 cm2)
200
250
325
375
495
630
720
900
1035
Inside Air from
2 Ducts Delivered from Interior
Space
2
Opening, in
(2581 cm2)
(3226 cm2)
(4194 cm2)
(4839 cm2)
(6388 cm2)
(8130 cm2)
(9291 cm2)
(11614 cm2)
(13356 cm2)
Top
400
500
650
750
990
1260
1440
1800
2070
2
Opening, in
(2581 cm2)
(3226 cm2)
(4194 cm2)
(4839 cm2)
(6388 cm2)
(8130 cm2)
(9291 cm2)
(11614 cm2)
(13356 cm2)
Bottom
400
500
650
750
990
1260
1440
1800
2070
2
*Outside air openings shall directly communicate with the outdoors. When combustion air is drawn from the outside through a
duct, the net free area of each of the two openings must have twice (2 times) the free area required for Outside Air/2 Openings.
The above requirements are for the boiler only; additional gas fired appliances in the equipment room will require an increase in
the net free area to supply adequate combustion air for all appliances.
11
1 Determine unit location
Installation & Operation Manual
Exhaust fans
Any fan or equipment which exhausts air from the boiler room
may deplete the combustion air supply and/or cause a down
draft in the venting system. Spillage of flue products from the
venting system into an occupied living space can cause a very
hazardous condition that must be immediately corrected. If a
fan is used to supply combustion air to the boiler room, the
installer must make sure that it does not cause drafts which
could lead to nuisance operational problems with the boiler.
Vertical DirectAire™, Horizontal DirectAire™, and Direct Vent
venting systems have specific requirements for combustion air
ducts from the outside which are directly connected to the unit.
See the requirements for combustion air duct in the venting
section.
NOTICE
Use of filters having MERV (Minimum
Efficiency Reporting Value) ratings higher than
4 is not recommended. Higher efficiency
low-micron filters can limit combustion
air leading to either nuisance problems or
potential component damage if used over
prolonged periods of time. Filters having
a MERV rating of 5 to 6 may be used
on a limited basis during the construction
phase of a project provided they are replaced
once filter loading becomes apparent. After
the construction phase is completed, it is
recommended that the filter be changed to a
4 or lower MERV disposable type filter.
Combustion air filter
This unit has a standard air filter located at the combustion air
inlet. This filter helps ensure clean air is used for the combustion
process. Check this filter every month and replace when it
becomes dirty. The filter size on Models 402 - 752 is 12" x 12"
x 1" (30.5cm x 30.5cm x 2.5cm) and 16" x 16" x 1" (40.6cm x
40.6cm x 2.5 cm) on Models 992 - 2072. You can find these
commercially available filters at any home center or HVAC
supply store.
For convenience and flexibility, you can direct the combustion
air inlet from either the back or right side of the unit. To arrange
the combustion air inlet for side entry, follow the steps below:
1. Remove the metal panel from the unit’s side wall (see
FIG. 1-6).
2. Remove screws from the air filter/bracket assembly.
3. Move the filter/bracket assembly from the rear of unit to the
side opening (see FIG. 1-7).
4. Attach filter/bracket assembly to the unit’s side using the
pre-drilled screw holes.
5. Attach the metal panel to the rear combustion air opening
to seal it off.
Figure 1-6_Metal Panel Covering Side Combustion
Air Inlet
NOTICE
CAUTION
During construction the air filter should be checked more frequently to ensure it does not become clogged with
combustion dirt and debris.
Sustained operation of an appliance with a clogged filter may result in nuisance operational problems, bad
combustion, and non-warrantable component failures.
12
Figure 1-7_Moving Air Filter / Bracket Assembly from
Rear of Unit to Side
Installation & Operation Manual
2 Venting
BEFORE YOU BEGIN
Identify your appliance’s vent system:
This manual covers venting requirements for CAT I models and CAT IV vent materials. Be sure to correctly identify the type of
vent system your appliance requires before proceeding.
C(F,H) (N,L)0402
C(F,H) (N,L)0502
C(F,H) (N,L)0652
C(F,H) (N,L)0752
C(F,H) (N,L)0992
C(F,H) (N,L)1262
C(F,H) (N,L)1442
C(F,H) (N,L)1802
C(F,H) (N,L)2072
Venting options:
A B C
E
F
= Direct Vent Options
CAT IV
= Outdoor Vent Option
D
= B-Vent Material
CAT I
DANGER
Failure to use correct venting materials can result in loss of life from flue gas spillage into working or living
space.
Venting Category Definitions: (Reference National Fuel Gas Code ANSI Z223.1)
CAT I: Negative pressure non-condensing
An appliance that operates with a non-positive vent static pressure with a vent gas temperature that avoids excessive condensate
production in the vent.
CAT IV: Positive pressure condensing
An appliance that operates with a positive vent static pressure with a vent gas temperature that may cause excessive condensate
production in the vent.
CAT IV Flue pipe materials
The following manufacturers supply flue materials suitable for these models when installed as CAT IV. All materials are made with
AL29-4C stainless steel.
Heat-Fab Inc., Saf-T CI Vent with AL29-4C stainless steel
Protech Systems Inc., Fas N Seal Vent with AL29-4C stainless steel
Metal-Fab Inc., Corr/Guard Vent with AL29-4C stainless steel
Or other listed Category IV vent systems suitable for a condensing, positive pressure, gas fired appliance.
A Category IV flue MUST have all vent joints and seams sealed gastight and have provisions for a drain to properly collect and
dispose of condensate that may occur in the venting system.
13
12"
MIN
3'
MIN
Installation & Operation Manual
2 Venting
Vent system options: (Note: Installations shown below are representative, actual installations may vary from those shown.)
This option uses a vertical rooftop flue termination
with air supplied from the equipment room - see
A
CONVENTIONAL NEGATIVE
DRAFT VENTING
page 16.
This option uses a vertical conventional vent for
flue products with air supplied by a pipe from the
B
VERTICAL DIRECTAIRE VENTING
sidewall or rooftop - see page 19.
This option uses a powered vent assembly to
exhaust the flue products out a sidewall with air
D
HORIZONTAL DIRECTAIRE
VENTING
supplied by a pipe from the sidewall - see page 25.
3'
MIN
12"
MIN
This option uses a sealed AL29-4C flue and a
separate combustion air pipe to the outdoors.
E
This system terminates both the flue and
combustion air inlet in the same pressure zone
DIRECT VENT
- see page 26.
NOTE: CAT I B-VENT MATERIALS MAY BE USED WHEN THE
POWERED VENT IS CONNECTED DIRECTLY TO THE OUTSIDE
VENT CAP. IF THE POWERED VENT IS NOT CONNECTED
DIRECTLY TO THE OUTSIDE VENT CAP, THEN CAT IV - AL29-4C
VENT MATERIALS MUST BE USED FROM THE POWERED VENT
TO THE OUTSIDE VENT CAP.
3'
This option uses the installation of a special air
inlet / vent cap on top of the unit - see page 30.
C
This option uses a powered vent assembly
to exhaust the flue products out a sidewall
vent termination with air supplied from the
F
equipment room - see page 22.
SIDEWALL VENTING
NOTE: CAT I B-VENT MATERIALS MAY BE USED WHEN THE
POWERED VENT I S CONNECTED DIRECTLY TO THE OUTSIDE
VENT CAP. IF THE POW ERED VENT IS NOT CONNECTED
DIRECTLY TO THE OUTSIDE VENT CAP, THEN CAT IV - AL29-4C
VENT MATERIALS MUST BE USED FROM THE POWERED VENT
TO THE OUTSIDE VENT CAP.
OUTDOOR VENTING
14
Installation & Operation Manual
2 Venting (continued)
General information
You must supply adequate combustion and ventilation air to this unit. You must provide minimum clearances for the vent
terminal from adjacent buildings, windows that open, and building openings. Follow all requirements set forth in the latest edition
of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of CAN/CGA Standard B149 Installation Code for Gas
Burning Appliances and Equipment or applicable local building codes. Vent installations for connection to gas vents or chimneys
must be in accordance with “Venting of Equipment” of the above-mentioned standards.
NOTICE
Examine the venting system at least once each year. Check all joints and vent pipe connections for tightness. Also
check for corrosion or deterioration. If you find any problems, correct them at once.
Venting support
Support horizontal portions of the venting system to prevent sagging. Provide an upward slope of at least 1/4 inch per foot
(21mm/m) on all horizontal runs from the unit to the vertical flue run or to the vent terminal on sidewall venting installations.
Do not use an existing chimney as a raceway if another appliance or fireplace is vented through the chimney. The weight of the
venting system must not rest on the unit. Provide adequate support of the venting system. Follow all local and applicable codes.
Secure and seal all vent connections. Follow the installation instructions from the vent material manufacturer.
Barometric damper location
Any venting system option that requires a barometric damper must adhere to the following directions for optimum performance.
The preferred location for the barometric damper is in a tee or collar installed in the vertical pipe rising from the unit’s flue outlet.
The barometric damper MUST NOT be installed in a bull head tee installed on the unit’s flue outlet. The tee or collar containing
the barometric damper should be approximately three feet vertically above the connection to the unit’s flue outlet. This location
ensures that any positive velocity pressure from the unit’s internal combustion fan is dissipated and the flue products are rising
due to buoyancy generated from the temperature of the flue products. Adjust the weights on the damper to ensure that draft is
maintained within the specified range.
TABLE - 2A
FLUE AND AIR INLET PIPE SIZES
MODEL FLUE SIZE AIR INLET SIZE MODEL FLUE SIZE AIR INLET SIZE*
402 6" 6" 992 10" 10"
502 6" 6" 1262 12" 12"
652 8" 8" 1442 12" 12"
752 8" 8" 1802 14" 12"
-- -- -- 2072 14" 12"
*Minimum diameter for air inlet pipe. Installer may increase diameter one pipe size for ease of installation, if needed.
15
2 Venting
Conventional negative draft venting - see page 14.
A
NOTICE
This option uses Type-B double-wall flue outlet piping. The blower brings in combustion air. The buoyancy of the
heated flue products cause them to rise up through the flue pipe. The flue outlet terminates at the rooftop.
Negative draft
The negative draft in a conventional vent installation must be within the range of 0.02 to 0.08 inches w.c. to ensure
proper operation. Make all draft readings while the unit is in stable operation (approximately 2 to 5 minutes).
Connect the flue vent directly to the flue outlet opening on the top of the unit. No additional draft diverter or
barometric damper is needed on single unit installations with a dedicated stack and a negative draft within the
specified range of 0.02 to 0.08 inches w.c. If the draft in a dedicated stack for a single unit installation exceeds the
maximum specified draft, you must install a barometric damper to control draft. Multiple unit installations with
combined venting or common venting with other Category I negative draft appliances require each boiler to have a
barometric damper installed to regulate draft within the proper range.
Do not connect vent connectors serving appliances vented by natural draft (negative draft) to any portion of a
mechanical draft system operating under positive pressure. Connecting to a positive pressure stack may cause flue
products to be discharged into the living space causing serious health injury.
Installation & Operation Manual
Before installing a venting system, follow requirements found in the General Venting section.
Flue outlet piping
With this venting option, you must use Type-B double-wall vent materials. Vent materials must be listed by a
nationally-recognized test agency for use as vent materials. Make the connections from the unit vent to the outside
stack as direct as possible with no reduction in diameter. Use the National Fuel Gas Code venting tables for doublewall vent to properly size all vent connectors and stacks. Follow the vent manufacturer’s instructions when installing
Type-B vents and accessories, such as firestop spacers, vent connectors, thimbles, caps, etc.
Provide adequate clearance to combustibles for the vent connector and firestop.
When planning the venting system, avoid possible contact with plumbing or electrical wiring inside walls, ceilings,
and floors. Locate the unit as close as possible to a chimney or gas vent.
Avoid long horizontal runs of the vent pipe, 90° elbows, reductions and restrictions.
No additional draft diverter or barometric damper is required on single unit installations with a dedicated stack and
a negative draft maintained between 0.02 to 0.08 inches w.c.
Common Venting Systems
You can combine the flue with the vent from any other negative draft, Category I appliance. Using common venting
for multiple negative draft appliances requires you to install a barometric damper with each unit. This will regulate
draft within the proper range. You must size the common vent and connectors from multiple units per the venting
tables for Type-B double-wall vents in the latest edition of the National Fuel Gas Code, ANSI Z223.1 and/or CAN/
CGA-B149 Installation Code.
16
Common venting systems may be too large when an existing unit is removed.
At the time of removal of an existing appliance, the following steps shall be followed with each appliance remaining
connected to the common venting system placed in operation, while other appliances remaining connected to the
common venting system are not in operation.
1. Seal any unused opening in the common venting system.
2. Visually inspect the venting system for proper size and horizontal pitch. Make sure there is no blockage or
restriction, leakage, corrosion and other unsafe conditions.
3. If possible, close all building doors and windows. Close all doors between the space in which the appliances
remaining connected to the common venting system are located and other building spaces.
Installation & Operation Manual
2 Venting (continued)
4. Turn on clothes dryers and any other appliances 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.
5. Close fireplace dampers.
6. Place in operation the unit being inspected. Follow the lighting instructions. Adjust thermostat so unit will operate continuously.
7. 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.
8. After making sure that each appliance remaining connected to the common venting system properly vents when tested as above,
return doors, windows, exhaust fans, fireplace dampers and other gas burning appliances to their previous conditions of use.
9. Correct any improper operation of the common venting system so that the installation conforms to the latest edition of the
National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of CAN/CGA-B149 Installation Code for Gas Burning
Appliances and Equipment. When resizing any portion of the common venting system, resize to approach the minimum size as
determined using the appropriate tables of the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest
edition of CAN/CGA-B149 Installation Code for Gas Burning Appliances and Equipment.
Masonry chimney installations
A masonry chimney must be properly sized for the installation of a high efficiency gas-fired appliance. Venting of a high efficiency
appliance into a cold or oversized masonry chimney can result in operational and safety problems. Exterior masonry chimneys,
with one or more sides exposed to cold outdoor temperatures, are more likely to have venting problems. The temperature of the
flue products from a high efficiency appliance may not be able to sufficiently heat the masonry structure of the chimney to generate
proper draft. This will result in condensing of flue products, damage to the masonry flue/tile, insufficient draft and possible spillage
of flue products into an occupied living space. Carefully inspect all chimney systems before installation.
WARNING
NOTICE
Inspection of a masonry chimney
A masonry chimney must be carefully inspected to determine its suitability for the venting of flue products. A clay-tile-lined
chimney must be structurally sound, straight and free of misaligned tile, gaps between liner sections, missing sections of liner or any
signs of condensate drainage at the breaching or clean out. If there is any doubt about the condition of a masonry chimney, it must
be relined with a properly-sized and approved chimney liner system. An unlined masonry chimney must not be used to vent flue
products from this high-efficiency unit. An unlined chimney must be relined with an approved chimney liner system when a new
appliance is being attached to it. Metallic liner systems (Type-B double-wall or flexible or rigid metallic liners) are recommended.
Consult with local code officials to determine code requirements or the advisability of using or relining a masonry chimney.
Do not vent this unit into a masonry chimney without a sealed stainless steel liner system. Any breaks, leaks,
or damage to the masonry flue/tile will allow the flue products to leak from the chimney and into occupied
living spaces. This could cause serious injury or death due to carbon monoxide poisoning and other harmful
flue products.
Check with local code officials to determine code requirements or the advisability of using a masonry chimney
with a sealed corrosion-resistant liner system.
Vertical vent termination clearances and location
The vent terminal should be vertical and exhaust outside the building at least 2 feet (0.61m) above the highest point of the roof
within a 10 foot (3.05m) radius of the termination.
The vertical termination must be a minimum of 3 feet (0.91m) above the point of exit.
A vertical termination less than 10 feet (3.05m) from a parapet wall must be a minimum of 2 feet (0.61m) higher than the parapet
wall.
Keep the vent cap clear of snow, ice, leaves, and debris to avoid blocking the flue.
17
2 Venting
Installation & Operation Manual
Figure 2-1_Vent Termination from Peaked Roof - 10 ft.
or Less From Ridge
NOTICE
Figure 2-3_Vent Termination from Flat Roof - 10 ft.
or Less From Parapet Wall
Vent terminations are not shown in FIG.’s 2-1 thru 2-4. Make sure all vertical vents are installed with vent
terminations recommended by the vent manufacturer.
Figure 2-2_Vent Termination from Peaked Roof - 10 ft.
or More From Ridge
Figure 2-4_Vent Termination from Flat Roof - 10 ft. or
More From Parapet Wall
18
2 Venting (continued)
Vertical DirectAire ™ venting - see page 14.
NOTICE
B
Combustion air inlet piping
The Vertical DirectAire™ vent system is the same as the Conventional Negative Draft vent system, except it pulls
combustion air from the outdoors through a separate air inlet pipe. Follow all requirements in the Conventional
Negative Draft Venting section on page 16.
The Vertical DirectAire™ vent system requires you to install two pipes directly to the unit; one vertical pipe with
a rooftop termination for the flue products and one pipe for combustion air. For this venting option, you must
purchase the DV box adapter from the appliance manufacturer. The DV box attaches to the air inlet of the unit. The
pipe for combustion air attaches to the DV box (see FIG. 2-11 on page 28). Reference page 28 for a list of approved
air intake materials.
Before installing a venting system, follow requirements found in the General Venting section.
Installation & Operation Manual
WARNING
The sidewall or vertical rooftop DirectAire™ combustion air supply system has specific material and installation requirements. The
air inlet pipe connects directly to the unit to supply combustion air. In most installations, the combustion air inlet pipe will be a
dedicated system with one air inlet pipe per unit. You can combine multiple air inlets if the guidelines in Combined Air Inlet Points,
page 20 are followed. The air inlet pipe will be connected to a combustion air inlet cap as specified in this section.
For normal installations, this system uses a single-wall pipe to supply combustion air from outdoors directly to the unit.
In cold climates, use a Type-B double-wall vent pipe or an insulated single-wall pipe for combustion air. This will help prevent
moisture in the cool incoming air from condensing and leaking from the inlet pipe.
Length of air inlet pipe
The installed length of air inlet pipe from the unit to the outside air inlet cap must not exceed 50 equivalent feet (15.2m). Subtract
5 feet (1.5m) of equivalent length for each 90° elbow. Subtract 2.5 feet (0.7m) of equivalent length for each 45° elbow.
Do not exceed the limits for the combustion air inlet piping lengths.
Sidewall air inlet
The sidewall air inlet cap is supplied in the Sidewall Air Inlet Kit. Order the kit from the appliance manufacturer. This sidewall cap
supplies combustion air for a single unit only. See Table 2B, page 21, for kit numbers.
Locate the unit as close as possible to the sidewall where you will install the combustion air supply system.
Locate and install the combustion air inlet cap correctly. Failure to do so can allow the discharge of flue products
to be drawn into the combustion process. This can result in incomplete combustion and potentially hazardous
levels of carbon monoxide in the flue products. This will cause operational problems and the spillage of flue
products. Spillage of flue products can cause personal injury or death due to carbon monoxide poisoning.
Figure 2-5_Sidewall Combustion Air Inlet
Figure 2-6_Air Inlet Cap for Sidewall Termination
19
Installation & Operation Manual
2 Venting
To prevent recirculation of flue products from an adjacent vent cap into the combustion air inlet, follow all applicable clearance
requirements in the latest edition of the National Fuel Gas Code and/or CAN/CGA-B149 Installation Code and instructions in the
Installation and Operation Manual.
Clearances
You must install the combustion air inlet cap at least one foot (0.30m) above ground level and above normal snow levels.
The point of termination for the combustion air inlet cap must be at least 3 feet (0.91m) below the point of flue gas termination if
it is located within 10 feet (3.05m) of the flue outlet. Make sure to properly install the air inlet cap assembly on the air inlet pipe.
Do not install the combustion air inlet cap closer than 10 feet (3.05m) from an inside corner of an L-shaped structure.
Vertical Rooftop Air Inlet
Use the vertical air inlet terminations available from the appliance manufacturer, recommended and/or supplied by the vent
manufacturer, or use two 90° elbows as described on page 29.
3'
MIN
12"
MIN
You must locate the air inlet termination elbow at least 12"
(30cm) above the roof or above normal snow levels.
If the air inlet cap is within a 10-foot (3.05m) radius of the flue
outlet, the point of termination for the combustion air inlet
cap must be at least 3 feet (0.91m) below the point of flue gas
termination (vent cap).
Do not install the combustion air inlet cap closer than 10 feet
(3.05m) from an inside corner of an L-shaped structure.
Combined air inlet points
The air inlet pipes from multiple boilers can be combined to a
single common connection if the common air inlet pipe has a
cross sectional area equal to or larger than the total area of all air
inlet pipes connected to the common air inlet pipe.
Example: Two 10" air inlet pipes (78.5 in2 area each) have a total
Figure 2-7_Rooftop Combustion Air Inlet
The air inlet point for multiple boiler air inlets must be provided with an exterior opening which has a free area equal to or greater
than the total area of all air inlet pipes connected to the common air inlet. This exterior opening for combustion air must connect
directly to the outdoors. The total length of the combined air inlet pipe must not exceed a maximum of 50 (15.2m) equivalent feet.
Subtract 5 feet (1.5m) for each 90° elbow in the air inlet pipe. You must deduct the restriction in area provided by any screens, grills
or louvers installed in the common air inlet point. These are common on the sidewall air inlet openings. Screens, grills or louvers
installed in the common air inlet can reduce the free area of the opening from 25% to 75% based on the materials used.
area of 157 in2 and will require a 15" (176.7 in2 area) common
air inlet pipe.
You can terminate the combustion air pipe either horizontally with a sidewall air inlet or vertically with a rooftop air inlet. The
installed length of air inlet pipe from the unit to the outside air inlet cap must not exceed 50 equivalent feet (15.2m).
20
2 Venting (continued)
Installation & Operation Manual
WARNING
3'
MIN
12"
MIN
Figure 2-8_Vertical DirectAire™ Installation
w/Rooftop Combustion Air Inlet
Only use a sidewall air inlet cap supplied by the appliance
manufacturer or a rooftop air inlet cap supplied by either the vent
or appliance manufacturer. Using any other air inlet cap for single
unit installations or using a common air inlet cap for multiple
units with insufficient free area and/or protections from wind and
weather may result in operational problems and the spillage of
flue products. Spillage of flue products can cause personal injury
or death due to carbon monoxide poisoning.
For single unit installations with sidewall air inlet you must order the sidewall air
inlet kit from the appliance manufacturer. The part number for each SVK kit is
listed by unit size in Table 2B.
For single unit installations with rooftop air inlet (see FIG. 2-8), you must order
the rooftop air inlet kit from the appliance manufacturer. The part number for
each VDK kit is listed by unit size in Table 2B. Purchase the flue pipe, rooftop
flue termination, and air inlet pipe locally.
There is no vent kit for combined air supply systems for multiple units. Make
sure the air inlet cap is properly sized. You must purchase this cap locally.
Venting of flue products
For venting flue products vertically to the outdoors, follow all requirements in
the installation instructions for conventional venting in this manual.
Follow all clearance requirements in Vertical Vent Termination Clearances and
Location on page 17.
A barometric damper is not required in the flue on Vertical DirectAire™
installations if the draft is within the negative 0.02 to 0.08 inches w.c. required
for proper operation. If the draft exceeds this range, install a barometric damper.
TABLE - 2B
DIRECTAIRE KITS
MODEL HORIZONTAL KIT* VERTICAL KIT*
402 SVK3047 VDK3026
502 SVK3047 VDK3026
652 SVK3048 VDK3027
752 SVK3048 VDK3027
992 SVK3040 VDK3023
1262 SVK3041 VDK3024
1442 SVK3041 VDK3024
1802 SVK3041 VDK3024
2072 SVK3041 VDK3024
*The SVK kits include a DV box adapter and sidewall air inlet cap. The VDK kits include a DV box adapter and a rooftop air inlet cap.
21
2 Venting
Sidewall venting - see page 14.
Installation & Operation Manual
C
NOTICE
This option uses a powered vent assembly which pulls the flue products out of the stack. This fan generates a negative
draft at the unit. Combustion air is drawn from the equipment room (see Combustion and Ventilation Air on 10).
Sidewall with fan
The sidewall fan can be mounted on the inside/outside (depending upon model) with a sidewall vent hood installed
on the exterior wall. The sidewall fan and accessories are included in a venting kit provided by the appliance
manufacturer. See Table 2C on page 24 for kit numbers.
The venting kit includes the sidewall fan, vent hood, tapered vent adapter, barometric damper (992 - 2072 Models),
proving switch and all necessary relays to interlock with the heaters control system. The tapered vent adapter reduces
the vent size at the inlet to the fan. There should be no reduction in vent diameter from the unit’s flue outlet to the
sidewall fan. The barometric damper must be installed on the flue and adjusted to supply a negative draft within the
range of 0.04 to 0.08 inches w.c. while unit is operating.
Flue outlet piping
With this venting option, you must use Type-B double-wall (or equivalent) vent materials. Vent materials must be
listed by a nationally-recognized test agency for use as vent materials. Make the connections from the unit vent to the
sidewall fan/cap as direct as possible with no reduction in diameter. Use the National Fuel Gas Code venting tables
for double-wall vent to properly size all vent connectors and stacks. Follow the vent manufacturer’s instructions
when installing Type-B vents and accessories, such as firestop spacers, vent connectors, thimbles, caps, etc.
When planning the venting system, avoid possible contact with plumbing or electrical wiring inside walls.
Before installing a venting system, follow all requirements found in the General Venting
section.
The maximum installed length of sidewall vent pipe with an induced draft fan must not exceed 100 feet (30.5m).
Subtract 5 feet (1.5m) for each 90° elbow. Subtract 2.5 feet (0.7m) for each 45° elbow.
Sidewall venting termination
The sidewall vent cap must be installed on an exterior sidewall. The sidewall fan/powered sidewall vent cap and
accessories are included in a venting kit which is furnished by the appliance manufacturer in accordance with CSA
International requirements. This venting kit includes the powered sidewall fan/cap, proving switch and all necessary
relays to interlock with the heaters control system.
The sidewall fan/powered vent cap must be interlocked with the units control system to start the fan on a call for
heat and prove fan operation before the boiler fires. Plug-in and terminal strip connections are provided on the unit
for easy connection of the factory supplied vent kit and control package for the sidewall vent fan. See the installation
instructions provided with the vent kit.
Sidewall vent termination clearances and location
Locate the bottom of the vent terminal at least 12 inches (30cm) above grade and above normal snow levels. Locate
the bottom of the vent terminal at least 7 feet (2.13m) above grade when located adjacent to public walkways. Do
not terminate directly above a public walkway.
Do not terminate the venting system in a window well, stairwell, alcove, courtyard, or other recessed area. Do not
terminate the venting system below grade.
Locate vent termination at least 3 feet (0.91m) from an inside corner of an L-shaped structure.
Provide a minimum clearance of 4 feet (1.2m) horizontally from electric meters, gas meters, regulators, and relief
equipment. Never locate vent cap above or below electric meters, gas meters, regulators, and relief equipment unless
a 4 foot (1.2m) horizontal clearance is maintained.
22
Installation & Operation Manual
2 Venting (continued)
Terminate the venting system at least 3 feet (0.9m) above any forced air inlet within 10 feet (3.05m).
Terminate the venting system at least 4 feet (1.2m) below, 4 feet (1.2m) beside, or 1 foot (30cm) above any door, window, or gravity
air inlet into any building.
Locate vent termination at least 8 feet (2.4m) horizontally from any combustion air intake located above the sidewall termination
cap.
CAUTION
Sidewall venting without fan
For Models 402 - 752 which are approved for sidewall venting without an external power vent fan, you must install specific vent
kits and venting materials (reference Table 2C on page 24 for kit numbers).
The following is a detailed explanation of Sidewall Venting Without an External Power Vent Fan installation requirements.
Flue outlet piping
Venting Guidelines
Units which are shut down or will not operate may experience freezing due to convective air flow in the flue
pipe, through the air inlet, or from negative pressure in the equipment room. In cold climates, operate the
pump continuously to help prevent freezing of boiler water. Provide proper freeze protection. See Freeze
Protection, page 47.
If using this venting option, a sealed AL29-4C venting system for flue products is required on all models of this appliance. This
venting system operates with a positive pressure in the vent. The internal combustion air blower generates this positive pressure
which operates the combustion process and also exhausts the flue products from the building.
This vent system has specific vent material and installation requirements. Only use listed sealed AL29-4C vent system materials.
Follow all installation requirements. See Table 2A for proper pipe size for your unit. A list of sealed AL29-4C flue pipe manufacturers
is located on page 15.
Seal all vent joints and seams gas-tight.
Drain tee installation
A drain tee must be installed in the vent pipe to collect and dispose of any condensate that may occur in the vent system. The drain
tee must be installed as the first fitting after the horizontal ell on the top of the unit (see FIG. 2-9). Plastic drain tubing, sized per
the vent manufacturer’s instructions, shall be provided as a drain line from the tee. The drain tubing must have a trap provided by
a 3" (7.6cm) diameter circular trap loop in the drain tubing. Prime the trap loop by pouring a small quantity of water into the drain
hose before assembly to the vent. Secure the trap loop in position with nylon wire ties. Use caution not to collapse or restrict the
condensate drain line with the nylon wire ties. The condensate drain must be routed to a suitable drain for disposal of condensate
that may occur in the direct vent system. Refer to the condensate drain installation instructions as supplied by the manufacturer
of the vent material.
Figure 2-9_Sidewall Vent - Models 402 - 752 (Only)
23
2 Venting
Installation & Operation Manual
WARNING
Connect the flue vent directly to the flue outlet opening on the top of the unit. Make the connections from the unit vent to the
outside stack as direct as possible with no reduction in diameter. Provide adequate clearance to combustibles for the vent connector
and firestop. Follow the vent manufacturer’s instructions when installing sealed AL29-4C vents and accessories, such as firestop
spacers, vent connectors, thimbles, caps, etc.
Provide adequate clearance to combustibles for the vent connector and firestop.
When planning the venting system, avoid possible contact with plumbing or electrical wiring inside walls, ceilings, and floors.
Locate the unit as close as possible to chimney or gas vent. When a vent system is disconnected for any reason, the flue must be
reassembled and resealed according to the vent manufacturer’s instructions.
The installed length of flue from the unit to the outside point of termination must not exceed 50 equivalent feet (15.2m). Subtract
5 feet (1.5m) of equivalent length for each 90° elbow. Subtract 2.5 feet (0.7m) of equivalent length for each 45° elbow.
Sidewall vent termination clearances and location
Follow all sidewall venting termination information for clearances and location under Sidewall Vent Termination Clearances and
Location on page 22.
Do not combine the flue from this unit with the vent from any other appliance. Do not combine flues from
multiple appliances into a common vent. The flue from this unit must be a dedicated stack.
TABLE - 2C
SIDEWALL VENT KITS
MODEL
402 SVK3006 100 ft. SVK3043 50 ft.
502 SVK3006 100 ft. SVK3043 50 ft.
652 SVK3008 100 ft. SVK3044 50 ft.
752 SVK3008 100 ft. SVK3044 50 ft.
992 SVK3009* 100 ft. N/A N/A
1262 SVK3010* 100 ft. N/A N/A
1442 SVK3010* 100 ft. N/A N/A
1802 SVK3012* 100 ft. N/A N/A
2072 SVK3012* 100 ft. N/A N/A
*These kits include a barometric damper.
(W/POWER FAN ASSY.)
KIT
MAX. VENT
LENGTH
VENT TERMINATION
ONLY
(MODELS 402 - 752)
MAX. VENT
LENGTH
24
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