Lochinvar CBL045 Service Manual

0 (0)

SBRX-I-S Rev E

Installation & Service Manual

Models: 45,000 - 260,000 Btu/hr

WARNING:

This manual supplies information for the installation, operation, and servicing of the appliance. It is strongly recommended that this 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 .....................

3-4

RATINGS ...........................................................................

5

THE SOLUTION -- HOW IT WORKS...................................

6-8

1. DETERMINE BOILER LOCATION

 

Location of Unit ..................................................................

9

Clearances .........................................................................

9

Combustion and Ventilation Air..................................

10-12

2. VENTING

 

A Conventional Negative Draft Venting System .........

13-14

Vertical Vent Termination Clearances .............................

15

Masonry Chimney Installation ..........................................

16

Inspection of a Masonry Chimney ..............................

16

Automatic Vent Damper ...................................................

17

3. GAS CONNECTIONS

 

Gas Supply.......................................................................

18

Gas Pressure Test ...........................................................

18

Gas Connection ...............................................................

18

Gas Piping........................................................................

19

Gas Manifold Pressure Adjustment Procedure................

20

Checking Gas Supply Pressure .......................................

21

Combination Gas Valves..................................................

22

4. WATER CONNECTIONS

 

Relief Valve ......................................................................

23

Water Flow Switch (if equipped) ......................................

23

Low Water Cutoff (if equipped) ........................................

24

Typical Heating Boiler Installations .............................

24-25

Piping of the Boiler System..............................................

25

Performance Loop............................................................

27

Primary/Secondary Boiler Piping ................................

27-28

Low Temperature Bypass Requirements.........................

28

Boiler Flow Rates .............................................................

28

Primary / Secondary Piping ...................................

29-31

Full System Flow ........................................................

32

5. ELECTRICAL CONNECTIONS

 

Room Thermostat or Remote Thermostat Connection

.... 33

Auxiliary Device Connection to Terminal Strip.................

33

Pump Wiring for a Heating Boiler ....................................

34

Boiler Operating Temperature Control.............................

34

Additional Temperature Controls ................................

34-35

Temperature Adjustment..................................................

35

Temperature Control Settings ..........................................

36

Maximum Set Point Determination ..................................

36

Wiring of the Outdoor Air Sensor.....................................

38

6. STARTUP

 

Initial Startup ....................................................................

39

Lighting Instructions for Spark Ignition Pilot Models (M9).......

39

Safety Shutoff Test for Spark Ignition Pilot System............

40

Intermittent Pilot Spark Ignition System (M9)........................

41

Freeze Protection ...........................................................................

41

Water Treatment .............................................................................

41

7. MAINTENANCE

 

Maintenance and Annual Startup................................

42-47

8. TROUBLESHOOTING

 

Checking Temperature Sensors ......................................

48

Troubleshooting Guide: M9 Solution Boilers ..................

49

9. DIAGRAMS..................................................................

50

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

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.

2

Installation & Service Manual

Please read before proceeding

NOTICE

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.

 

WARNING

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.

WARNING

Improper installation, adjustment, alteration,

 

service or maintenance can result in severe

 

 

personal injury, death, or substantial

 

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 the packing slip with those actually received. In case there is damage or a shortage, immediately notify the carrier.

What to do if you smell gas –

Do not try to light any appliance.

Do not touch any electric 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.

Warranty –

Installation and service must be performed by a qualified service installer, service agency or the gas supplier.

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).

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.

Owner warning –

NOTE: Retain this manual for future reference.

The information contained in this manual is intended for use by qualified professional installers, service technicians, or gas suppliers. Consult your local expert for proper installation or service procedures.

Consult and follow all local Building and IMPORTANT Fire Regulations and other Safety Codes

that apply to this installation. Consult your local gas utility company to authorize and inspect all gas and flue connections.

Your conventionally vented gas appliance must have a supply of fresh air circulating around it during burner operation for proper gas combustion and proper venting.

WARNING

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.

3

Installation & Service Manual

Please read before proceeding

WARNING To minimize the possibility of serious personal injury, fire, or damage to your appliance, never violate the following safety rules:

1.Boilers 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.

2.Never cover your appliance, 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 appliance.

3.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.

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 regulations 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 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 gas-fired appliances, ANSI Z21.13 and ANSI Z21.10.3.

4

Installation & Service Manual

Ratings

Solution Boiler

AHRI Rating

Model Number

 

Input MBH

Gross

Net

Note: Change

 

(Note 4)

Output

AHRI

“N” to “L”

 

MBH

Ratings

 

 

 

for LP gas

 

 

 

 

Water,

Min

 

Max

(Note 1,5)

MBH

models

 

 

 

 

 

 

(Note 1,5)

CBN045

23

 

45

37

32

 

 

 

 

 

 

CBN075

38

 

75

62

54

 

 

 

 

 

 

CBN090

45

 

90

75

65

 

 

 

 

 

 

CBN135

68

 

135

112

97

 

 

 

 

 

 

CBN180

90

 

180

149

130

 

 

 

 

 

 

CBN215

108

 

215

178

155

 

 

 

 

 

 

CBN260

130

 

260

216

188

 

 

 

 

 

 

Other Specifications

Boiler Water

Water

Gas

Vent

Content

Connections

Connections

Size

Gallons

 

 

 

 

 

 

(Note 3)

 

 

 

 

0.87

1 1/2"

1/2"

4"

 

 

 

 

0.91

1 1/2"

1/2"

5"

 

 

 

 

0.91

1 1/2"

1/2"

5"

 

 

 

 

0.95

1 1/2"

1/2"

6"

 

 

 

 

0.99

1 1/2"

3/4"

7"

 

 

 

 

1.02

1 1/2"

3/4"

7"

 

 

 

 

1.06

2"

3/4"

8"

 

 

 

 

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 AHRI 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.

3. Use only the vent materials and methods specified in the Installation and Service Manual.

4. The Solution is orificed for operation up to 2000 feet

 

altitude. The appliance will be derated 4% per 1000

 

feet above 2000 feet elevation. Consult the factory for

Figure A High Altitude Label Location

installations above 2000 feet elevation.

 

5.Ratings have been confirmed by the Hydronics Section of AHRI.

UNIT EQUIPPED FOR

HIGH ALTITUDE

UPTO2000 FT.

5

The Solution - How it works...

1.Control panel cover

The control panel cover provides access to the thermostat, ignition module, and transformer.

2.Burner (not shown)

The burner is a cylindrical stainless steel tube used to regulate burner flame.

3.Drain port

Location from which the heat exchanger can be drained.

4.Flue outlet

The flue outlet allows the connection of the vent pipe to the unit.

5.Gas connection

The gas pipe connection on this appliance is 1/2", or 3/4" NPT. To deliver the correct amount of gas volume to the appliance it may be necessary to have a larger gas line reduced at the appliance. Please reference the National Fuel Gas Code charts for more details.

6.Gas valve

The gas valve allows the proper amount of gas to pass into the burner for combustion.

7.Heat exchanger

The heat exchanger allows system water to flow through specially designed tubes for maximum heat transfer. The glass lined headers and copper finned tubing are encased in a jacket that contains the combustion process.

8.High limit sensor

Device that monitors the outlet water temperature to ensure safe operation. If the temperature exceeds its setting, it will break the control circuit, shutting the appliance down.

9.Ignition module

The ignition module responds to a call for heat signal to provide burner operation.

10.Junction box

The junction box contains the connection points for the line voltage power and all pumps.

11.Performance loop

A pumped bypass provides constant flow through the heat exchanger when the building system flow is reduced.

12.Performance Loop Pump

The pump ensures adequate flow to operate the unit.

13.Pilot (not shown)

The pilot is a spark ignition device used to light a pilot flame which in turn is used to light the main burners.

14.Pump relay

The pump relay energizes the pump on a call for heat.

15.Relief valve

The relief valve is a safety device that ensures the maximum pressure of the appliance is not exceeded.

6

Installation & Service Manual

16.Sight Glass

The sight glass provides a view of the burner surface, burner flame, and the pilot flame.

17.Temperature and pressure gauge

The temperature and pressure gauge monitors the outlet temperature of the appliance as well as the system water pressure.

18.Temperature sensor

This sensor monitors inlet water temperature. If selected as the controlling sensor, the appliance will maintain the set point at this sensor.

19.Terminal strip

The boiler is equipped with a terminal strip on the left side of the unit to allow easy connection to contact points.

20.Top panel

Removable panel to gain access to the internal components.

21.Thermostat

The thermostat monitors the water temperature via a temperature sensor and will initiate a call for heat when the water temperature drops below the set point plus the differential on the thermostat.

22.Transformer

The transformer reduces 120 VAC supply voltage to 24 VAC for the control circuit.

23.Water inlet (system return)

The water inlet is a 1 1/2" pipe connection that receives water from the system and delivers it to the heat exchanger.

24.Water outlet (system supply)

The water outlet is a 1 1/2" pipe connection that supplies water to the system with connections for a flow switch, a relief valve, and a temperature and pressure gauge.

25.Gas manifold pipe

Delivers gas from the gas valve to the main burners through a number of orifices.

Installation & Service Manual

The Solution - How it works... (continued)

4

10

20

17

15

1

8

 

3

 

5

19

 

Models 45,000 - 90,000 Btu/hr Front View

Models 45,000 - 90,000 Rear View

 

7

22

 

21

18

9

12

 

6

11

 

23

25

 

 

24

 

14

 

16

Models 45,000 - 90,000 Right Side (inside unit)

Models 45,000 - 90,000 Left Side (inside unit)

7

Lochinvar CBL045 Service Manual

Installation & Service Manual

The Solution - How it works...

10

 

4

 

 

 

 

20

17

 

 

15

 

 

 

 

1

8

 

 

3

 

 

 

19

 

5

 

 

Models 135,000 - 260,000 Btu/hr Front View

 

Models 135,000 - 260,000 Btu/hr Rear View

 

 

7

 

 

9

 

 

18

 

 

12

 

 

3

 

 

6

 

 

3

11

21

 

 

 

23

25

24

22

 

 

14

 

 

Models 135,000 - 260,000 Btu/hr Right Side (inside unit)

Models 135,000 - 260,000 Btu/hr Left Side (inside unit)

8

Installation & Service Manual

1 Determine boiler location

Location of unit

1.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 appliance. The pan must not restrict combustion air flow. Under no circumstances is the manufacturer to be held responsible for water damage in connection with this appliance, or any of its components.

2.The appliance must be installed indoors where it is protected from exposure to wind, rain and weather.

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" (46cm) 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.All units have been approved for alcove installation (an ALCOVE is a closet enclosure without a front door).

7.The appliance must not be installed on carpet.

8.All units have been approved for use on combustible surfaces.

9.Allow sufficient space for servicing pipe connections, pump and other auxiliary equipment, as well as the appliance.

NOTICE

Clearances from combustible construction

are noted on the appliance rating plate.

Recommended Service Clearances:

Left - 24”

Front - 24”

14" TOP

6 " RIGHT

6 " REAR

18 "

18 "

FRONT

LEFT

Figure 1-1_Alcove Installation - Models45,000180,000Btu/hr

Recommended Service Clearances:

Left - 24”

Front - 24”

29" TOP

6 " RIGHT

6 " REAR

18 "

18 "

FRONT

LEFT

Figure 1-2_Alcove Installation - Models215,000-260,000Btu/hr

9

Installation & Service Manual

1 Determine boiler location

Combustion and ventilation air requirements for conventionally vented appliances

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 CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment, or applicable provisions of the local building codes.

The room where the appliance is installed MUST be provided with properly sized openings to assure adequate combustion air and proper ventilation when the appliance is installed with conventional venting.

Figure 1-3_Combustion Air Direct from Outside

1.If air is taken directly from outside the building with no duct, provide two permanent openings (see FIG. 1-3):

(a)Combustion air opening, with a minimum free area of one square inch per 4000 Btu/hr input (5.5 cm2 per kW). This opening must be located within 12" (30 cm) of the floor.

(b)Ventilation air opening, with a minimum free area of one square inch per 4000 Btu/hr input

(5.5 cm2 per kW). This opening must be located within 12" (30 cm) of the ceiling.

Figure 1-4_Combustion Air Through Ducts

2.If combustion and ventilation air is taken from the outdoors using a duct to deliver the air to the room where the appliance is installed, each of the two openings should be sized based on a minimum free area of one square inch per 2000 Btu/hr (11cm2 per kW) (see FIG. 1-4).

Figure 1-5_Combustion Air from Interior Space

3.If air is taken from another interior space that is adequately ventilated, each of the two openings specified above should have a net free area of one square inch for each 1000 Btu/ hr (22cm2 per kW) of input, but not less than 100 square inches (645cm2) (see FIG. 1-5).

10

Installation & Service Manual

1 Determine boiler location (continued)

CAUTION

Under no circumstances should the room where the appliance is installed 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 appliance.

Figure 1-6_Combustion Air from Outside Single Opening

4.If a single combustion air opening is provided to bring combustion air in directly from the outdoors, the opening must be sized based on a minimum free area of one square inch per 3000 Btu/hr (7 cm2 per kW). This opening must be located within 12" (30 cm) of the top of the enclosure (see FIG. 1-6).

Combustion air requirements are based on the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada refer to National Standard CAN B149.1. Check all local code requirements for combustion air.

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 room where the appliance is installed. Each opening must have a net free area as specified in Table 1B (on page 12). Single openings shall be located within 12" (30 cm) of the ceiling.

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, tricholorethylene, 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 appliance failure.

The result is improper combustion and a non-warrantable, premature appliance failure.

EXHAUST FANS: Any fan or equipment which exhausts air from the equipment room may deplete the combustion air supply and/or cause a downdraft 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 equipment room, the installer must make sure that it does not cause drafts which could lead to nuisance operational problems with the appliance.

11

Installation & Service Manual

1 Determine boiler location

TABLE - 1B

MINIMUM RECOMMENDED COMBUSTION

AIR SUPPLY TO EQUIPMENT ROOM

 

*Outside Air from

 

*Outside Air from

**Inside Air from

Input

2 Openings Directly from

*Outside Air from

2 Ducts Delivered from

2 Ducts Delivered from

Outdoors

1 Opening Directly

Outdoors

Interior Space

Btu/hr

Top

Bottom

from Outdoors, in2

Top

Bottom

Top

Bottom

 

 

 

 

Opening, in2

Opening, in2

 

Opening, in2

Opening, in2

Opening, in2

Opening, in2

45,000

12

12

15

23

23

100

100

(78 cm2)

(78 cm2)

(97 cm2)

(149 cm2)

(149 cm2)

(646 cm2)

(646 cm2)

 

 

 

 

 

 

 

 

75,000

19

19

25

38

38

100

100

(123 cm2)

(123 cm2)

(162 cm2)

(246 cm2)

(246 cm2)

(646 cm2)

(646 cm2)

90,000

23

23

30

45

45

100

100

(148 cm2)

(148 cm2)

(194 cm2)

(291 cm2)

(291 cm2)

(646 cm2)

(646 cm2)

 

 

 

 

 

 

 

 

135,000

34

34

45

68

68

135

135

(220 cm2)

(220 cm2)

(291 cm2)

(439 cm2)

(439 cm2)

(871 cm2)

(871 cm2)

180,000

45

45

60

90

90

180

180

(291 cm2)

(291 cm2)

(388 cm2)

(581 cm2)

(581 cm2)

(1,162 cm2)

(1,162 cm2)

 

 

 

 

 

 

 

 

215,000

54

54

72

108

108

215

215

(349 cm2)

(349 cm2)

(465 cm2)

(697 cm2)

(697 cm2)

(1,388 cm2)

(1,388 cm2)

260,000

65

65

87

130

130

260

260

(420 cm2)

(420 cm2)

(562 cm2)

(839 cm2)

(839 cm2)

(1,678 cm2)

(1,678 cm2)

*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.

**Combined interior space must be 50 cubic feet per 1,000 Btu/hr input. Buildings MUST NOT be of *“Tight Construction”. For buildings of *“Tight Construction”, provide air openings into the building from outside.

*No combustion air openings are needed when the water heater is installed in a space with a volume NO LESS than 50 cubic feet per 1,000 Btu/hr of all installed gas fired appliances. Buildings MUST NOT be of *“Tight Construction”.

*”Tight Construction” is defined as a building with less than 0.40 ACH (air changes per hour).

Vent installations for connection to gas vents or chimneys must be in accordance with “Venting of Equipment,” of the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment or applicable provisions of the local building codes.

Adequate combustion and ventilation air must be supplied to the room where the appliance is installed in accordance with the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment, or applicable provisions of the local building codes.

The distance of the vent terminal from adjacent buildings, windows that open and building openings MUST comply with the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment.

Vent connection is made directly to the top of the appliance. This appliance is designed with a built-in draft diverter. No additional external draft hood is required. The connection from the appliance vent to the common vent or chimney must be made as direct as possible.

12

2 Venting

A Conventional Negative Draft

Venting System

The negative draft in a conventional vent installation must be within the range of a negative 0.02 to 0.05 inches water column to ensure proper operation. All draft readings are made while the appliance is in stable operation (approximately 2 to 5 minutes).

Multiple appliance installations with combined venting or common venting with other negative draft appliances require that each appliance must have draft within the proper range. If the draft measured above the appliance’s built-in draft diverter exceeds the specified range in a dedicated chimney for a single appliance installation or in combined venting with other negative draft appliances, a barometric damper must be

installed to control draft.

Installation & Service Manual

TABLE - 2A

VENT PIPE SIZES

Input Btu/hr

Flue Size

 

 

45,000

4"

75,000

5"

 

 

90,000

5"

 

 

135,000

6"

 

 

180,000

7"

 

 

215,000

7"

 

 

260,000

8"

 

 

On a conventionally vented, negative draft appliance, the connection from the vent to the chimney or vent termination on the outside of the building MUST be made with listed Type “B” double wall (or equivalent) vent connectors and must be 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. The Type “B” vent and accessories, such as firestop spacers, thimbles, caps, etc., MUST be installed in accordance with the manufacturer’s listing. The vent connector and firestop must provide correct spacing to combustible surfaces and seal to the vent connector on the upper and lower sides of each floor or ceiling through which the vent connector passes.

Any vent materials used must be listed by a nationally recognized test agency for use as vent material.

Figure 2-1_Conventional Negative Draft Vertical Venting

13

2 Venting

Locate appliance as close as possible to a chimney or gas vent.

Avoid long horizontal runs of the vent pipe, 90° elbows, reductions and restrictions. Horizontal portions of the venting system shall be supported to prevent sagging. Horizontal runs must slope upwards not less than 1/4 inch per foot (21 mm/m) from the appliance to the vent terminal. Follow manufacturer’s instructions.

Do not use an existing chimney as a raceway for a flue pipe if another appliance or fireplace is vented through the chimney.

The weight of the venting system must not rest on the appliance. Adequate support of the venting system must be provided in compliance with local codes and other applicable codes. All connections should be secured with rustproof sheet metal screws.

Vent connectors serving appliances vented by natural draft shall not be connected to any portion of a mechanical draft system operating under positive pressure. Connection to a positive pressure chimney may cause flue products to be discharged into the living space causing serious health injury.

Common venting systems may be too large when an existing appliance 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.

(a)Seal any unused opening in the common venting system.

(b)Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition.

(c)Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any 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. Close fireplace dampers.

(d)Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliance will operate continuously.

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Installation & Service Manual

(e)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.

(f)After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and other gas burning appliances to their previous conditions of use.

(g)Any improper operation of the common venting system should be corrected so that the installation conforms to the latest edition of the National Fuel Gas Code, ANSI Z223.1. In Canada, the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part 11 in the latest edition of the National Fuel Gas Code, ANSI Z223.1. In Canada, the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment.

Installation & Service Manual

2 Venting (continued)

Vertical Vent Termination Clearances

10' OR LESS

10' OR LESS

10' OR LESS

CHIMNEY

 

 

2' MIN

2' MIN

3' MIN

2' MIN

3' MIN

RIDGE

 

CHIMMEY WALL OR

CHIMMEY

 

PARAPET

 

Figure 2-2_Vent Termination from Peaked Roof 10' or

Figure 2-4_Vent Termination from Flat Roof 10' or

Less from Ridge

Less from Parapet Wall

 

 

10' OR MORE

MORE THAN 10'

 

10'

3'

 

2' MIN

CHIMNEY

RIDGE

 

 

3' MIN

 

NOTE:

 

NO HEIGHT ABOVE

 

PARAPET REQUIRED

 

WHEN DISTANCE

 

FROM WALLS OR

 

PARAPETS IS MORE

 

THAN 10'.

 

WALL OR

CHIMNEY

 

PARAPET

 

 

Figure 2-3_Vent Termination from Peaked Roof More

Figure 2-5_Vent Termination from Flat Roof More Than

than 10' from Ridge

10' from Parapet Wall

 

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 terminal less than 10 feet (3.05m) from a parapet wall must be a minimum of 2 feet (0.61m) higher than the parapet wall.

The vent cap should have a minimum clearance of 4 feet (1.22m) horizontally from and in no case above or below, unless a 4 foot (1.22m) horizontal distance is maintained from electric meters, gas meters, regulators and relief equipment.

Do not terminate the vent in a window well, stairwell, alcove, courtyard or other recessed area. The vent can not terminate below grade. The bottom of the vent terminal shall be located at least 12 inches (30cm) above grade.

To avoid a blocked vent condition, keep the vent cap clear of snow, ice, leaves, debris, etc.

Flue gases will form a white plume in winter. Plume could obstruct window view.

Flue gas condensate can freeze on exterior surfaces or on the vent cap. Frozen condensate on the vent cap can result in a blocked vent condition. Flue gas condensate can cause discoloration of exterior building surfaces. Adjacent brick or masonry surfaces should be protected with a rust resistant sheet metal plate.

The venting system shall terminate at least 3 feet (0.9m) above

 

Examine the venting system at least once

any forced air inlet within 10 feet (3.05m).

NOTICE

a year. Check all joints and vent pipe

The venting system shall terminate at least 4 feet (1.2m)

 

 

connections for tightness. Also check for

below, 4 feet (1.2m) horizontally from, or 1 foot (30cm)

 

corrosion or deterioration. Immediately

above any door, window or gravity air inlet into any building.

 

correct any problems observed in the

 

 

venting system.

 

15

 

 

 

 

 

 

 

 

 

 

2 Venting

Masonry Chimney Installation

A masonry chimney must be properly sized for the installation of a gas fired appliance. Venting of an 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 gases from an 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 gases, damage the masonry flue/tile, insufficient draft and possible spillage of flue gases into an occupied living space. Carefully inspect all chimney systems before installation. If there is any doubt about the sizing or condition of a masonry chimney, it must be relined with a properly sized and approved chimney liner system.

Inspection of a Masonry Chimney

A masonry chimney must be carefully inspected to determine its suitability for the venting of flue gases. 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. An unlined masonry chimney must not be used to vent flue gases from this appliance. 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.

Sidewall Venting - Negative Draft

This appliance is NOT approved for sidewall venting as shipped from the factory. If installation requires that the flue gases be vented out a sidewall, either an induced draft fan or a power venter MUST be used. A power venter that plugs directly into the vent damper plug is available for models up to 135,000 Btu/hr and may be used for both sidewall and vertical venting configurations, see Fan Assisted Venting. Larger models may use an induced draft fan, which will connect to the terminal strip on the side of the boiler, see Auxiliary Power Venting Connection to Terminal Strip, page 33 for more information. A properly sized and installed induced draft fan may also be used to vent the flue gases vertically if required by jobsite restrictions. The induced draft fan must be listed by a nationally recognized test agency, be properly sized and installed per the recommendations of the induced draft fan manufacturer and meet local code requirements. Use care to ensure that the mechanically supplied draft operates within the range of a negative 0.02 to 0.05 inches water column to ensure proper operation.

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Installation & Service Manual

If draft exceeds the specified range, the fan must be adjusted or the installation of a barometric damper in the flue may be required to properly control draft. An induced draft fan MUST be interlocked into the appliance’s control circuit to start when the appliance calls for heat. The induced draft fan MUST also be equipped with a proving switch, properly interlocked into the appliance’s control circuit to prove fan operation before the main burners are allowed to fire. A vertical or sidewall vent termination for an induced draft fan MUST be installed per the recommendations of the fan manufacturer and provide proper clearances from any combustion or ventilation openings, windows, doors or other openings into the building. All induced draft fan installations must comply with local code requirements.

Fan Assisted Venting

A Power Venter Kit is available on Models 45,000 - 135,000 Btu/hr only (see Table 2B).

TABLE 2B - VENT MATERIALS

Kit

Input

Material

Number

Btu/hr

 

KIT3103

45,000

PVC Rated (CPVC Optional)

75,000

PVC Rated (CPVC Optional)

 

 

 

 

KIT3104

90,000

CPVC Rated

135,000

CPVC Rated

 

 

 

 

Minimum Vent Length = 12 Equivalent Feet*

(ALL UNITS)

Maximum Vent Length = 25 Equivalent Feet*

(ALL UNITS)

* Equivalent Feet: 90° Elbow = 5 Feet

45° Elbow = 3 Feet

CAUTION

DO NOT use Radel or cellular (foam) core

PVC or CPVC pipe.

 

NOTE: In Canada, CPVC and PVC vent pipe, fittings and cement/primer must be ULC-S636 certified.

WARNING DO NOT insulate PVC or CPVC venting materials. Use of insulation will cuase

increased vent wall temperatures, which could result in vent pipe failure.

Figure 2-6_Unit with Fan Assisted Venting

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