Lochinvar EWL200PM Service Manual

EW-I-S Rev B_2000003735_100207764

Installation & Service

Manual

Models: EW150 - 300

LOW LEAD CONTENT

LOW LEAD CONTENT

 WARNING

Save this manual for future reference.

This manual must only be used by a
qualified heating installer / service
technician. Read all instructions
in this manual before installing.
Perform steps in the order given.
Failure to comply could result in
severe personal injury, death, or
substantial property damage.

Contents

PLEASE READ BEFORE PROCEEDING ...................... 3

Hazard Definitions ...................................................... 3

Safety Warnings and Codes ........................................3

1. DETERMINE WATER HEATER LOCATION

Location ........................................................................ 4-5

Clearances ....................................................................... 5

Combustion/Ventilation Air Requirements ................... 5-7

2. GENERAL VENTING

Conventional Venting .................................................... 8-9

Vent System Options ................................................ 10-24

E+Venting .................................................................. 10

Direct Vent Sidewall ................................................. 16

Direct Vent Vertical .....................................................20

Outdoor Installation .....................................................24

3. GAS CONNECTIONS

Gas Supply ..................................................................... 25

Gas Pressure and Piping ............................................... 25

Manifold Pressure and Piping .................................. 27-29

Supply Pressure Measurement ................................ 27-29

4. SYSTEM PIPING

Water Connections ......................................................... 30

Relief Valve and Low Water Cutoff ................................ 30

Heating Domestic Water ................................................ 31

Typical Piping ............................................................ 32-33

Scald ......................................................................... 33-34

5. ELECTRICAL CONNECTIONS

Electrical Requirements ................................................... 35

Temperature Adjustment .................................................. 35

Temperature Sensors ...................................................... 36

Room Thermostat Connections ........................................ 37

6. OPERATION AND STARTUP

Lighting Instructions ......................................................... 38

Hot Surface Ignition Control ..............................................38

Operation and Diagnostic Lights ...................................... 39

Freeze Protection ............................................................. 39

Maintenance ................................................................ 40-41

Flame Patterns ................................................................. 40

Combustion Air Adjustments ....................................... 40-41

Burner Cleaning .......................................................... 41-42

Heat Exchanger Inspection ...............................................42

Gas Train...........................................................................42

7. DIAGRAMS

Ladder Diagram ............................................................... 43

Wiring Diagram................................................................. 44

8. TROUBLESHOOTING

Troubleshooting Charts ............................................... 45-46

REVISION NOTES ........................................................... 48

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

Please read before proceeding

Installation & Service Manual

 WARNING

NOTICE

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 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.

 WARNING

Upon receiving equipment, check for signs of shipping
damage. Pay particular attention to parts accompanying the
appliance 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 carrier.

 WARNING

Installer – Read all instructions, in this
manual before installing. Perform steps in
the order given.

Have this water heater serviced/inspected
by a qualified service technician, at least
annually.

Failure to comply with the above could result
in severe personal injury, death or substantial
property damage.

When calling or writing about the water
heater – Please have the water heater model
and serial number from the water heater
rating plate.

Consider piping and installation when
determining water heater location.

Any claims for damage or shortage in
shipment must be filed immediately against
the transportation company by the consignee.

Factory warranty (shipped with unit) does
not apply to units improperly installed or
improperly operated.

Failure to adhere to the guidelines on this
page can result in severe personal injury,
death, or substantial property damage.

The California Safe Drinking Water
and Toxic Enforcement Act requires
the Governor of California to publish a
list of substances known to the State of
California to cause cancer, birth defects,
or other reproductive harm, and requires
businesses to warn of potential exposure to
such substances.

This product contains a chemical known to
the State of California to cause cancer, birth
defects, or orther reproductive harm. This
boiler can cause low level exposure to some
of the substances listed in the Act.

When servicing the water heater –

• To avoid electric shock, disconnect electrical supply
before performing maintenance.

• To avoid severe burns, allow the water heater to cool
before performing maintenance.

 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.

Water heater operation –

• Do not block flow of combustion or ventilation air to
the water heater.

• Should overheating occur or gas supply fail to shut off,
do not turn off or disconnect electrical supply to
circulator. Instead, shut off the gas supply at a location
external to the appliance.

• Do not use this water heater 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.

 WARNING

1. 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.

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 ap pli ance.

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.

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

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1 Determine water heater location

Installation & Service Manual

Installation

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 and/or
CAN/CGA-B149 Installation Code. 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 appliances conform to the latest edition of
the ASME Boiler and Pressure Vessel Code, Section IV. Where
required by the authority having jurisdiction in Canada, the
installation must comply with the CSA International CAN/
CGA-B149 and Installation Code 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, and
ANSI Z21.10.3

Locating the water heater

Figure 1-1 Typical (Front View) Cabinet Construction

Figure 1-2 Typical (Rear View) Cabinet Construction

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 so that the ignition

system components are protected from water (dripping,
spraying, rain, etc.) during appliance operation and
service (circulator replacement, control replacement, etc.).

3. 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 appliance 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.

4. DO NOT install this appliance in any location where

gasoline or flammable vapors are likely to be present.

5. The appliance must be installed on a level floor. A

combustible wood floor may be used without additional
bases or special floor buildup. Maintain required
clearances from combustible surfaces.

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Installation & Service Manual

1 Determine water heater location (continued)

Locating the water heater (continued)

6. The appliance must not be installed on carpet or other
combustible material other than wood flooring.

7. Outdoor models require the installation of an optional
outdoor kit. Instructions for mounting the parts in the
kit are included in the venting section of this manual.
Outdoor models MUST NOT be installed directly on
the ground. The outdoor appliance must be installed
on a concrete, brick, block or wood flooring. Outdoor
models have additional special location and clearance
requirements.These are specifically addressed in the
venting section under Outdoor Installation. A windproof/
rainproof cabinet protects the appliance from the weather.

Provide clearances:

Clearances from combustible materials

Right Side - 1" (25.4 mm)
Rear - 1" (25.4 mm)
Left Side - 6" (15 cm) (24" (61 cm) suggested for
service)
Front - 3" (76.2 mm) (24" (61 cm) suggested for
service)
Top - 3" (76.2 mm)
Flue - 1" (25.4mm)

Combustion and Ventilation Aire
Requirements for Conventionally
Vented Appliances

Provisions for combustion and ventilation air must be
in accordance with Section 5.3, 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 1-4 Combustion Air Direct from Outside

All appliances have been approved for closet installation .

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

Figure 1-3 Installation Clearances

1. If air is taken directly from outside the building with no
duct, provide two permanent openings:

a. Combustion air opening, with a minimum free

area of one square inch per 4000 Btu/hr input
(5.5cm
within 12" (30 cm) of the top of the enclosure.

b. Ventilation air opening, with a minimum free

area of one square inch per 4000 Btu/hr input
(5.5cm2 per kW). This opening must be located
within 12" (30 cm) of the bottom of the enclosure.

2

per kW). This opening must be located

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1 Determine water heater location

Installation & Service Manual

Figure 1-5 Combustion Air through Ducts

2. If combustion and ventilation air is taken from the
outdoors using a duct to deliver the air to the mechanical
room, 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).

Figure 1-6 Air from an Interior Space

Figure 1-7 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 (7cm2 per kW). This
opening must be located within 12" (30 cm) of the top of
the enclosure.

5. See venting section for combustion air requirements on

E+Venting and direct vent applications.

3. If air is taken from another interior space, 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 (645 cm2).

TABLE 1A

MINIMUM RECOMMENDED COMBUSTION

AIR SUPPLY TO MECHANICAL ROOM

Input/

BTU

150,000 38 in

199,000 50 in

250,000 63 in

300,000 75 in

*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 opening must have
twice (2 times) the free area required for each Outside Air
Openings. The above requirements are for the appliance
only, additional gas fired appliances in the mechanical room
will require an increase in the net free area to supply
adequate combustion air for all appliances. Combustion air
requirements are based on the latest edition of the National
Fuel Gas Code, ANSI Z223.1, in Canada refer to CSA
International CAN/CGA B149.1 or B149.2 Installation Code.
Check all local code requirements for combustion air.

Outside Air*

2 Openings

2

2

2

2

Outside Air*

1 Opening

2

50 in

2

67 in

2

83 in

2

100 in

Inside Air*

2 Openings

2

150 in

2

200 in

2

250 in

2

300 in

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Installation & Service Manual

1 Determine water heater location (continued)

All dimensions 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 mechanical room. Each opening
must have net free area as specified in Table A. Single
openings shall commence within 12" (30 cm) of the ceiling.

 CAUTION

The combustion air supply must be completely free of any
chemical fumes which may be corrosive to the appliance.
Common 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, tube headers, flue
collectors, and the vent system. The result is improper
combustion and a non-warrantable, premature appliance
failure.

EXHAUST FANS: Any fan or equipment which exhausts
air from the mechanical 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 room, the installer must
make sure that it does not cause drafts which could lead to
nuisance operational problems with the appliance.

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.

E+Vent and Direct Vent venting systems have specific
requirements for combustion air ducts from the outside
which are directly connected to the appliance. See the
requirements for this combustion air duct in the venting
section for each specialized vent system.

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2 General venting

Installation & Service Manual

General

Vent installations for connection to gas vents or chimneys
must be in accordance with Part 7, “Venting of Equipment,”
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.

Conventionally vented applications where outside air is
used must have adequate combustion and ventilation air
supplied to the mechanical room in accordance with 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.

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 CAN/CGA
B149 Installation Code for Gas Burning Appliances and
Equipment.

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.

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 appliance’s flue
outlet. The barometric damper MUST NOT be installed in a bull
head tee installed on the appliance’s flue outlet. The tee or collar
containing the barometric damper should be approximately
three feet vertically above the connection to appliance’s flue
outlet. This location ensures that any positive velocity pressure
from the appliance’s internal combustion fan is dissipated and
the flue products are rising due to buoyancy generated from the
temperature of the flue products. Adjust weights on damper to
ensure that draft is maintained within the specified range.

Figure 2-1 Vent Termination from a Peaked Roof 10” or
Less from Ridge

Vent connection is made directly to the top of the appliance.
No additional draft diverter is required. The connection
from the appliance vent to the stack must be made as direct
as possible.

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

Locate units as close as possible to chimney or gas vent.

See the vent material requirements for each of the specific
venting options. Conventional venting systems use Type
“B” double wall vent material. Direct vent systems have
specific vent kits and material requirements noted for each
application.

Any vent materials not provided or specified must be
listed by a nationally recognized test agency for use as vent
material.

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 per meter) from the appliance to the vent
terminal. Follow manufacturers instructions.

Figure 2-2 Vent Termination from a Peaked Roof 10” or
More from Ridge

8

2 General venting (continued)

Installation & Service Manual

The vertical vent terminal should exhaust outside the
building at least 2 feet (61 cm) above the highest point of
the roof within a 10 foot (3.05 m) radius of the termination.

The vertical termination must be a minimum of 3 feet
(91 cm) above the point of exit.

Figure 2-3 Vent Termination from a Flat Roof 10' or
Less from Parapet Wall

unless a 4 foot (1.22 m) 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 cannot

terminate below grade.

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

To avoid a blocked flue 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 flue 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.

IMPORTANT

Examine the venting system at least
once a year. Check all joints and vent
pipe connections for tightness. Also
check for corrosion or deterioration.
Immediately correct any problems
observed in the venting system.

Figure 2-4 Vent Termination from a Flat Roof 10' or
More from Parapet Wall

A vertical termination less than 10 feet (3.05 m) from a
parapet wall must be a minimum of 2 feet (61 cm) higher
than the parapet wall.

The vent cap should have a minimum clearance of 4 feet
(1.22 m) horizontally from and in no case above or below,

9

2 General venting

Vent system options

Installation & Service Manual

This appliance has five venting options. They are:

1. Conventional Negative Draft Venting
Conventional negative draft venting with vertical
termination.

2. E+ with a Vertical Conventional Vent
E+Vent with a vertical conventional vent for flue
products and a combustion air pipe from either the
sidewall or roof top.

3. Direct Venting with Sidewall Terminations
Direct vent with sidewall terminations for flue
products and combustion air.

4. Direct Venting with Vertical Terminations
Direct vent with vertical through-roof terminations
for flue products and combustion air.

5. Outdoor Installation
Outdoor installation consists of the installation of

a special vent cap / top assembly, gas valve cover,
deflectors, and a weatherproof junction box.

All appliances are shipped from the factory equipped for
conventional negative draft venting. All other optional vent
systems require the installation of specific vent kits and
venting materials. The following is a detailed explanation
of the installation requirements for each venting system,
components used and part numbers of vent kits for each
model.

E+Conventional Venting

Figure 2-5 Conventional Venting Installation

Conventional Negative Draft Venting
System

Follow all requirements in the General Venting section for
venting flue products to the outdoors, obtaining adequate
combustion and ventilation air and general installation
instructions. All conventionally vented appliances must have
combustion and ventilation air supplied to the mechanical
room in accordance with 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.

A bell increaser is installed directly on the appliance vent
outlet. The bell increases the vent size by 1 inch (25.4 mm)
in diameter. The bell increaser MUST be installed on the
appliance vent outlet for all conventional negative draft vent
systems. Vent connection is made directly to the bell increaser
on top of the appliance. No additional draft diverter or
barometric damper is required on single appliance installations
with a dedicated stack and a negative draft within the specified
range of a negative 0.02 to 0.05 inches water. Multiple
appliance installations with combined venting or common
venting with other negative draft appliances require that each
appliance must have a barometric damper installed to regulate
draft within the proper range. If the draft in a dedicated stack
for a single appliance installation exceeds the specified draft, a
barometric damper must be installed to control draft.

The vent pipe sizes are:

TABLE 2A

CONVENTIONAL VENT FLUE SIZE

Input Btu/hr Flue Size*

150,000 5"

199,999 5"

250,000 6"

300,000 6"

10

*Vent size with 1” bell increaser installed for conventional
negative draft venting

On a conventionally vented, negative draft appliance, the
connection from the vent to the stack or vent termination
outside 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.

2 General venting (continued)

Installation & Service Manual

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.

Locate appliances as close as possible to chimney or gas vent.

Horizontal runs must slope upwards not less than 1/4 inch
per foot (21 mm per meter) from the appliance to the vent
terminal. Follow manufacturers instructions.

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 stack may cause flue products to be
discharged into the living space causing serious health injury.

Any vent materials not provided or specified must be
listed by a nationally recognized test agency for use as vent
material.

The vent terminal should be vertical and exhaust outside the
building at least 2 feet (61 cm) above the highest point of the
roof within a 10 foot (3.05 m) radius of the termination.

The vertical termination must be a minimum of 3 feet
(91 cm) above the point of exit.

A vertical termination less than 10 feet (3.05 m) from a
parapet wall must be a minimum of 2 feet (61 cm) higher
than the parapet wall.

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. An
unlined masonry chimney must not be used to vent flue
products from this high efficiency 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.

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.

1. Seal any unused opening in the common venting
system.

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

Masonry Chimney Installations
(Conventional venting only)

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 the masonry flue/tile, insufficient
draft and possible spillage of flue products 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.

2. Visually inspect the venting system for proper
size and horizontal pitch and determine there is
no blockage or restriction, leakage, corrosion
and other unsafe condition.

3. 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 fire place dampers.

4. Place in operation, the appliance being
inspected. Follow the lighting instructions. Adjust
thermostat so appliance will operate continuously.

5. Test for spillage at the draft hood/relief opening
after 5 minutes of main burner operation. Use
the flame of a match or candle, or smoke from a
cigarette, cigar or pipe.

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2 General venting

Installation & Service Manual

6. After it has been determined 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
there previous conditions of use.

7. 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 CAN/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
Appendix G 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.

The common vent and connectors from multiple appliances
must be sized per the requirements of the venting tables
for type “B” double wall vents in the latest edition of the
National Fuel Gas Code, ANSI Z223.1.

The sidewall or vertical roof top E+Vent combustion air
supply system has specific vent material and installation
requirements. The air inlet pipe connects directly to the
appliance to supply combustion air. In most installations,
the combustion air inlet pipe will be a dedicated system with
one air inlet pipe per appliance. Multiple air inlets may be
combined if the guidelines in “Combined Air Inlet Points”
are followed. The air inlet pipe will be connected to a
combustion air inlet cap as specified in this section.

Combustion air supplied from outdoors must be free of
contaminants (see Combustion and Ventilation Air Section).

Figure 2-6 E+ Vent with Sidewall Air

A Conventional Vertical Negative Draft
Venting System with Combustion Air
Provided from a Sidewall or Roof Top
Inlet Cap

Follow all requirements in the General Venting section
and Conventional Negative Draft Venting for venting
flue products to the outdoors and general installation
instructions.

This vent system uses two pipes, one vertical pipe with a
roof top termination for the flue products and one pipe for
combustion air. The combustion air pipe may terminate
horizontally with a sidewall air inlet or vertically with a
roof top air inlet. A bell increaser is installed directly
on the vent outlet. This bell increases the vent size by
1” (25.4 mm) in diameter. The bell increaser MUST be
installed on the vent outlet for all conventional negative
draft vent systems. Vent connection is made directly to
the bell increaser on top of the appliance. No additional
draft diverter or barometric damper is required on single
appliance installations with a dedicated stack and a negative
draft maintained between 0.02 to 0.05 inches water. The
flue may be combined with the vent from any other
negative draft, Category I appliances. Multiple appliance
installations common vented with other negative draft
appliances require that each appliance must have a barometric
damper installed to regulate draft within the proper range.

Sidewall Air Inlet

The sidewall air inlet cap is supplied in the E+Sidewall Vent
Kit which should be ordered from the manufacturer. This
sidewall cap will supply combustion air for a single appliance
only.

Locate appliances as close as possible to sidewall where the
combustion air supply system will be installed.

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 instructions in this manual.

The combustion air inlet cap must be installed at least one
foot (30 cm) above ground level and above normal snow
levels.

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2 General venting (continued)

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Installation & Service Manual

Figure 2-7 E+ Vent with Roof Top Air

Vertical Roof Top Air Inlet

The air inlet cap for the vertical roof top air inlet is
assembled from components purchased locally. The air
inlet cap consist of two 90° ells installed at the point of
termination for the air inlet pipe. The first 90° ell is installed
on the roof top at the highest vertical point of the air inlet
pipe and turned horizontal, the second 90° ell is installed on
the horizontal outlet of the first ell and turned down. A 90°
ell and a 90° street ell may be used to make this assembly. If
a straight piece of pipe is used between the two ells, it should
not exceed 6” (51 mm) in length. The termination ell on the
air inlet must be located a minimum of 12” (30 cm) above the
roof or above normal levels of snow accumulation.

Figure 2-8 Air Inlet Cap for Roof Top Termination

EXHAUST
TERMINAL

NOTE: IF FLUE PASSES

THROUGH A FLAT ROOF

WITH PARAPET WALLS SEE

FLAT ROOF TERMINATION IMAGES

The point of termination for the combustion air inlet cap
MUST be at least 2 feet (61 cm) below the point of flue gas
termination (vent cap) if it is located within 10’ (3.05 m) of
the flue outlet. Use care to ensure that the 90° ell assembly
is properly installed on the air inlet pipe.

The combustion air inlet cap must not be installed closer than
10 feet (3.05 m) from an inside corner of an L-shaped structure.

The combustion air inlet cap must be installed at least one
foot (30 cm) above the roof top and above normal snow
levels.

Incorrect installation and/or location of the air inlet cap
can allow the discharge of flue products to be drawn into
the combustion process on the heater. This can result in
incomplete combustion and potentially hazardous levels
of carbon monoxide in the flue products. This will cause
operational problems with the heater and possible spillage
of flue products which can cause personal injury, death or
property damage

Combined Air Inlet Points

The air inlet pipes from multiple appliances 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 5" air inlet pipes
(19.6 in2 area each) have a total area of 39.2 in2 require a
8"(50.3 in2 area) common air inlet pipe.] The air inlet point
for multiple appliance 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 (15.25 m) equivalent feet. 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.

IF FLUE PASSES THROUGH A
SLOPED OR PEAKED ROOF SEE
VENT TERMINATION IMAGES

TYPICAL SOIL PIPE

INTAKE
TERMINA

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2 General venting

Installation & Service Manual

Air Inlet Pipe Materials

The air inlet pipe(s) must be sealed. Choose acceptable
combustion air inlet pipe materials from those specified in
this section.

Select air inlet pipe material from the following specified
materials:

PVC or CPVC (4", 5" or 6" I.D.)*

Dryer Vent (not recommended for roof top air inlet)

Galvanized steel vent pipe with joints and seams
sealed as specified below.

Type “B” double wall vent with joints and seams
sealed as specified below.

* Plastic pipe requires an adapter (not provided) to
transition between the air inlet and cap.

 WARNING

NOTICE

Length of Air Inlet Pipe

The total equivalent length of the sidewall or vertical roof
top E+Vent combustion air inlet pipe must not exceed a
maximum of 50 (15.24 m) equivalent feet in length. Subtract
5 feet (1.52 m) for each elbow in the air intake system. Do
not exceed limits for the combustion air inlet piping lengths.

Using other vent or air intake materials,
failure to properly seal all seams and
joints or failure to follow vent pipe
manufacturer’s instructions can result
in personal injury, death or property
damage. Mixing of venting materials will
void the warranty and certification of the
appliance.

The use of double wall vent material
for the combustion air inlet pipe is
recommended in cold climates to prevent
the condensation of airborne moisture in
the incoming combustion air.

4. Ensure that the air inlet pipes are properly
supported.

The PVC or CPVC air inlet pipe should be cleaned and
sealed with the pipe manufacturers recommended solvents
and standard commercial pipe cement for the material used.
The PVC, CPVC, or Dryer Vent air inlet pipe should use
a silicone sealant to ensure a proper seal at the appliance
connection and the air inlet cap connection. Dryer vent
should use a screw type clamp to seal the vent to the
appliance and air inlet cap. Proper sealing of the air inlet pipe
ensures that combustion air will be free of contaminants and
supplied in proper volume.

When a sidewall or vertical roof top E+Vent combustion air
supply system is disconnected for any reason, the air inlet
pipe must be resealed to ensure that combustion air will be
free of contaminants and supplied in proper volume.

 WARNING

CAUTION

NOTE: In Canada, CPVC and PVC vent pipe,  ttings and
cement/primer must be ULC-S636 certi ed.

 WARNING

Figure 2-9 Sidewall Air Inlet Cap

Failure to properly seal all joints and
seams as required in the air inlet piping
may result in flue gas recirculation,
spillage of flue products and carbon
monoxide emissions causing severe
personal injury or death.

DO NOT use Radel or cellular (foam) core
PVC or CPVC pipe.

DO NOT insulate PVC or CPVC
venting materials. Use of insulation will
cause increased vent wall temperatures,
which could result in vent pipe failure.

Sealing of Type “B” double wall vent material or galvanized
vent pipe material used for air inlet pipe on a sidewall or
vertical roof top E+Vent Combustion Air Supply System

1. Seal all joints and seams of the air inlet pipe using
either Aluminum Foil Duct Tape meeting UL
Standard 723 or 181A-P or a high quality UL
Listed silicon sealant such as those manufactured
by Dow Corning or General Electric.

2. Do not install seams of vent pipe on the bottom of
horizontal runs.

3. Secure all joints with a minimum of three sheet
metal screws or pop rivets. Apply aluminum foil
duct tape or silicone sealant to all screws or rivets
installed in the vent pipe.

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2 General venting (continued)

Installation & Service Manual

Vent Kits

The sidewall E+Vent Kit must be ordered from the
manufacturer for single appliance installations with sidewall
air inlet. The part number for each kit is listed by appliance
size. Each kit includes a sidewall combustion air inlet cap
to supply air to a single appliance and instructions for proper
installation. The flue pipe, roof top vent cap and air inlet
pipes are purchased locally. The air inlet cap for a vertical
roof top termination is fabricated from materials purchased
locally. The air inlet cap for the combined air supply from
multiple appliances must be purchased locally.

TABLE 2B

SIDEWALL VENT KITS

Input

Btu/hr

150,000 5" 4" SVK3020

199,999 5" 4" SVK3020

250,000 6" 5" SVK3021

300,000 6" 6" SVK3021

*Vent size with 1" increaser installed for conventional
negative draft venting.

**Minimum diameter, installer may increase diameter one
pipe size for ease of installation if needed. A 6" diameter air
inlet cap may be ordered as Sidewall E+Vent Kit SVK3022.

Conventional

Flue Size*

Air Inlet

Pipe**

Sidewall

E+

Vent Kit

Venting of Flue Products

On a conventionally vented, negative draft appliance, the
connection from the vent to the stack or vent termination
outside 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. The bell
increaser, factory installed on the flue outlet, MUST be used.
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 manufacturers 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. The vertical flue of an E+Vent must maintain a
negative draft within the specified range.

An appliance installed in an application such as a restaurant
or industrial installation where exhaust fans, air handlers
or other mechanical equipment are creating an excessive
negative pressure in the mechanical room may require
that the appliance be installed with an optional direct vent
system. Local codes which require the installation of a
certified direct vent system must use one of the ANSI tested
direct vent systems. The direct vent system uses a sealed
AL29-4C stainless steel vent material and a sealed
combustion air inlet pipe. See E+Vertical Direct Vent System
or E+Sidewall Direct Vent System installation requirements
in this manual.

The sidewall air inlet cap supplied in the Sidewall E+Vent
Kit is used to supply combustion air to a single appliance.
The roof top vent cap for flue products should be a standard
commercial cap purchased locally. The use of a sidewall
air inlet cap other than the manufacturers recommended
cap for single appliance installations or use of a common
air inlet cap for multiple appliances with insufficient free
area and/or protection from wind and weather may result
in operational problems with the appliance or potentially
hazardous spillage of flue products which can cause personal
injury, death or property damage.

The connection from the vent to the vent termination
outside the building MUST be made with type “B” double
wall vent materials and must be direct as possible with no
reduction in diameter. The vent accessories, such as firestop
spacers, thimbles, caps, etc., MUST be from the same vent
material and installed in accordance with the manufacturers
listing. The vent connection through the roof must provide
correct spacing to combustible surfaces.

Horizontal runs must slope upwards not less than 1/4 inch
per foot (21 mm per meter) from the appliance to the vent
terminal. Follow manufacturers instructions.

The vent cap shall terminate at least 3 feet (91 cm) above any
forced air inlet within 10 feet (3.05 m).

The vent shall terminate at least 4 feet (1.22 m) below, 4 feet
(1.22 m) horizontally from or 1 foot (30 cm) above any door,
window or gravity air inlet to the building.

Do not terminate the vent in a window well, stairwell, alcove,
courtyard other recessed area. The vent can not terminate
below grade.

15