Lochinvar Power-Fin Series Installation And Service Manual

FIG. 1 Front View
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).
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.
Upon receiving equipment, check for signs of shipping damage. Pay particular attention to parts accompanying the boiler, 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.
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.
DO NOT:
CHECKING EQUIPMENT
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.
WARNING
Retain this manual for future reference.
NOTE:
SPECIAL INSTRUCTIONS
TO OWNER
WARRANTY
INSTALLATION AND SERVICE MANUAL
Power-Fin
®
HOT WATER HEATING BOILERS
DOMESTIC WATER HEATERS
500,000, 750,000, 1,000,000 and 1,300,000 Btu/hr MODELS
PB-PF-i&s-03
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Installation Requir
ements
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Combustion/Ventilation Air Requirements . . . . . . . . . . . . . .4
Combustion Air Supplied to the Equipment Room . . . . . . .6
V
enting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
General Venting Information . . . . . . . . . . . . . . . . .7
Common Venting Systems . . . . . . . . . . . . . . . . . . .9
Conventional Vertical Category I Negative Draft . . . . . . . .10
A Vertical Category II Negative Draft Venting System . . .10
Sidewall Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Direct Vent and DirectAire Vent Systems . . . . . . . . . . . . . .13
DirectAire Vent Systems . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Vertical DirectAire w/Sidewall Combustion Air . . . . . . . .15
Vertical DirectAire Venting w/
Rooftop Combustion Air . . . . .16
Horizontal DirectAire w/Vertical Combustion Air . . . . . . .17
Horizontal DirectAire w/Sidewall Combustion Air . . . . . .17
Vertical Direct Vent Systems . . . . . . . . . . . . . . . . . . . . . . . .18
Horizontal Direct Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Gas Supply
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Gas Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Gas Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Gas Train and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Gas Manifold Pressure Adjustment . . . . . . . . . . . . . . . . . .22
Checking Gas Supply Pressure . . . . . . . . . . . . . . . . . . . . . .22
Checking Manifold Gas Pressure . . . . . . . . . . . . . . . . . . . .23
Water Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Minimum Water Temperatures . . . . . . . . . . . . . . . . . . . . . .24
Low Water Cutoff Devices . . . . . . . . . . . . . . . . . . . . . . . . .24
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Electrical Connections
. . . . . . . . . . . . . . . . . . . . . . . . . . .25
Access to Components and Controls . . . . . . . . . . . . . . . . .25
Setting Temperature Control - F9 . . . . . . . . . . . . . . . . . . . .26
Diagnostic Information Center - F9 . . . . . . . . . . . . . . . . . .28
Data Points Visible from Diagnostic Center . . . . . . . . . . . . . . .28
LED Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Default Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Sensor Faults Shown in Digital Display . . . . . . . . . . . . . . .29
Electronic Temperature Control - Modulating Burner . . . .30
Data Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Changeable Data Points . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Status LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Operational LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Fault Status LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Power-Up Default Display . . . . . . . . . . . . . . . . . . . . . . . . .31
Temperature Adjustment Procedure . . . . . . . . . . . . . . . . . .32
Outdoor Air Reset Function . . . . . . . . . . . . . . . . .32
User Lockout Procedure . . . . . . . . . . . . . . . . . . . .33
Limited Access Mode . . . . . . . . . . . . . . . . . . . . . .33
Limited Access Features . . . . . . . . . . . . . . . . . . . .33
Limited Access Feature Setting Procedure . . . . . .33
Error Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
High Water Temperature Limit Control . . . . . . . .34
Condensate Trap Installation . . . . . . . . . . . . . . . . . . . . . . . .35
Hot Surface Ignition System . . . . . . . . . . . . . . . . . . . . . . . .36
Lighting Instructions
. . . . . . . . . . . . . . . . . . . . . . . . . . . .37
To Turn Off Gas to Appliance . . . . . . . . . . . . . . .38
Ignition System Checkout . . . . . . . . . . . . . . . . . . .38
Sequence of Operation . . . . . . . . . . . . . . . . . . . . .38
Maintenance
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Burner Removal and Cleaning . . . . . . . . . . . . . . .40
Combustible Materials . . . . . . . . . . . . . . . . . . . . .42
Freeze Protection . . . . . . . . . . . . . . . . . . . . . . . . .42
Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . .42
Heating Boiler
Installations . . . . . . . . . . . . . . . . . . . . . . .43
Water Connections Heating Boilers Only . . . . . . . . . . . . . .43
Boiler Circulator Requirements . . . . . . . . . . . . . . . . . . . . .43
Primary / Secondary Boiler Piping.. . . . . . . . . . . . . . . . . . .43
Minimum Boiler Water Temperatures . . . . . . . . . . . . . . . . .44
Low Temperature Bypass Requirements . . . . . . . . . . . . . .44
Radiant Floor and Snowmelt Heating Systems . . . . . . . . .45
Temperature / Pressure Gauge . . . . . . . . . . . . . . . . . . . . . .46
Installation with a Chilled Water System . . . . . . . . . . . . . .47
Remote Enable Connections . . . . . . . . . . . . . . . . . . . . . . . .47
Domestic
Water Heaters . . . . . . . . . . . . . . . . . . . . . . . . . .48
Water Velocity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Water Chemistry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Multiple Storage Tank / Water Heater Installations . . . . . .50
If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.
This appliance MUST NOT be installed in any location where gasoline or flammable vapors are likely to be present.
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 neighbors 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.
WARNING
2
CONTENTS
Pump Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Thermostat Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Minimum Water Temperatures
(Domestic Hot Water Use) . . .51
Optional Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Thermal Expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Cathodic Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Ladder Diagram - F9 Units . . . . . . . . . . . . . . . . . . . . . . . .54
Ladder Diagram - M9 Units . . . . . . . . . . . . . . . . . . . . . . .55
Wiring Diagram - M9 Units . . . . . . . . . . . . . . . . . . . . . . .56
Wiring Diagram - F9 Units . . . . . . . . . . . . . . . . . . . . . . . .58
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.
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.
1. Always keep the area around your appliance free of
combustible materials, gasoline, and other flammable liquids and vapors.
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.
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 gas-fired units, ANSI Z21.13.
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 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.
2. The appliance must be installed so that the ignition system components are protected from water (dripping, spraying, etc.,) during appliance operation and service (circulator replacement, control replacement, etc.,).
3. Appliances located in a garage or parking structure shall be installed so that all burners and burner ignition devices have a minimum clearance of 18" (46cm) above the floor. The appliance shall be located or protected so that it is not subject to physical damage by a moving vehicle.
4. The appliance must be installed on a level floor. Combustible floor locations may be used. Maintain required clearances from combustible surfaces.
5. The appliance must not be installed on carpet.
6. The appliance must be installed indoors where it is protected from exposure to wind, rain and weather.
INSTALLATION PROCEDURE
LOCATION OF UNIT
CODES
To minimize the possibility of serious personal injury, fire or damage to your appliance, never violate the following safety rules.
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.
WARNING
Consult and follow 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.
IMPORTANT:
OWNER WARNING
3
NOTE:
The words “Appliance” and “Unit” are used interchangeably throughout this manual.
7. This appliance may condense the products of combustion when operating at water temperatures below 140°F (60°C). Ensure that the appliance is located near an acceptable drain where condensate that may form in the venting system may be properly collected and disposed.
Maintain minimum specified clearances for adequate operation. All installations must allow sufficient space for servicing the vent connections, water pipe connections, piping and other auxiliary equipment, as well as the appliance. The clearance labels on each appliance note the same service and combustible clearance requirements as shown above.
Multiple appliances may be installed in a modular boiler or water heater installation. Multiple appliances may be installed side by side with no clearance between adjacent appliances because this appliance is approved for zero clearance from combustible surfaces and no service access is required from the sides.
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 equipment room MUST be provided with properly sized openings to assure adequate combustion air and proper ventilation.
COMBUSTION AND VENTILATION
AIR REQUIREMENTS FOR
APPLIANCES DRAWING AIR
FROM THE EQUIPMENT ROOM
Clearances from combustible construction are noted on the appliance rating plate.
NOTE:
Right Side - 0" Rear - 6" (15cm) (Minimum 24" (0.61m) suggested for service to pump and components) Left Side - 0" Front - ALCOVE* (Minimum 24" (0.61m) suggested for service) Top - 6" (15cm) (Minimum 24" (0.61m) suggested for service) Flue - 2" (51mm) Hot Water Pipes - 1" (25.4mm)
*An ALCOVE is a closet without a door.
TABLE — A
Clearances from Combustible
Construction:
4
CLEARANCES FROM COMBUSTIBLE CONSTRUCTION
FIG. 2 Clearances from Combustible Construction - Front & Rear View
FIG. 3 Combustion Air Direct from Outside
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 input (5.5 cm
2
per kW). This opening must be located within 12" (30 cm) of the bottom of the enclosure.
b. Ventilation air opening, with a minimum free area of
one square inch per 4000 Btu input (5.5 cm
2
per kW). This opening must be located within 12 inches (30 cm) of the top of the enclosure.
FIG. 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 equipment room, each of the two openings should be sized based on a minimum free area of one square inch per 2000 Btu (11 cm
2
per kW)
of input.
FIG. 5 Combustion Air from Interior Space
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 (22 cm
2
per kW) of input, but
not less than 100 square inches (645 cm2).
FIG. 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 (7 cm
2
per kW). This opening must be
located within 12 inches (30 cm) of the top of the enclosure.
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 inches (30 cm) of the ceiling and one must be within 12 inches (30 cm) of the floor of the mechanical room. Each opening must have net free area as specified in the chart on page 6. Single openings shall commence within 12 inches (30 cm) of the ceiling.
5
6
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 non-warrantable, premature appliance failure.
5. A gas fired boiler, water heater, or combination of units may be installed in an equipment room and have the required combustion and ventilation air supplied by a mechanical fan. The total Btu/hr input of all gas appliances in the equipment room must be considered to properly size a combustion air fan. Per the latest edition of the National Fuel Gas Code, a fan used to mechanically supply air to the equipment room must be sized to provide a minimum of
0.35 ft
3
per minute per 1000 Btu/hr of the total gas input in
the equipment room.
EXHAUST FANS: Any fan or equipment which exhausts air from the equipment 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 equipment room, the installer must make sure that it does not cause drafts that could lead to nuisance operational problems with the appliance.
The optional Direct Vent and DirectAire venting systems have specific requirements for a special combustion air duct from the outside that is directly connected to the appliance. See the requirements for this combustion air duct in the venting section for each specialized vent system.
Vent Options
This appliance has several vent options available depending on the firing control of the unit
For units with on/off burner firing, the available venting options are:
(1) Conventional Vertical Negative Draft Venting using a
Category I double-wall flue with a vertical rooftop termination and combustion air supplied from the equipment room. These units operate with on/off burner firing and are identified with an “F” prefix on the firing controls.
(2) Vertical DirectAire Venting which uses a vertical negative draft flue with a rooftop termination for flue products and a combustion air pipe from the sidewall or rooftop.
For units that operate with modulating burner operation, the available venting options are:
(1) Vertical Negative Draft Venting using a Category II
corrosion resistant flue with a vertical rooftop termination and combustion air supplied from the equipment room. These units operate with a modulating burner firing and are identified with an “M” prefix on the firing controls.
(2) Sidewall Venting which uses which uses the unit’s internal fan to exhaust the flue products out to a sidewall vent
VENTING
Under no circumstances should the mechanical 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.
CAUTION
COMBUSTION AIR SUPPLIED TO
THE EQUIPMENT ROOM BY A FAN
TABLE — B
Minimum Recommended Combustion Air Supply to Equipment Room
Boiler
Input
500,000
750,000
1,000,000
1,300,000
Outside Air* 2 - Openings
125 in
2
(806 cm2)
188 in2(1,213 cm2)
250 in2(1,613 cm2)
325 in2(2,097 cm2)
Outside Air*
1 - Opening
167 in
2
(1,077 cm2)
250 in2(1,613 cm2)
334 in2(2,155 cm2)
434 in2(2,800 cm2)
Inside Air
2 - Openings
(500 in
2
) (3,226 cm2)
(750 in2) (4,839 cm2) (1000 in
2
) (6,452 cm2)
(1300 in
2
) (8,387 cm2)
COMBUSTION AIR SOURCE
*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. Combustion air requirements are based on the latest edition of the National Fuel Gas Code, ANSI Z223.1; in Canada refer to the latest edition of CGA Standard CAN B149.1 or .2. Check all local code requirements for combustion air.
termination with a sealed Category IV flue and combustion air supplied from the equipment room.
(3) Vertical DirectAire Venting which uses a vertical negative draft flue with a rooftop termination for flue products and a combustion air pipe from the sidewall.
(4) Horizontal DirectAire Venting which uses the unit’s internal fan to exhaust the flue products out a sidewall vent termination with a sealed Category IV flue and a combustion air pipe from the rooftop or from a sidewall other than the one where the flue terminates.
(5) Direct Venting with a sealed Category IV flue and a separate combustion air pipe to the outdoors. This system terminates both the flue and combustion air inlet in the same pressure zone. Both the flue outlet and combustion air intake may terminate at either a sidewall (horizontal) or the rooftop (vertical).
All units are shipped from the factory equipped for a vertical negative draft venting system. 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 type of venting system, components used, and part numbers of vent kits for each model.
General Venting Information
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 Standard B149 Installation Code for Gas Burning Appliances and Equipment or applicable provisions of the local building codes.
All venting applications where combustion air is drawn from the equipment room must have adequate combustion and ventilation air supplied to the equipment room 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 minimum clearances stated in this manual and 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.
Vent connection is made directly to the flue outlet opening on the back of the unit. The connection from the appliance vent to the stack must be made as direct as possible with no reduction in diameter.
Negative Draft General Venting Information
The negative draft in the flue of a Category I or II vent installation must be within the range of a negative 0.02 to 0.08 inches water column to ensure proper operation. All draft readings are made while the unit is in stable operation (approximately 2 to 5 minutes). If draft exceeds the maximum specified, a barometric damper must be installed to regulate draft. Mount the barometric damper in the vertical flue at least three feet above the connection to the unit’s flue outlet.
Use the National Fuel Gas Code venting tables to properly size all vent connectors and stacks for all Category I and II systems. The vent and accessories, such as firestop spacers, thimbles, caps, etc., MUST be installed in accordance with the manufacturer’s instructions. 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 specified must be listed by a nationally recognized test agency for use as vent material appropriate for the specified vent category.
Follow the installation instructions from the manufacturer of the vent material.
Locate units as close as possible to a chimney or gas vent. When planning the venting system, avoid possible contact with plumbing or electrical wiring inside walls, ceilings and floors.
Provide adequate clearance from combustibles for the vent connector and firestop.
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 of vent pipe must slope upwards not less than 1/4 inch per foot (21 mm/m) from the appliance to the vent terminal. Vent systems equipped with a drain tee must slope upward from the drain to ensure proper removal of any condensate that may form in the flue.
7
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.
IMPORTANT
TABLE C
Minimum Flue Pipe & Optional
Air Inlet Pipe Sizes are:
Input Btu/hr Flue Size
Air Inlet
Pipe Size
500,000 7" 5"
750,000 9" 5" 1,000,000 10" 6" 1,300,000 12" 6"
When the appliance is installed as either a Category II or Category IV vent appliance, unique venting guidelines will apply. Refer to the appropriate section of the Installation and Service Manual for specific instructions for Category II or Category IV vent installations.
WARNING
Category IV General Venting Information
A Category IV venting system operates with a positive pressure in the vent. This positive pressure is generated by the internal combustion air blower which operates the combustion process and also exhaust the flue products from the building. The Category IV flue from this appliance cannot be combined with the vent from any other appliance. The Category IV flues from multiple appliances cannot be combined into a common vent. The Category IV flue from this appliance must be a dedicated stack. The flue from this Category IV appliance must have all vent joints and seams sealed gastight. A Category IV vent system has specific vent material and installation requirements.
The flue products in the vent system may be cooled below their dew point and form condensate in the flue. The flue materials used for a Category IV vent must be resistant to any corrosive damage from flue gas condensate. The flue from a Category IV vent system must have a condensate drain with provisions to properly collect and dispose of any condensate that may occur in the venting system.
The connection from the appliance vent to the stack or vent termination outside the building must be made with listed Category IV vent material and must be as direct as possible. The Category IV vent and accessories such as firestop spacers, thimbles, caps, etc., must be installed in accordance with the vent manufacturer’s instructions. 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 specified must be listed by a nationally recognized test agency for use as a Category IV vent material.
The venting system must be planned so as to avoid possible contact with concealed plumbing or electrical wiring inside walls, floors, or ceilings. Locate the appliance as close as possible to a chimney or gas vent.
Horizontal portions of the venting system shall be supported to prevent sagging. Horizontal runs should slope upwards not less than 1/4 inch per foot from the drain tee installed in the flue to the vertical portion of the flue or to the vent terminal on sidewall venting installations. This ensures proper removal of any condensate that may form in the flue. Follow the installation instructions from the vent material manufacturer.
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. Adequate support of the venting system must be provided in compliance with local codes and other applicable codes. All connections should be secured and sealed per the vent manufacturer’s specifications.
Vent connectors serving appliances vented by natural draft shall not be connected to any portion of the Category IV positive pressure vent system used by this appliance. Connection of a negative draft flue into the positive pressure stack from this appliance may cause flue products to be discharged into an occupied living space causing serious health injury.
When a Category IV vent system is disconnected for any
reason, the flue must be reassembled and resealed according to the vent manufacturer’s instructions.
The flue may terminate either vertically at the rooftop or horizontally on a sidewall. Refer to the specific vent termination sections for information about recommended vent termination location and clearances.
FIG. 7 Vent Termination from Peaked Roof - 10' or Less from Ridge
FIG. 8 Vent Termination from Peaked Roof More than 10' from Ridge
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.
8
When the appliance is installed as either a Category II or Category IV vent appliance, unique venting guidelines will apply. Refer to the appropriate section of the Installation and Service Manual for specific instructions for Category II or Category IV vent installations.
WARNING
ROOFTOP VENT TERMINATION
CLEARANCES FOR CATEGORY I, II,
OR IV VERTICAL VENTING SYSTEMS
FIG. 9 Vent Termination from Flat Roof 10' or Less from Parapet Wall
FIG. 10 Vent Termination from Flat Roof More Than 10' from Parapet Wall
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.
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.
The venting system shall terminate at least 3 feet (0.9m) above any forced air inlet within 10 feet (3.05m).
The venting system shall terminate at least 4 feet (1.2m) below, 4 feet (1.2m) horizontally from, or 1 foot (30cm) above any door, window, or gravity air inlet into any building.
Do not terminate the vent in a window well, stairwell, alcove, courtyard, or other recessed area. The vent cannot terminate below grade. The bottom of the vent terminal shall be located at least 12 inches (30cm) above the roof or above normal snow levels.
To avoid a blocked flue condition, keep the vent cap clear of snow, ice, leaves, debris, etc.
Flue gases from this appliance may contain large amounts of water vapor that 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.
The manufacturer shall NOT be held liable for any personal injury or property damage due to ice formation or dislodging of ice from the vent system or vent termination.
Common Venting Systems
When this appliance is equipped with ON/OFF burner firing and a Category I flue, the flue may be combined with the flue from any other negative draft, Category I appliance. Common venting of multiple negative draft appliances requires that you MUST install a barometric damper on each unit to regulate draft. Install per the requirements of the latest edition of the National Fuel Gas Code, ANSI Z223.1 and/or CAN/CGA-B149 Installation Code.
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.
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 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 in this manual. Adjust thermostat so appliance will operate continuously.
e.) Test for spillage at the draft hood / relief opening after five
(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 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
9
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 CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment.
A masonry chimney must be properly sized and lined for the installation of a high efficiency gas fired appliance. Venting of a high efficiency appliance into a cold, oversized and unlined masonry chimney can result in operational and safety problems. A standard masonry chimney must not be used to vent the products of combustion from this high efficiency gas fired appliance.
A masonry chimney must be carefully inspected to determine its suitability for the venting of flue products.
An unlined chimney must be relined with an approved chimney liner system when a new appliance is being attached to it. For appliances with ON/OFF burner firing, metallic liner systems (Type “B” double-wall, flexible, or rigid metallic liners) are recommended
For appliances with modulating burner operation, sealed, metallic, corrosion resistant liner systems (single-wall, double­wall, flexible, or rigid metallic liners) rated for use with a high efficiency, Category IV appliance must be used.
Corrosion resistant chimney liner systems are typically made from a high grade of corrosion resistant stainless steel, such as AL29-4C. The corrosion resistant liner must be properly sized and fully sealed throughout the entire length contained within the masonry lined chimney. Both the top and bottom of the masonry chimney must be capped and sealed to provide a dead air space around the liner.
FIG. 11 Conventional Negative Draft Vertical Venting with Combustion Air Supplied to the Equipment Room
Units that may be vented with a Category I, Type “B” vent material operate with ON/OFF burner firing. A unit with ON/OFF burner operation can be identified by the “Category I and the “F” prefix on the firing controls as noted on the unit’s rating plate. These are the only units that can be vented with standard double-wall vent material. See the General Venting and the Negative Draft General Venting Sections in this manual. The flue must terminate at the rooftop. Combustion air is supplied from the equipment room. The installation of the vent must conform 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.
FIG. 12 Vertical Category II Negative Draft Venting with Combustion Air Supplied to the Equipment Room
Units that must be vented with a Category II corrosion resistant vent material operate with modulating burner firing. The unit can be identified by the “Category II” and the “M” prefix on the firing controls as noted on the unit’s rating plate. Vent connection is made directly to the back of the unit using an AL29-4C corrosion resistant vent pipe. See the General Venting and the Negative Draft General Venting Sections in this manual. The flue must terminate at the rooftop. Combustion air is supplied from the equipment room. The modulating burner may result in flue gas temperatures below their dew point forming condensate in the flue. The vent materials must be corrosion resistant. Materials used for a Category IV vent are also corrosion resistant. The system must maintain a negative draft within the specified range. Use a barometric damper if system has excess draft.
Vent Materials: The connection from the vent to the stack or vertical vent termination outside the building MUST be made with a listed Category II corrosion resistant vent material (or equivalent) and must be direct as possible with no reduction in diameter. Currently there are not any vent manufacturers producing Category II vent material, a Category IV vent material may be used to meet material requirements for this venting option.
10
CONVENTIONAL VERTICAL
CATEGORY I NEGATIVE DRAFT
VENTING SYSTEM
MASONRY CHIMNEY INSTALLATION
Check with local code officials to determine code requirements or the advisability of using a masonry chimney with a sealed corrosion resistant liner system.
IMPORTANT
(VERTICAL CATEGORY II NEGATIVE
DRAFT VENTING SYSTEM
Category IV Flue Pipe Materials
Select venting material from the following specified vent distributors:
Heat-Fab Inc., Saf-T CI Vent with AL29-4C stainless steel (Call 1-800-772-0739 for nearest distributor) Protech Systems Inc., Fas N Seal Vent with AL29-4C stainless steel (Call 1-800-766-3473 for nearest distributor) Flex-L International Inc., StaR 34 Vent with AL29-4C stainless steel (Call 1-800-561-1980 for nearest distributor) Metal-Fab Inc., Corr/Guard Vent with AL29-4C stainless steel (Call 1-800-835-2830 for nearest distributor) Z-Flex Z-Vent with AL29-4C stainless steel (Call 1-800-654­5600 for nearest distributor)
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.
Drain Tee Installation
FIG. 13 Drain Tee Installed in Category II or IV Venting
The drain tee should be installed at the point where the flue turns vertical for a rooftop termination or as one of the first fittings in a horizontal flue connector that will terminate on a sidewall. Ensure that horizontal portions of the vent are properly sloped to allow condensate to be evacuated at the drain tee. 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 4" (10.2cm) 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 condensate neutralization system or a suitable drain for disposal. Ensure that the drain from the condensate tee is not exposed to freezing temperatures. See “Freeze Protection” for more information.
Common Venting System
You can combine the flue with the vent from other negative draft Category II appliances ONLY. The vent from other Category I appliances CANNOT be combined with the flue from Category II appliances unless the entire vent system for all units use Category IV vent materials. A barometric damper must be installed on each unit when common venting multiple negative draft Category II appliances.
This vent option is only available on units with modulating burner firing. The unit can be identified by the “Category IV” and the “M” prefix on the firing controls as noted on the unit’s rating plate.
This venting system option uses the unit’s internal combustion fan to force the flue products out of a sidewall vent cap assembly. The unit’s internal fan generates a positive draft pressure to exhaust the flue products. Combustion air is drawn from the equipment room (see the Combustion and Ventilation
Air Requirements section).
FIG. 14 Sidewall Venting Installation
The connection from the appliance flue outlet to the sidewall vent cap MUST be made with listed type Category IV vent materials and accessories. See Category IV flue pipe material specifications. The installer must supply suitable vent pipe material. The sidewall vent cap is available from the appliance manufacturer as a vent kit.
Alternate Sidewall Vent Kits with reduced vent sizes are also approved and available from the manufacturer. These kits include a vent reducer, as well as a reduced diameter vent cap. See Table D for Standard and Alternate Sidewall Vent Kit numbers. Each appliance must have a dedicated flue with no other appliance interconnected to any part of the dedicated flue.
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SIDEWALL VENTING
The Category IV flue from this appliance CANNOT be combined with the vent from any other appliance. The Category IV flue from this appliance must be a dedicated stack and the flue from this appliance must have all vent joints and seams sealed gastight. A Category IV vent system has specific vent material and installation requirements.
WARNING
Maximum Vent Length
The installed length of the Category IV flue from the appliance to the point of termination, outside of the building must not exceed a maximum of 50 equivalent feet (15.2m) in length. Subtract 5 feet (1.5m) of equivalent length for each 90° elbow installed in the vent. Subtract 2 1/2 feet (0.7m) of equivalent length for each 45° elbow installed in the vent.
All connections should be secured and sealed per the vent manufacturer’s specifications.
Vent connectors serving appliances vented by natural draft shall not be connected to any portion of the Category IV positive pressure vent system used by this appliance. Connection of a negative draft flue into the positive pressure stack from this appliance may cause flue products to be discharged into an occupied living space causing serious health injury.
When a Category IV vent system is disconnected for any reason, the flue must be reassembled and resealed according to the vent manufacturer’s instructions.
The flue for a sidewall venting system must terminate horizontally on a sidewall. See specific information concerning vent termination location for recommended clearances and location.
The sidewall vent cap kit includes the wall penetration assembly and the discharge screen assembly. All required Category IV vent pipe and fittings must be purchased locally.
The installed sidewall vent cap assembly may be painted to match the exterior décor.
The opening through the wall for installation of the sidewall vent cap must provide an air space clearance of 2 inches (5.1cm) around the flue pipe. The diameter of the opening for installation of the sidewall cap will be 4 inches (10.2cm) larger (minimum) than the nominal diameter of the installed vent pipe to the sidewall cap.
The sidewall cap is installed from the outside and mounted to the wall with four (4) screws or wall anchors. Seal under the screw heads with caulking. Install the screen assembly using the stainless steel screws provided in the kit. Install the Category IV vent pipe from the appliance to the vent cap. The installed vent pipe must protrude at least 2 inches (5.1cm) into the screen area beyond the thimble portion of the sidewall cap assembly. See detailed instructions packed with the sidewall vent kit.
Follow all requirements in the Category IV General Venting Information section for proper installation and for venting flue products to the outdoors. See the Combustion and Ventilation
Air Requirements section to ensure that adequate combustion and ventilation air is supplied to the equipment room. All other general installation requirements must be followed.
Location of a Sidewall Vent Termination
Follow all requirements in the General Venting section.
FIG. 15 Sidewall Venting Installation with Clearances from Vent Cap
The vent cap shall terminate at least 3 feet (0.91m) above any forced air inlet within 10 feet (3.05m).
The vent shall terminate at least 4 feet (1.22m) below, 4 feet (1.22m) horizontally from or 1 foot (0.30m) above and 2 feet (0.60m) horizontally from any door, window, or gravity air inlet to the building.
The sidewall vent termination must be at least 8 feet (2.4m) horizontally from any combustion air intake located above the sidewall termination cap.
Do not terminate the vent in a window well, stairwell, alcove, courtyard, or other recessed area. The vent cannot terminate below grade.
The vent shall not terminate directly above a public walkway due to the normal formation of water vapor in the combustion process. Horizontal terminations must not be located over areas of pedestrian or vehicular traffic.
The vent system shall terminate at least 1 foot (0.30m) above grade, above normal snow levels and at least 7 feet (2.13m) above grade when located adjacent to public walkways.
The vent terminal shall not be installed closer than 3 feet (0.91m) from an inside corner of an L-shaped structure.
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.
Flue gas condensate can freeze on exterior walls or on the vent cap. Frozen condensate on the vent cap can result in a blocked flue condition. Some discoloration to exterior building surfaces can be expected. Adjacent brick or masonry surfaces should be protected with a rust resistant sheet metal plate.
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TABLE D
Sidewall Vent Kits
Input
Btu/hr
Flue Size
Sidewall
Vent Kit
Alt. Flue
Size
Alt. Sidewall
Vent Kit
500,000 7" SVK3027 4" SVK3056
750,000 9" SVK3049 5" SVK3057
1,000,000 10" SVK3029 6" SVK3058
1,300,000 12" SVK3050 8" SVK3059
The sidewall vent system must use the sidewall vent cap kit provided by the appliance manufacturer for installation on a sidewall termination.
The sidewall vent cap MUST be purchased as a kit from the appliance manufacturer to ensure proper operation. Locally purchased or fabricated sidewall vent caps should not be used.
Direct Vent and DirectAire Vent Systems are installed with specific flue pipe material requirements based on the type of firing controls used on the unit. Direct Vent and DirectAire systems both use a separate combustion air pipe to the outdoors. The Direct Vent System terminates both the flue and combustion air inlet in the same pressure zone. The DirectAire Vent System may terminate the flue and combustion air inlet in different pressure zones. The flue outlet and combustion air intake may terminate with either a sidewall or a rooftop termination based on the specific venting option selected.
Follow all requirements for the specific venting option selected to determine vent material requirements and proper installation to discharge the flue products vertically or horizontally to the outdoors. All other general installation requirements must be followed.
The Direct Vent and DirectAire Vent Systems require the installation of an additional pipe to supply combustion air from outdoors directly to the appliance.
Length of Air Inlet Pipe
The maximum total length of the sidewall or vertical rooftop combustion air inlet pipe as installed from the appliance to the air inlet cap must not exceed 50 equivalent feet (15.2m) in length. Subtract 5 feet (1.52m) of equivalent length for each 90° elbow installed in the air inlet pipe system. Subtract 2 1/2 feet (0.7m) of equivalent length for each 45° elbow installed in the air inlet pipe system. Do not exceed limits for the combustion air inlet piping lengths.
Air Inlet Pipe Materials
The air inlet pipe(s) must be sealed. Choose acceptable combustion air inlet pipe materials from the following list:
PVC, CPVC or ABS (5" or 6" I.D.)* Dryer Vent or Sealed Flexible Duct (not recommended for rooftop 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 may require an adapter (not provided) to transition between the air inlet connection on the appliance and the plastic air inlet pipe.
Sealing of Type “B” double-wall vent material or galvanized vent pipe material used for air inlet piping on a sidewall or vertical rooftop Combustion Air Supply System:
a. 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 silicone sealant such as those manufactured by Dow Corning or General Electric.
b. Do not install seams of vent pipe on the bottom of horizontal
runs.
c. 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.
d. Ensure that the air inlet pipes are properly supported.
The PVC, CPVC, or ABS air inlet pipe should be cleaned and sealed with the pipe manufacturer’s recommended solvents and standard commercial pipe cement for the material used. The PVC, CPVC, ABS, Dryer Vent or Flex Duct 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 or flex duct should use a screw type clamp to seal the vent to the appliance air inlet and the 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 rooftop 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.
13
Appliances that are shut down or will not operate may experience freezing due to convective airflow in the air inlet pipe connected to the appliance.
WARNING
DIRECT VENT AND DIRECTAIRE
VENT SYSTEMS
When the appliance is installed as either a Category II or Category IV vent appliance, unique venting guidelines will apply. Refer to the appropriate section of the Installation and Service Manual for specific instructions for Category II or Category IV vent installations.
WARNING
Using vent or air intake materials other than those specified, 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.
WARNING
The use of double-wall vent or insulated material for the combustion air inlet pipe is recommended in cold climates to prevent the condensation of airborne moisture in the incoming combustion air.
NOTE
A DirectAire vent system uses a flue to the sidewall or rooftop with a separate combustion air pipe to the outdoors. The DirectAire vent system may terminate the flue and the combustion air inlet pipe in different pressure zones in any one of four configurations. These are: (1) The flue on the rooftop and combustion air intake on the sidewall. (2) Both the flue and air inlet terminated on the rooftop using a Category I flue for units with ON/OFF burner firing. (3) The flue terminated on the sidewall and combustion air from the rooftop. (4) The flue terminated on the sidewall and the combustion air intake on a sidewall other than the sidewall where the flue is located.
All appliances are shipped from the factory with a flue outlet that allows the connection of Category I or Category IV venting systems. Check the vent category rating on your unit to ensure that proper vent material is used. The optional DirectAire vent systems require the installation of specific venting materials that are purchased locally. Rooftop termination caps for flue products and combustion air must be purchased locally. Sidewall termination caps for flue products and combustion air must be purchased from the manufacturer. The sidewall caps for combustion air and flue products are available as vent kits. 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.
Follow all requirements for the type of vent materials used with your unit.
A Category I or II vertical flue must follow the requirements in the Vertical Negative Draft Venting sections. A Category IV flue must follow the requirements under the Category IV General Venting Information section. All other general venting installation requirements must be followed.
The DirectAire vent system always requires the installation of an additional pipe to supply combustion air from outdoors directly to the appliance. The air inlet pipe must use one of the materials specified in the Air Inlet Pipe Materials section.
Combined Combustion Air Inlet Points for DirectAire Systems Only
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" (12.7cm) air inlet pipes (19.63 in
2
(126.6 cm2) area each) have a total area of 39.26 in2(253.3 cm2) requires an 8" (20.3 cm) (50.26 in2area) 324.3 cm2) common air inlet pipe.] 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. You must deduct the restriction in area provided by any screens, grills or louvers installed in the common air inlet point. 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.
FIG. 16 Vertical DirectAire Installation with Rooftop Combustion Air Inlet
This venting option is only for units that operate with single stage ON/OFF burner firing. These units will be marked as Category I and have an “F” prefix on the firing controls as noted on the rating plate. This venting option uses a Category I, Type “B” double-wall vent material terminated at the rooftop and a separate combustion air pipe also terminating at the rooftop. The flue must be installed per all requirements in the Conventional Vertical Negative Draft Venting section for a Category I vent. Follow all requirements in the Conventional Vertical Negative Draft Venting section for the materials required to ensure that flue products are properly vented vertically to the outdoors. All other general installation requirements must be followed. The flue outlet and combustion air intake terminate in the same pressure zones, but because of the use of a Category I flue it does not meet the specifications for a Direct Vent System.
The maximum installed length of the flue pipe from the appliance to the termination cap is limited only by the requirement to maintain a negative draft within the limits specified in the Negative Draft General Venting Information section.
Air Inlet Pipe Materials
A DirectAire Vent System always requires the installation of an additional pipe to supply combustion air from outdoors directly to the appliance. The air inlet pipe must use one of the materials specified in the Air Inlet Pipe Materials section.
14
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.
DANGER
DIRECTAIRE VENT SYSTEMS
VERTICAL DIRECTAIRE VENTING
WITH ROOFTOP COMBUSTION AIR
In cold climates, the use of Type “B” double-wall vent pipe or an insulated single-wall pipe is recommended to help prevent moisture in the cool incoming air from condensing and leaking from the inlet pipe.
Vertical Combustion Air Inlet
The air inlet cap for the vertical rooftop inlet is assembled from components purchased locally. The air inlet cap consists of two 90° elbows installed at the point of termination for the air inlet pipe. The first 90° elbow is installed on the rooftop at the highest vertical point of the air inlet pipe and turned horizontal; the second 90° elbow is installed on the horizontal outlet of the first elbow and turned down. A 90° elbow and a 90° street elbow may be used to make this assembly. If a straight piece of pipe is used between the two elbows, it should not exceed 6" (51mm) in length. The termination ell on the air inlet must be located a minimum of 12" (0.30m) above the roof or above normal levels of snow accumulation.
Location of a Rooftop Air Inlet Cap
The point of termination for the combustion air inlet cap MUST be at least 3 feet (0.91m) below any point of flue gas termination (vent cap) if it is located within a 10 foot (3.05m) radius of the flue outlet. Use care to ensure that the 90° ell assembly is properly installed on the air inlet pipe. The assembled combustion air cap assembly used MUST adequately protect the combustion air inlet from wind and weather.
The combustion air inlet cap must not be installed closer than 10 feet (3.05m) from an inside corner of an L-shaped structure.
The termination point of the combustion air inlet cap must be installed at least one foot (0.30m) above the rooftop and above normal snow levels.
The combustion air cap assembly used MUST adequately protect the combustion air inlet from wind and weather.
Combustion air supplied from outdoors must be free of contaminants (see Combustion and Ventilation Air). To prevent recirculation of flue products into the combustion air inlet, follow all instructions in this section.
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 that can cause personal injury, death, or property damage.
For clearances between multiple air inlet caps, see the Multiple Vertical Direct Vent Installation section.
FIG. 17 Vertical DirectAire Installation with Sidewall Combustion Air Inlet
Vertical DirectAire vent systems are installed with the flue terminating at the rooftop and a separate combustion air pipe at the sidewall to the outdoors. The flue outlet and combustion air intake terminate in different pressure zones.
Flue Requirements - ON/OFF Burner Operation
This unit, which operates with an on/off burner firing, may be vented to the rooftop with a Type “B” vent material. These units will be marked as Category I and have an “F” prefix on the firing controls as noted on the rating plate. The flue must be installed per all requirements in the Conventional Vertical Negative Draft Venting section for a Category I vent. Follow all requirements in the Conventional Vertical Negative Draft Venting section for the materials required to ensure that flue products are properly vented vertically to the outdoors. All other general installation requirements must be followed.
Flue Requirements - Modulating Burner Operation
A unit, which operates with a modulating burner firing, may be vented to the rooftop with a Category II vent material or equivalent (Category IV) vent material. These units will be marked as Category II and have an “M” prefix on the firing controls as noted on the rating plate. The flue must be installed per all requirements in the Vertical Category II Negative Draft Venting section using a Category II corrosion resistant flue or equivalent. Follow all requirements in the Vertical Category II Negative Draft Venting section for the Category II materials required to ensure that flue products are properly vented vertically to the outdoors. All other general installation requirements must be followed.
Alternate vertical venting with reduced vent sizes is also approved by the manufacturer. Refer to Table E - Vertical DirectAire Vent Kits for the alternate flue sizes approved and the vent reducer part number available from the manufacturer.
When using the reduced vent size the vent will become a positive pressure vent requiring the use of Category IV vent material. Follow all requirements in the Category IV General Venting Information section for proper installation and for
15
Appliances that are shut down or will not operate may experience freezing due to convective airflow in the air inlet pipe connected to the appliance.
CAUTION
VERTICAL DIRECTAIRE WITH SIDEWALL COMBUSTION AIR
venting flue products to the outdoors. All other general installation requirements must be followed.
The maximum installed length of the Category IV flue from the appliance to the point of termination must not exceed 50 equivalent feet in length. Subtract 5 feet of equivalent length for each 90° elbow installed in the vent. Subtract 2 1/2 feet of equivalent length for each 45° elbow installed in the vent.
Air Inlet Pipe Materials
A DirectAire Vent System always requires the installation of an additional pipe to supply combustion air from outdoors directly to the appliance. The air inlet pipe must use one of the materials specified in the Air Inlet Pipe Materials section.
In cold climates, the use of Type “B” double-wall vent pipe or an insulated single-wall pipe is recommended to help prevent moisture in the cool incoming air from condensing and leaking from the inlet pipe.
Sidewall Combustion Air Inlet
The air inlet cap for the sidewall air inlet must be purchased from the appliance manufacturer.
The part numbers for the required sidewall air inlet cap kit are listed by unit size. The appliance manufacturer, in accordance with CSA International/CGA requirements, must furnish the sidewall air inlet cap. Each kit includes the special combustion air inlet cap for installation on an exterior sidewall for operation of a single appliance only.
Flue piping from the appliance to the rooftop termination may be increased to 8 inches or 10 inches based on field availability of 7 inch and 9 inch flue material.
Location of a Sidewall Air Inlet Ca\p
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 that can cause personal injury, death, or property damage. The termination point of the sidewall air inlet must be installed a minimum of 12 inches (0.30m) above ground level and above normal levels of snow accumulation.
The point of termination for the sidewall combustion air inlet cap MUST be located a minimum of 3 feet (0.91m) horizontally and 12 inches (0.30m) below any point of flue gas termination (vent cap) if it is located within a 10 foot (3.05m) radius of the flue outlet.
The sidewall combustion air inlet cap MUST NOT be installed above the sidewall flue outlet if it is located within a 10 foot (3.05m) radius of the flue outlet.
The sidewall combustion air inlet cap must not be installed closer than 10 feet (3.05m) from an inside corner of an L-shaped structure.
The sidewall combustion air cap assembly used MUST adequately protect the combustion air inlet from wind and weather.
The sidewall combustion air inlet cap and the rooftop flue gas outlet are located in different pressure zones in a DirectAire system.
Combustion air supplied from outdoors must be free of contaminants (see Combustion and Ventilation Air). To prevent recirculation of flue products into the combustion air inlet, follow all instructions in this section.
For clearances between multiple vent caps, see the Multiple Horizontal Direct Vent Installation section.
This vent option is only available on units with modulating burner firing. The unit can be identified by the “Category IV” and the “M” prefix on the firing controls as noted on the unit’s rating plate.
FIG. 18 Horizontal DirectAire Installation with Rooftop Combustion Air Inlet
The Horizontal DirectAire System terminates the flue at the sidewall using Category IV vent materials and a combustion air inlet pipe to draw air from the rooftop. Horizontal DirectAire
16
Appliances that are shut down or will not operate may experience freezing due to convective airflow in the air inlet pipe connected to the appliance.
CAUTION
TABLE E
Vertical DirectAire Vent Kits
Input
Btu/hr
Flue Size
Alt.
Flue
Vent
Reducer
Alt. Inlet Pipe Size
DirectAire
Inlet
Sidewall
Cap Size Kit
500,000 7" 4" DRH2435 5" SAK3003
750,000 9" 5" DRH2436 5" SAK3003
1,000,000 10" 6" DRH2437 6" SAK3000
1,300,000 12" 8" DRH2438 6" SAK3000
HORIZONTAL DIRECTAIRE WITH
VERTICAL COMBUSTION AIR
Vent Systems are installed with the flue outlet and combustion air intake located in different pressure zones.
Follow all requirements in the Sidewall Venting and Category IV General Venting Information sections for proper installation and for venting flue products horizontally out a sidewall to the outdoors. All other general installation requirements must be followed.
Air Inlet Pipe Materials
A DirectAire Vent System always requires the installation of an additional pipe to supply combustion air from outdoors directly to the appliance. The air inlet pipe must use one of the materials specified in the “Air Inlet Pipe Materials” section.
In cold climates, the use of Type “B” double-wall vent pipe or an insulated single-wall pipe is recommended to help prevent moisture in the cool incoming air from condensing and leaking from the inlet pipe.
The termination point for the flue products must follow the clearance requirements in the Sidewall Venting section for use with Category IV venting.
The flue and air inlet duct sizes for a Horizontal DirectAire Installation with Rooftop Combustion Air Inlet are listed by unit size. The sidewall vent cap must be purchased from the appliance manufacturer as a vent kit. This venting option uses the sidewall venting kit with the combustion air inlet system constructed from materials purchased locally by the installer.
Alternate sidewall vent kits with reduced vent sizes are also approved and available from the manufacturer. These kits include a vent reducer, as well as a reduced diameter vent cap. See Table F for Standard and Alternate Sidewall Vent Kit numbers. All required Category IV vent pipe and fittings must be purchased locally. The installed sidewall vent cap assembly may be painted to match the exterior dècor.
Vertical Combustion Air Inlet
FIG. 19 Air Inlet Cap for Rooftop Termination
Follow the vertical combustion air inlet material and location requirements as listed in the Vertical DirectAire Venting and Rooftop Combustion Air section.
The rooftop combustion air inlet cap and the sidewall flue gas outlet are located in different pressure zones in a DirectAire Vent System.
This vent option is only available on units with modulating burner firing. The unit can be identified by the “Category IV” and the “M” prefix on the firing controls as noted on the unit’s rating plate.
This vent system is installed with a Category IV flue and a separate combustion air pipe to the outdoors. The Horizontal DirectAire System terminates the flue at the sidewall and the combustion air on a sidewall other than the sidewall where the flue is located. The sidewall flue outlet and sidewall combustion air intake terminate in different pressure zones.
17
Appliances that are shut down or will not operate may experience freezing due to convective airflow in the air inlet pipe connected to the appliance.
CAUTION
TABLE F
Sidewall Vent Cap Kit for use with DirectAire with Rooftop Combustion Air
Input Btu/hr
Sidewall Flue
Size
Vertical Air Inlet
Pipe Size
Sidewall Vent Kit Alt. Flue Size
Alt. Sidewall
Vent Kit
500,000 7" 5" SVK3027 4" SVK3056
750,000 9" 5" SVK3049 5" SVK3057 1,000,000 10" 6" SVK3029 6" SVK3058 1,300,000 12" 6" SVK3050 8" SVK3059
The sidewall vent cap kit includes the wall penetration assembly and the discharge screen assembly.
HORIZONTAL DIRECTAIRE WITH
SIDEWALL COMBUSTION AIR
FIG. 20 Horizontal DirectAire Installation with Sidewall Combustion Air in a Different Pressure Zone
Follow all requirements in the Sidewall Venting and Category IV General Venting Information sections for proper installation
and for venting flue products horizontally out a sidewall to the outdoors. All other general installation requirements must be followed.
Air Inlet Materials
A DirectAire Vent System always requires the installation of an additional pipe to supply combustion air from outdoors directly to the appliance. The air inlet pipe must use one of the materials specified in the Air Inlet Pipe Materials section.
In cold climates, the use of Type “B” double-wall vent pipe or an insulated single-wall pipe is recommended to help prevent moisture in cool incoming air from condensing and leaking from the inlet pipe.
The maximum installed length of the air inlet pipe from the appliance to the air inlet cap is 50 equivalent feet (15.2m) in length. The maximum installed length of the flue pipe from the appliance to the termination cap is 50 equivalent feet (15.2m) in length. Subtract 5 feet (1.52m) of equivalent length for each 90° elbow installed in either the flue pipe or the air inlet pipe.
The termination point of the flue and air inlet must follow the clearance requirements in the Sidewall Venting and Horizontal Direct Vent sections.
This vent option is only available on units with modulating burner firing. The unit can be identified by the “Category IV” and the “M” prefix on the firing controls as noted on the unit’s rating plate.
A Vertical Direct Vent System is installed with a Category IV flue and a separate combustion air pipe to the outdoors. The Direct Vent System terminates both the flue and air inlet in the same pressure zone. The combustion air cap and flue gas outlet MUST be located on the same rooftop surface and in the same pressure zone.
FIG. 21 Vertical Direct Vent Installation with Rooftop Combustion Air Inlet
Follow all requirements in the Category IV General Venting Information section for proper installation and for venting flue products vertically to the outdoors. All other general installation requirements must be followed.
Alternate Vertical Venting with reduced vent sizes are also approved by the manufacturer. Refer to the Vertical DirectAire Table for the alternate flue sizes approved and the vent reducer part number available from the manufacturer. Use the appropriate Category IV venting materials to ensure that flue products are properly vented vertically to the outdoors.
The Direct Vent System always requires the installation of an additional pipe to supply combustion air from outdoors directly to the appliance. The air inlet pipe must use one of the materials specified in the Air Inlet Pipe Materials section.
The maximum installed length of the air inlet pipe from the appliance to the air inlet cap is 50 equivalent feet (15.2m) in length. The maximum installed length of the flue pipe from the appliance to the termination cap is 50 equivalent feet (15.2m) in length. Subtract 5 feet (1.52m) of equivalent length for each 90° elbow installed in either the flue pipe or the air inlet pipe.
The termination point for the flue products must follow the clearance requirements in the Rooftop Vent Termination
Clearances for Category I, II, or IV Vertical Venting Systems.
18
Appliances that are shut down or will not operate may experience freezing due to convective airflow in the air inlet pipe connected to the appliance.
CAUTION
VERTICAL DIRECT VENT SYSTEMS
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