Lochinvar WBN051 Installation Manual

WBII-I-O Rev I
Installation & Operation Manual
Models: 51 - 211
WARNING
This manual must only be used by a qualified heating installer / service technician. Read all instructions, including this manual and the Knight Wall Mount Service Manual, before installing. Perform steps in the order given. Failure to comply could result in severe personal injury, death, or substantial property damage.
Save this manual for future reference.
Contents
HAZARD DEFINITIONS .................................................... 2
PLEASE READ BEFORE PROCEEDING ........................ 3
THE KNIGHT WALL MOUNT BOILER -- HOW IT WORKS .. 4-5
RATINGS ........................................................................... 6
1. DETERMINE BOILER LOCATION
Provide Clearances ............................................................ 7
Provide Air Openings to Room .......................................... 9
Wall Mounting Location ..................................................... 9
Residential Garage Installation .......................................... 9
Vent and Air Piping ............................................................ 9
Prevent Combustion Air Contamination ............................. 9
Corrosive Contaminants and Sources ............................. 10
Using an Existing Vent System to Install a New Boiler ... 10
Removing a Boiler from Existing Common Vent .............. 11
2. PREPARE BOILER
Remove Boiler from Wood Pallet ..................................... 12
Gas Conversions .............................................................. 12
Mounting the Boiler .......................................................... 13
3. GENERAL VENTING
Direct Venting Options ..................................................... 14
Install Vent and Combustion Air Piping ........................... 15
Requirements for Installation in Canada .......................... 16
Sizing ............................................................................... 16
Min./Max. Combustion Air & Vent Piping Lengths ............16
Materials ............................................................................17
Optional Room Air ............................................................ 18
PVC/CPVC ....................................................................... 19
Polypropylene ................................................................... 20
Stainless Steel Vent ......................................................... 21
4. SIDEWALL DIRECT VENTING
Vent/Air Termination - Sidewall ................................... 22-25
Determine Location ................................................ 22-23
Prepare Wall Penetrations .......................................... 24
Multiple Vent/Air Terminations ......................................... 25
Sidewall Termination - Optional Concentric Vent ....... 26-28
5. VERTICAL DIRECT VENTING
Vent/Air Termination - Vertical .................................... 29-30
Determine Location ..................................................... 29
Prepare Roof Penetrations ......................................... 30
Multiple Vent/Air Terminations .................................... 30
Vertical Termination - Optional Concentric Vent ... 31-32
Alternate Vertical Concentric Venting .................... 33-34
6. HYDRONIC PIPING
System Water Piping Methods ......................................... 35
Low Water Cutoff Device ................................................. 35
Chilled Water System ....................................................... 35
Freeze Protection ............................................................. 35
General Piping Information .............................................. 35
Near Boiler Piping Components ....................................... 36
Near Boiler Piping Connections ....................................... 37
Circulator Sizing ............................................................... 37
Variable Speed Pump Option .......................................... 39
7. GAS CONNECTIONS
Connecting Gas Supply Piping ........................................ 48
Natural Gas ...................................................................... 49
Pipe Sizing for Natural Gas ........................................ 49
Natural Gas Supply Pressure Requirements ............. 49
Propane Gas .................................................................... 49
Pipe Sizing for Propane Gas ...................................... 49
Propane Supply Pressure Requirements ................... 49
Check Inlet Gas Supply ................................................... 50
Gas Pressure ................................................................... 51
Gas Valve Replacement .................................................. 51
8. FIELD WIRING
Line Voltage Connections ................................................ 52
Low Voltage Connections ................................................ 52
Wiring of the Cascade ...................................................... 54
9. CONDENSATE DISPOSAL
Condensate Drain ............................................................ 56
10. STARTUP ............................................................. 57-62
11. OPERATING INFORMATION
General ............................................................................. 63
Cascade ........................................................................... 66
Sequence of Operation ............................................... 67-68
Knight Wall Mount Boiler Control Module ........................ 69
Status Display Screens ............................................... 70-72
12. MAINTENANCE
Maintenance and Annual Startup ................................ 73-77
13. DIAGRAMS
Ladder Diagram ............................................................... 78
Wiring Diagram................................................................. 79
Revision Notes .................................................. Back Cover
Hazard definitions
The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product.
DANGER
WARNING
CAUTION
CAUTION
NOTICE
2
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.
NOTICE indicates special instructions on installation, operation, or maintenance that are important but not related to personal injury or property damage.
Please read before proceeding
Installation & Operation Manual
WARNING
NOTICE
WARNING
WARNING
Installer – Read all instructions, including this manual and the Knight Wall Mount Service Manual, before installing. Perform steps in the order given.
User – This manual is for use only by a qualified heating installer/ service technician. Refer to the User’s Information Manual for your reference.
Have this boiler 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 boiler – Please have the boiler model and serial number from the boiler rating plate.
Consider piping and installation when determining boiler 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.
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 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.
When servicing boiler –
• To avoid electric shock, disconnect electrical supply before performing maintenance.
• To avoid severe burns, allow boiler to cool before performing maintenance.
Boiler operation –
• Do not block flow of combustion or ventilation air to the boiler.
• 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 boiler 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.
Boiler water –
• Thoroughly flush the system (without boiler connected) to remove sediment. The high-efficiency heat exchanger can be damaged by build-up or corrosion due to sediment.
• Continual fresh make-up water will reduce boiler life. Mineral buildup in the heat exchanger reduces heat transfer, overheats the stainless steel heat exchanger, and causes failure. Addition of oxygen carried in by makeup water can cause internal corrosion in system components. Leaks in boiler or piping must be repaired at once to prevent makeup water.
CAUTION
CAUTION
Do not use petroleum-based cleaning or sealing compounds in the boiler system. Gaskets and seals in the system may be damaged. This can result in substantial property damage.
Do not use “homemade cures” or “boiler patent medicines”. Serious damage to the boiler, personnel, and/or property may result.
Freeze protection fluids –
• NEVER use automotive antifreeze. Use only inhibited propylene glycol solutions, which are specifically formulated for hydronic systems. Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems.
3
Installation & Operation Manual
The Knight Wall Mount Boiler - How it works...
1. Stainless steel heat exchanger
Allows system water to flow through specially designed coils for maximum heat transfer, while providing protection against flue gas corrosion. The coils are encased in a jacket that contains the combustion process.
2. Combustion chamber access cover
Allows access to the combustion side of the heat exchanger coils.
3. Blower
The blower pulls in air and gas through the venturi (item
5). Air and gas mix inside the blower and are pushed into the burner, where they burn inside the combustion chamber.
4. Gas valve
The gas valve senses the negative pressure created by the blower, allowing gas to flow only if the gas valve is powered and combustion air is flowing.
5. Venturi
The venturi controls air and gas flow into the burner.
6. Flue gas sensor (limit rated)
This sensor monitors the flue gas exit temperature. The control module will modulate and shut down the boiler if flue gas temperature gets too hot. This protects the flue pipe from overheating.
7. Boiler outlet temperature sensor (housed with high limit sensor)
This sensor monitors boiler outlet water temperature (system supply). If selected as the controlling sensor, the control module adjusts boiler firing rate so the outlet temperature is correct.
8. Boiler inlet temperature sensor
This sensor monitors return water temperature (system return). If selected as the controlling sensor, the control module adjusts the boiler firing rate so the inlet temperature is correct.
9. Temperature and pressure gauge (field installed, not shown)
Monitors the outlet temperature of the boiler as well as the system water pressure.
10. Electronic LCD display
The electronic display consists of 4 buttons, a navigation dial and a multiple line liquid crystal display.
11. Flue pipe adapter
Allows for the connection of the PVC vent pipe system to the boiler.
12. Burner (not shown)
Made with metal fiber and stainless steel construction, the burner uses pre-mixed air and gas and provides a wide range of firing rates.
13. Water outlet (system supply)
The water outlet is the water connection for water leaving the boiler and entering the system. Boiler connection is 1".
14. Water inlet (system return)
The water inlet is the water connection for water entering the boiler from the system. Boiler connection is 1".
15. Gas connection pipe
Threaded pipe connection of 1/2". This pipe should be connected to the incoming gas supply for the purpose of delivering gas to the boiler.
16. SMART SYSTEM Control Module
The SMART SYSTEM Control responds to internal and external signals and controls the blower, gas valve, and pumps to meet the heating demand.
17. Air intake adapter
Allows for the connection of the PVC air intake pipe to the boiler.
18. High voltage junction box
The junction box contains the connection points for the line voltage power and all pumps.
19. Manual air vent
Designed to remove trapped air from the heat exchanger coils.
20. Low voltage connection board
The connection board is used to connect external low voltage devices.
21. Low voltage wiring connections (knockouts)
Conduit connection points for the low voltage connection board.
22. Condensate drain connection
Connects the condensate drain line to a 1/2" pipe.
23. Access door
Provides access to all internal components.
24. Ignition electrode
Provides direct spark for igniting the burner.
25. Flame inspection window
The quartz glass window provides a view of the burner surface and flame.
26. Gas shutoff switch
An electrical switch designed to cut power to the gas valve to prevent releasing any gas.
27. High limit sensor (housed with outlet sensor)
Device that monitors the outlet water temperature. If the temperature exceeds its setting, it will break the control circuit, shutting the boiler down.
28. Relief valve
Protects the heat exchanger from an over pressure condition. The relief valve provided with the unit is set at 30 psi.
29. Flame sensor
Used by the control module to detect the presence of burner flame.
30. Line voltage wiring connections (knockouts)
Conduit connection points for the high voltage junction box.
31. Air pressure switch
The air pressure switch detects blocked inlet conditions.
32. Transformer
The transformer provides 24V power to the integrated control.
4
Installation & Operation Manual
The Knight Wall Mount Boiler - How it works... (continued)
Models 51 - 211
11
28
Front View
17
19
10
23
22
15
21
Bottom View
14
13
30
FRONT
OF UNIT
6
1
32
16
8
7
27
14
13
3
20
29
31
2
25
24
5
4
22
26
18
Left Side (inside unit)
Right Side (inside unit)
5
Ratings
Installation & Operation Manual
Knight Wall Mount Boiler
AHRI Rating
Model Number
Note: Change
“N” to “L” for
L.P. gas models.
Min Max
WBN051 10 50 45 39 95.3
WBN081 16 80 72 63 95.3
WBN106 21 105 94 82 95.4
WBN151 30 150 135 119 95.5
WBN211 42 210 190 165 95.7
NOTICE
Input MBH
(Note 5)
Heating
Capacity
MBH
(Note 2, 8
Maximum allowed working pressure is located on the rating plate.
Notes:
1. As an Energy Star Partner, Lochinvar has determined that Knight wall mount boilers meet the Energy Star guidelines for energy efficiency.
2. The ratings are based on standard test procedures prescribed by the United States Department of Energy.
3. Net AHRI ratings are based on net installed radiation of sufficient quantity for the requirements of the building and nothing need be added for normal piping and pickup. Ratings are based on a piping and pickup allowance of 1.15.
4. Knight wall mount boilers require special gas venting. Use only the vent materials and methods specified in the Knight Wall Mount Installation and Operation Manual.
5. Standard Knight wall mount boilers are equipped to operate from sea level to 4,500 feet only with no adjustments. The boiler will de-rate by 4% for each 1,000 feet above sea level up to 4,500 feet.
6. High altitude Knight wall mount boilers are equipped to operate from 3,000 to 12,000 feet only with no field adjustments. The boiler will de-rate by 2% for each 1,000 feet above 3,000 feet. High altitude models are manufactured with a different control module for altitude operation, but the operation given in this manual remains the same as the standard boilers. A high altitude label (as shown in FIG. A) is also affixed to the unit.
Net
AHRI
Ratings
Water,
MBH
(Note 3, 8)
Other Specifications
AFUE
%
(Note 1, 8)
Boiler Water
Content Gallons
0.6 1" 1/2" 2"
0.6 1" 1/2" 2"
0.7 1" 1/2" 2"
1.3 1" 1/2" 3"
1.7 1" 1/2" 3"
Water
Connections
Gas
Connections
7. The Knight Wall Mount boiler input rate, on some models, is reduced for vent lengths beyond the minimum. Models WB(N,L)081 and WB(N,L)106 with 2" vent will reduce 1% for every 10 feet of vent. Models WB(N,L)151 and WB(N,L)211 with 3" vent will reduce 0.5% for every 10 feet of vent.
8. Ratings have been confirmed by the Hydronics Section of AHRI.
9. Knight wall mount boilers comply with the requirements of CSD-1 Section CW-400 requirements as a temperature operation control. The manual reset high limit provided with the Knight wall mount is listed to UL353.
Vent/Air Size
(Note 4)
UNIT EQUIPPED FOR
HIGH ALTITUDE
3,000 FT. TO 12,000 FT.
6
Figure A High Altitude Label Location
1 Determine boiler location
Installation & Operation Manual
Installation must comply with:
• Local, state, provincial, and national codes, laws, regulations, and ordinances.
• National Fuel Gas Code, ANSI Z223.1 – latest edition.
• Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1, when required.
• National Electrical Code.
• For Canada only: B149.1 Installation Code, CSA C22.1 Canadian Electrical Code Part 1 and any local codes.
NOTICE
The Knight wall mount boiler gas manifold and controls met safe lighting and other performance criteria when the boiler underwent tests specified in ANSI Z21.13 – latest edition.
Before locating the boiler, check:
1. Check for nearby connection to:
• System water piping
• Venting connections
• Gas supply piping
• Electrical power
2. Locate the appliance so that if water connections should
leak, water damage will not occur. When such locations cannot be avoided, it is recommended that a suitable drain pan, adequately drained, be installed under the 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.
WARNING
WARNING
This appliance is certified as an indoor appliance. Do not install the appliance outdoors or locate where the appliance will be exposed to freezing temperatures or to temperatures that exceed 100°F.
Failure to install the appliance indoors could result in severe personal injury, death, or substantial property damage.
This appliance requires a special venting system. The vent connection to the appliance is made of CPVC. Field supplied vent fittings must be cemented to the CPVC fitting on the boiler. Use only the vent materials, primer, and cement specified in the manual to make the vent connections. Failure to follow this warning could result in fire, personal injury, or death.
Closet and alcove installations
A closet is any room the boiler is installed in which is less than 79 cubic feet for WBN051 through WBN106 models, 104 cubic feet for WBN151 models, and 125 cubic feet for WBN211 models.
An alcove is any room which meets the criteria for a closet with the exception that it does not have a door.
Example: Room dimensions = 4 feet long, 4 feet wide, and 9 foot ceiling = 4 x 4 x 9 = 144 cubic feet. This would be considered a closet for a Knight wall mount boiler.
3. Check area around the boiler. Remove any combustible
materials, gasoline and other flammable liquids.
WARNING
4. The Knight wall mount boiler must be installed so
that gas control system components are protected from dripping or spraying water or rain during operation or service.
5. If a new boiler will replace an existing boiler, check for
and correct system problems, such as:
• System leaks causing oxygen corrosion or heat exchanger cracks from hard water deposits.
• Incorrectly-sized expansion tank.
• Lack of freeze protection in boiler water causing system and boiler to freeze and leak.
Failure to keep boiler area clear and free of combustible materials, gasoline, and other flammable liquids and vapors can result in severe personal injury, death, or substantial property damage.
WARNING
For closet and alcove installations as shown in FIG.’s 1-1 and 1-2, CPVC or stainless steel vent material must be used inside the structure. The two ventilating air openings shown in FIG. 1-1 are required for this arrangement. Failure to follow this warning could result in fire, personal injury, or death.
Provide clearances:
Clearances from combustible materials
1. Hot water pipes—at least 1/4" from combustible materials.
2. Vent pipe – at least 1" from combustible materials.
3. See FIG.’s 1-1 and 1-2 on page 8 for other clearance minimums.
Clearances for service access
1. See FIG.’s 1-1 and 1-2 on page 8 for recommended
service clearances. If you do not provide the minimum clearances shown, it may not be possible to service the boiler without removing it from the space.
7
A
A
1 Determine boiler location
Figure 1-1 Closet Installation - Minimum Required Clearances
Installation & Operation Manual
TOP 6" MINIMUM
VENTILATING AIR OPENING
6"
FRONT 24" SERVICE 6" MINIMUM
1" MINIMUM CLEARANCE
ROUND VENT PIPE
LEFT 24" SERVICE 0" MINIMUM
BOTTOM 24" SERVICE 0" MINIMUM
*
A OF EA
ARE
1 SQ. INCH PER 1000 BTU PER HOUR INPUT WITH A MINIMUM OF 100 SQ. INCHES.
1/4" MINIMUM CLEARANCE AROUND HOT WATER PIPES
CH OPENING:
Figure 1-2 Alcove Installation - Minimum Required Clearances
TOP
LEFT 24" SERVICE 0" MINIMUM
6" MINIMUM
WARNING
*
RIGHT 0" MINIMUM
CLOSED DOOR
6"
VENTILATING AIR OPENING
Note: Service clearances are recommendations only.
WARNING
For closet installations, CPVC or stainless steel vent material MUST BE used in a closet structure due to elevated temperatures. Failure to follow this warning could result in fire, personal injury, or death.
*
For alcove installations, CPVC or stainless steel vent material MUST BE used in an alcove structure due to elevated temperatures. Failure to follow this warning could result in fire, personal injury, or death.
RIGHT 0" MINIMUM
1" MINIMUM CLEARANCE
ROUND VENT PIPE
FRONT
24" SERVICE BOTTOM 24" SERVICE 0" MINIMUM
Note: Service clearances are recommendations only.
1/4" MINIMUM CLEARANCE AROUND HOT WATER PIPES
6" MINIMUM
OPEN FRONT
8
Installation & Operation Manual
1 Determine boiler location (continued)
Provide air openings to room:
Knight wall mount boiler alone in boiler room
1. No air ventilation openings into the boiler room are needed when clearances around the Knight wall mount boiler are at least equal to the SERVICE clearances shown in FIG.’s 1-1 and 1-2. For spaces that do NOT supply this clearance, provide two openings as shown in FIG. 1-1. Each opening must provide one square inch free area per 1,000 Btu/hr of boiler input.
Knight wall mount boiler in same space with other gas or oil-fired appliances
1. Follow the National Fuel Gas Code (U.S.) or CSA B149.1 (Canada) to size/verify size of the combustion/ ventilation air openings into the space.
WARNING
2. Size openings only on the basis of the other appliances in the space. No additional air opening free area is needed for the Knight wall mount boiler because it takes its combustion air from outside (direct vent installation).
The space must be provided with combustion/ventilation air openings correctly sized for all other appliances located in the same space as the Knight wall mount boiler.
Do not install the boiler in an attic.
Failure to comply with the above warnings could result in severe personal injury, death, or substantial property damage.
Wall mounting location
Residential garage installation
Precautions
Take the following precautions when installing the appliance in a residential garage. If the appliance is located in a residential garage, it should be installed in compliance with the latest edition of the National Fuel Gas Code, ANSI Z223.1 and/or CAN/CGA-B149 Installation Code.
• Appliances located in residential garages and in adjacent spaces that open to the garage and are not part of the living space of a dwelling shall be installed so that all burners and burner ignition devices are located not less than 18 inches (46 cm) above the floor.
• The appliance shall be located or protected so that it is not subject to physical damage by a moving vehicle.
Vent and air piping
The Knight wall mount boiler requires a special vent system, designed for pressurized venting.
The boiler is to be used for either direct vent installation or for installation using indoor combustion air. When room air is considered, see Section 3, General Venting. Note prevention of combustion air contamination below when considering vent/ air termination.
Vent and air must terminate near one another and may be vented vertically through the roof or out a side wall, unless otherwise specified. You may use any of the vent/air piping methods covered in this manual. Do not attempt to install the Knight wall mount boiler using any other means.
Be sure to locate the boiler such that the vent and air piping can be routed through the building and properly terminated. The vent/air piping lengths, routing and termination method must all comply with the methods and limits given in this manual.
Ensure the wall for which the boiler is intended to be mounted is comprised of either, cement, brick, block, or wooden studs spaced 16" apart from center. Ensure the wall is capable of supporting at least 200 pounds.
If flooding is possible, elevate the boiler sufficiently to prevent water from reaching the boiler.
Ensure the boiler is installed in a location that minimizes the risk of water damage due to valves, pumps, etc.
Prevent combustion air contamination
Install air inlet piping for the Knight wall mount boiler as described in this manual. Do not terminate vent/air in locations that can allow contamination of combustion air. Refer to Table 1A, page 10 for products and areas which may cause contaminated combustion air.
WARNING
You must pipe combustion air to the boiler air intake. Ensure that the combustion air will not contain any of the contaminants in Table 1A, page 10. Contaminated combustion air will damage the boiler, resulting in possible severe personal injury, death or substantial property damage. Do not pipe combustion air near a swimming pool, for example. Also, avoid areas subject to exhaust fumes from laundry facilities. These areas will always contain contaminants.
9
1 Determine boiler location
Installation & Operation Manual
Table 1A Corrosive Contaminants and Sources
Products to avoid:
Spray cans containing chloro/fluorocarbons
Permanent wave solutions
Chlorinated waxes/cleaners
Chlorine-based swimming pool chemicals
Calcium chloride used for thawing
Sodium chloride used for water softening
Refrigerant leaks
Paint or varnish removers
Hydrochloric acid/muriatic acid
Cements and glues
Antistatic fabric softeners used in clothes dryers
Chlorine-type bleaches, detergents, and cleaning solvents found in household laundry rooms
Adhesives used to fasten building products and other similar products
Areas likely to have contaminants
Dry cleaning/laundry areas and establishments
Swimming pools
Metal fabrication plants
Beauty shops
Refrigeration repair shops
Photo processing plants
Auto body shops
Plastic manufacturing plants
Furniture refinishing areas and establishments
New building construction
Remodeling areas
Garages with workshops
When using an existing vent system to install a new boiler:
WARNING
Check the following venting components before installing:
• Material - For materials listed for use with this appliance, see Section 3 - General Venting. For polypropylene or stainless steel venting, an adapter of the same
manufacturer must be used at the flue collar connection.
• Size - To ensure proper pipe size is in place, see Table 3A. Check to see that this size is used throughout the vent system.
• Manufacturer - For a stainless steel or polypropylene application, you must use only the listed manufacturers and their type product listed in Tables 3E and 3G for CAT IV positive pressure venting with flue producing condensate.
• Supports - Non-combustible supports must be in place allowing a minimum 1/4" rise per foot. The supports should adequately prevent sagging and vertical slippage, by distributing the vent system weight. For additional information, consult the vent manufacturer’s instructions for installation.
• Terminations - Carefully review Sections 3 through 5 to ensure requirements for the location of the vent and air terminations are met and orientation of these fit the appropriate image from the Sidewall or Vertical options listed in the General Venting Section. For stainless steel vent, only use terminations listed in Table 3H for the manufacturer of the installed vent.
• Seal - With prior requirements met, the system should be tested to the procedure listed in parts (c) through (f) of the Removal of an Existing Boiler Section on page 11.
With polypropylene and stainless steel vent, seal and connect all pipe and components as specified by the vent manufacturer used; with PVC/CPVC vent, see the Installing Vent or Air Piping Section on page 19.
WARNING
Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.
If any of these conditions are not met, the existing system must be updated or replaced for that concern. Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.
10
Installation & Operation Manual
1 Determine boiler location (continued)
When removing a boiler from existing common vent system:
DANGER
WARNING
At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.
a. Seal any unused openings in the common venting system.
Do not install the Knight wall mount boiler into a common vent with any other appliance. This will cause flue gas spillage or appliance malfunction, resulting in possible severe personal injury, death, or substantial property damage.
Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.
g. Any improper operation of the common venting system
should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CAN/CSA B149.1, Natural Gas and Propane Installation Code. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part 11 of the National Fuel Gas Code, ANSI Z223.1/NFPA and/or CAN/CSA B149.1, Natural Gas and Propane Installation Code.
b. Visually inspect the venting system for proper size and
horizontal pitch and determine there is no blockage or restriction, leakage, corrosion, or other deficiencies, which could cause an unsafe condition.
c. Test vent system – 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 appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.
d. Place in operation the appliance being inspected. Follow
the lighting instructions. Adjust thermostat so appliance will operate continuously.
e. Test for spillage at the draft hood relief opening after
5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar, or pipe.
f. After it has been determined that each appliance remaining
connected to the common venting system properly vents when tested as outlined herein, return doors, windows, exhaust fans, fireplace dampers, and any other gas-burning appliance to their previous conditions of use.
11
2 Prepare boiler
Installation & Operation Manual
Remove boiler from wood pallet
1. After removing the outer shipping carton from the boiler, remove the parts box.
2. To remove the boiler from the pallet:
a. Remove the two (2) lag bolts securing the bottom
of the unit to the pallet.
b. Lift the boiler off the wall bracket mounted to
the pallet.
3. Remove the two (2) lag bolts securing the wall bracket to the wood pallet. Be certain not to lose the wall bracket as it will be needed for securing the boiler to the wall (FIG. 2-1).
NOTICE
Figure 2-1 Boiler Mounted on Shipping Pallet
Do not drop the boiler or bump the jacket on the floor or pallet. Damage to the boiler can result.
REMOVE SHIPPING [WALL] BRACKET
DO NOT DISCARD­WILL BE NEEDED TO SECURE THE BOILER TO THE WALL
Table 2A LP Conversion Table
LP Conversion Table
Model LP Orifice Stamping
51 50
81 80 106 105 151 210 / W150 211 210 / W150
1. Remove the front access cover from the unit (no tools required for removal).
2. Disconnect the ribbon cable from the control board. Remove the four (4) screws securing the bezel to the front of the unit and remove the bezel.
3. Locate the power switch on the gas valve and turn the power switch to the “OFF” position (FIG. 2-2).
4. Disconnect the Molex plug from the wiring connector located on the gas valve.
5. Using a 5/16" nut driver, loosen the band clamp securing the air intake coupler to the gas valve venturi. Remove the air intake pipe and coupler from the gas valve venturi.
6. Using a 4mm Allen wrench, remove the two (2) screws securing the gas valve venturi to the inlet of the combustion blower (FIG. 2-2). Remove the gas valve venturi assembly from the unit.
Figure 2-2 Gas Valve Power Switch & Venturi Removal
REMOVE THE TWO (2) SCREWS SECURING THE GAS VALVE VENTURI TO THE INLET OF THE COMBUSTION BLOWER
Gas conversions
WARNING
The gas conversion procedure should be accomplished BEFORE the boiler is installed. For a boiler already installed, you must turn off gas supply, turn off power, and allow the boiler to cool before proceeding. You must also completely test the boiler after conversion to verify performance as described under Start-up, Section 10 of this manual.
You must install the propane orifice to fire the Knight wall mount boiler on propane. Verify when installing that the orifice size marking matches boiler size (Table 2A). Failure to comply could result in severe personal injury, death, or substantial property damage.
12
POWER SWITCH
DETAIL
7. Using a 4mm Allen wrench, remove the four (4) screws securing the gas valve to the venturi (FIG. 2-3).
8. Locate the propane orifice disk from the conversion kit bag. Verify that the stamping on the orifice disk matches the boiler size (51 - 211, see Table 2A).
9. Place the orifice into the black rubber grommet in the side of the gas valve and secure inside the gas valve (see FIG. 2-3).
10. Reposition the gas valve against the venturi and replace the four (4) screws removed in Step 7, securing the valve to the venturi (FIG. 2-3).
11. Reposition the gas valve venturi assembly inside the unit. Secure the gas valve venturi to the combustion blower by replacing the two (2) screws removed in Step 6 (FIG. 2-2).
12. Reattach the air intake pipe and coupler to the gas valve venturi. Tighten the band clamp to secure.
2 Prepare boiler (continued)
13. Reattach the wiring connector to the gas valve. Tighten the screw on the wiring connector to secure to the gas valve.
14. Turn the gas valve power switch to the “ON” position.
15. Reattach the bezel to the unit. Reconnect the ribbon cable to the control board.
16. After installation is complete, fill out the gas conversion label (in the conversion kit bag) and affix it to the unit under the boiler rating plate inside the unit. Attach the LP caution label (in the conversion kit bag) to the left side of the unit in the lower left corner.
17. Replace the front access cover.
WARNING
Figure 2-3 Installing Propane Orifice
After converting to LP, check combustion per the Start-up procedure in Section 10 of this manual. Failure to check and verify combustion could result in severe personal injury, death, or substantial property damage.
Installation & Operation Manual
WARNING
Mounting to a concrete wall:
1. Mount the wall bracket using the two (2) wedge anchor bolts provided with the bracket. To mount the wedge anchor bolts, drill a 1/4" diameter hole 1 1/8" deep and insert anchor. Hang the bracket from the anchor and secure with the two nuts provided. Make sure the top edge of the bracket is away from the wall. Ensure bracket is level when mounted. Extreme care is needed to ensure the bolts are secured in the center of the studs.
Note: If wall thickness does not allow a 1 1/8" deep hole, field supplied hardware suitable for the application should be provided.
2. Hang the boiler on the bracket and secure the bottom of the boiler with two (2) remaining anchors, following the instructions above.
WARNING
Mounting to a metal studded wall:
The boiler is too heavy for a single person to lift. A minimum of two people is needed for mounting the boiler onto the bracket.
The boiler is too heavy for a single person to lift. A minimum of two people is needed for mounting the boiler onto the bracket.
Mounting the boiler
See page 9 of this manual for boiler mounting location instructions.
NOTICE
Mounting to a wood studded wall:
1. The wall mount bracket is designed for a stud spacing of
16 inches from center. For other stud spacing a solid mounting surface must be provided by the installer.
WARNING
The Knight Wall Mount boiler is not intended for floor installation.
Do not mount the boiler to a hollow wall. Be sure to mount the boiler to the studs only.
1. The wall mount bracket is designed for a stud spacing of 16 inches from center. For other stud spacing a solid mounting surface must be provided by the installer.
WARNING
Do not mount the boiler to a hollow wall. Be sure to mount the boiler to the studs only.
2. Mount the wall bracket using two (2) field supplied toggle bolts capable of supporting 100 pounds each. Ensure the top edge of the bracket is away from the wall. Ensure the bracket is level when mounted. Extreme care is needed to ensure the bolts are secured in the center of the studs.
3. Hang the boiler on the bracket and secure the bottom of the boiler with two (2) field supplied toggle bolts.
WARNING
The boiler is too heavy for a single person to lift. A minimum of two people is needed for mounting the boiler onto the bracket.
Figure 2-4 Mounting the Boiler
WALL: WOOD OR METAL STUDS ON 16" CENTERS
-OR­MASONRY / POURED CONCRETE
MOUNTING BRACKET (FACTORY SUPPLIED)
2. Mount the wall bracket using the 2 1/4" lag bolts
provided. Make sure the top edge of the bracket is away from the wall. Ensure the bracket is level when mounted. Extreme care is needed to ensure the bolts are secured in the center of the studs.
3. Hang the boiler on the bracket and secure the bottom of
the boiler with two (2) additional lag bolts provided.
FASTENERS APPROPRIATE FOR WALL TYPE QTY: 4
13
3 General venting
Direct venting options - Sidewall Vent
Installation & Operation Manual
Figure 3-1 Two-Pipe Sidewall Termination - See page 22 for more details
Direct venting options - Vertical Vent
Figure 3-2 PVC/CPVC Concentric Sidewall Termination - See page 26 for more details
Figure 3-3 Two-Pipe Vertical Termination - See page 29 for more details
14
Figure 3-4 PVC/CPVC Concentric
Vertical Termination - See page 31 for more details
Figure 3-5 Vertical Vent, Sidewall Air
3 General venting (continued)
Install vent and combustion air piping
Installation & Operation Manual
DANGER
WARNING
WARNING
NOTICE
WARNING
The Knight wall mount boiler must be vented and supplied with combustion and ventilation air as described in this section. Ensure the vent and air piping and the combustion air supply comply with these instructions regarding vent system, air system, and combustion air quality. See also Section 1 of this manual.
Inspect finished vent and air piping thoroughly to ensure all are airtight and comply with the instructions provided and with all requirements of applicable codes.
Failure to provide a properly installed vent and air system will cause severe personal injury or death.
This appliance requires a special venting system. Use only approved stainless steel,
PVC, CPVC or polypropylene pipe and fittings listed in Tables 3D, 3E, and 3G for vent pipe, and fittings. Failure to comply could result in severe personal injury, death, or substantial property damage.
DO NOT mix components from different systems. The vent system could fail, causing leakage of flue products into the
living space. Mixing of venting materials will void the warranty and certification of the appliance.
Installation must comply with local requirements and with the National Fuel Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations.
For closet and alcove installations, CPVC, polypropylene or stainless steel material MUST BE used in a closet/alcove structure. Failure to follow this warning could result in fire, personal injury, or death.
The Knight wall mount boiler vent and air piping can be installed through the roof or through a sidewall. Follow the procedures in this manual for the method chosen. Refer to the information in this manual to determine acceptable vent and air piping length.
You may use any of the vent/air piping methods covered in this manual. Do not attempt to install the Knight wall mount boiler using any other means.
You must also install air piping from outside to the boiler air intake adapter unless following the Optional Room Air instructions on page 18 of this manual. The resultant installation is direct vent (sealed combustion).
Air intake/vent connections
1. Combustion Air Intake Connector (FIG. 3-6) - Used to provide combustion air directly to the unit from outdoors. A fitting is provided on the unit for final connection. Combustion air piping must be supported per guidelines listed in the National Mechanical Code, Section 305, Table
305.4 or as local codes dictate.
2. Vent Connector (FIG.'s 3-7 thru 3-9) - Used to provide a passageway for conveying combustion gases to the outside. A transition fitting is provided on the unit for final connection. Vent piping must be supported per the National Building Code, Section 305, Table 305.4 or as local codes dictate.
Figure 3-6 Near Boiler Air Piping
AIR
CAUTION
NOTICE
WARNING
Improper installation of venting systems may result in injury or death.
Follow the instructions in Section 1, page 11 of this manual when removing a boiler from an existing vent system.
Do not connect any other appliance to the vent pipe or multiple boilers to a common vent pipe. Failure to comply could result in severe personal injury, death, or substantial property damage.
15
3 General venting
Installation & Operation Manual
Requirements for installation in Canada
1. Installations must be made with a vent pipe system
certified to ULC-S636.
IPEX is an approved vent manufacturer in Canada supplying vent material listed to ULC-S636.
2. The first three (3) feet of plastic vent pipe from the
appliance flue outlet must be readily accessible for visual inspection.
3. The components of the certified vent system must not be
interchanged with other vent systems or unlisted pipe/fittings.
4. The 2" and 3" Concentric Vent Kits available from
Lochinvar (see Section 4 – Sidewall Termination – Optional Concentric Vent) and the 2" and 3" Concentric Vent Kits available from IPEX are approved for use on the Knight wall mount boiler. Both kits are listed to the ULC-S636 standard for use in Canada.
Sizing
The Knight wall mount boiler uses model specific combustion air intake and vent piping sizes as detailed in Table 3A below.
Minimum / Maximum allowable combustion air and vent piping lengths are as follows:
Combustion Air = 12 equivalent feet minimum / 100 equivalent feet maximum
Vent = 12 equivalent feet minimum / 100 equivalent feet maximum
When determining equivalent combustion air and vent length, add 5 feet for each 90° elbow and 3 feet for each 45° elbow.
EXAMPLE: 20 feet of PVC pipe + (4) 90° elbows + (2) 45° elbows + (1) concentric vent kit (CVK3003) = 49 equivalent feet of piping.
NOTICE
Table 3B Concentric Vent Kit Equivalent Vent Lengths
Model Kit Number
The appliance output rating will reduce by up to 1.5% for each 25 feet of vent length.
Equivalent Vent
Length
Table 3A Maximum Combustion Air and Vent Piping Lengths
Model 2" Max Vent/Air 3" Max Vent/Air
51 40 feet 100 feet 81 40 feet 100 feet
106 40 feet 100 feet 151 N/A 100 feet 211 N/A 100 feet
NOTICE
Increasing or decreasing combustion air or vent piping sizes is not authorized.
51 - 106 CVK3008 3 feet 51 - 211 CVK3003 3 feet
16
3 General venting (continued)
Materials
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, Polypropylene or ABS Dryer Vent or Sealed Flexible Duct (not recommended for rooftop air inlet) Galvanized steel vent pipe with joints and seams sealed as specified in this section. Type “B” double-wall vent with joints and seams sealed as specified in this section. AL29-4C, stainless steel material to be sealed to specification of its manufacturer.
*Plastic pipe may require an adapter (not provided) to transition between the air inlet connection on the appliance and the plastic air inlet pipe.
WARNING
NOTICE
Using air intake materials other than those specified can result in personal injury, death or property damage.
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.
Installation & Operation Manual
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.
DANGER
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.
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 (3) 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.
17
3 General venting
Optional room air
NOTICE
Commercial applications utilizing the Knight wall mount boiler may be installed with a single pipe carrying the flue products to the outside while using combustion air from the equipment room. In order to use the room air venting option the following conditions and considerations must be followed.
The unit MUST be installed with the appropriate
room air kit (Table 3C).
• The equipment room MUST be provided with
properly sized openings to assure adequate combustion air. Please refer to instructions provided with the room air kit.
There will be a noticeable increase in the noise level
during normal operation from the inlet air opening.
Using the room air kit makes the unit vulnerable to
combustion air contamination from within the building. Please review Section 1, Prevent Combustion Air Contamination, to ensure proper installation.
Vent system and terminations must comply with the
standard venting instructions set forth in this manual.
WARNING
Optional room air is intended for commercial applications. Combustion air piping to the outside is recommended for residential applications.
When utilizing the single pipe method, provisions for combustion and ventilation air must be in accordance with Air for Combustion and Ventilation, of the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment, or applicable provisions of the local building codes.
Installation & Operation Manual
Air contamination
Pool and laundry products and common household and hobby products often contain fluorine or chlorine compounds. When these chemicals pass through the boiler, they can form strong acids. The acid can eat through the boiler wall, causing serious damage and presenting a possible threat of flue gas spillage or boiler water leakage into the building.
Please read the information given in Table 1A, page 10, listing contaminants and areas likely to contain them. If contaminating chemicals will be present near the location of the boiler combustion air inlet, have your installer pipe the boiler combustion air and vent to another location, per this manual.
WARNING
WARNING
If the boiler combustion air inlet is located in a laundry room or pool facility, for example, these areas will always contain hazardous contaminants.
To prevent the potential of severe personal injury or death, check for areas and products listed in Table 1A, page 10 before installing the boiler or air inlet piping.
If contaminants are found, you MUST:
• Remove contaminants permanently. —OR—
• Relocate air inlet and vent terminations to other areas.
Table 3C Optional Room Air Kit
Model Kit Number
51 - 106 KIT30051
151 - 211 KIT30052
18
3 General venting (continued)
PVC/CPVC
This product has been approved for use with the PVC/CPVC vent materials listed in Table 3D.
Installing vent and air piping
WARNING
NOTICE
NOTICE
WARNING
Table 3D PVC/CPVC Vent Pipe, and Fittings
Approved PVC/CPVC Vent Pipe and Fittings
Item Material Standard
Vent pipe
Vent fittings
Pipe Cement /
Primer
NOTICE: DO NOT USE CELLULAR (FOAM) CORE PIPE
The vent connection to the appliance must be made with the starter piece provided with the appliance if PVC/CPVC vent is to be used. The field provided vent fittings must be cemented to the CPVC pipe section using an “All Purpose Cement” suitable for PVC and CPVC pipe. Use only the vent materials, primer, and cement specified in Table 3D to make the vent connections. Failure to follow this warning could result in fire, personal injury, or death.
Use only cleaners, primers, and solvents that are approved for the materials which are joined together.
All PVC vent pipes must be glued, properly supported, and the exhaust must be pitched a minimum of a 1/4 inch per foot back to the boiler (to allow drainage of condensate).
Insulation should not be used on PVC or CPVC venting materials. The use of insulation will cause increased vent wall temperatures, which could result in vent pipe failure.
PVC Schedule 40, 80 ANSI/ASTM D1785 PVC - DWV ANSI/ASTM D2665 CPVC Schedule 40, 80 ANSI/ASTM F441 PVC Schedule 40 ANSI/ASTM D2466 PVC Schedule 80 ANSI/ASTM D2467 CPVC Schedule 80 ANSI/ASTM F439 PVC ANSI/ASTM D2564 CPVC ANSI/ASTM F493
Installation & Operation Manual
Examples: 1. Seven (7) feet vertical
2. Connector + 90° elbow + 2 feet horizontal
3. One (1) foot vertical + 90° elbow + 1 foot horizontal
1. Work from the boiler to vent or air termination. Do not exceed the lengths given in this manual for the air or vent piping.
2. Cut pipe to the required lengths and deburr the inside and outside of the pipe ends.
3. Chamfer outside of each pipe end to ensure even cement distribution when joining.
4. Clean all pipe ends and fittings using a clean dry rag. (Moisture will retard curing and dirt or grease will prevent adhesion.)
5. Dry fit vent or air piping to ensure proper fit up before assembling any joint. The pipe should go a third to two-thirds into the fitting to ensure proper sealing after cement is applied.
6. Priming and Cementing: a. Handle fittings and pipes carefully to prevent contamination of surfaces. b. Apply a liberal even coat of primer to the fitting socket and to the pipe end to approximately 1/2" beyond the socket depth. c. Apply a second primer coat to the fitting socket.
d. While primer is still wet, apply an even coat of approved cement to the pipe equal to the depth of the fitting socket along with an even coat of approved cement to the fitting socket. e. Apply a second coat of cement to the pipe. f. While the cement is still wet, insert the pipe into the fitting, if possible twist the pipe a 1/4 turn as you insert it. NOTE: If voids are present, sufficient cement was not applied and joint could be defective. g. Wipe excess cement from the joint removing ring or beads as it will needlessly soften the pipe.
Figure 3-7 Near Boiler PVC/CPVC Venting
CPVC STARTER PIECE
NOTE: In Canada, CPVC and PVC vent pipe, fi ttings and cement/ primer must be ULC-S636 certifi ed.
WARNING
For models 51 - 106 when transitioning from 2 to 3 inch vent diameter, a 2" pipe section and 2"to 3" increaser are required to be CPVC when PVC/CPVC vent is used.
For installations using 2" vent, the first seven (7) equivalent feet of vent must be CPVC (field supplied). See examples on this page.
19
3 General venting
Installation & Operation Manual
Polypropylene
This product has been approved for use with polypropylene vent with the manufacturers listed in Table 3E.
All terminations must comply with listed options in this manual and be a single-wall vent offering.
For use of flex pipe, it is recommended to have the vent material in 32°F or higher ambient space before bending at installation. No bends should be made to greater than 45° and ONLY installed in vertical or near vertical installations.
For support and special connections required, see the manufacturer's instructions. All vent is to conform to standard diameter and equivalent length requirements established.
Table 3E Polypropylene Vent Pipe and Fittings
Approved Polypropylene Vent Manufacturers
Make Model
Centrotherm Eco Systems
Duravent (M & G Group)
NOTICE
The installer must use a specific vent starter adapter at the flue collar connection. The adapter is supplied by the vent manufacturer to adapt to its vent system. See Table 3F for approved vent adapters. Discard CPVC starter piece.
PolyPro Single-Wall / PolyPro Flex
InnoFlue SW/Flex
WARNING
NOTICE
NOTICE
Figure 3-8 Near Boiler Polypropylene Venting
Use only the adapters and vent system listed in Tables 3E and 3F. DO NOT mix vent systems of different types or manufacturers. Failure to comply could result in severe personal injury, death, or substantial property damage.
Installations must comply with applicable national, state, and local codes. For Canadian installation, polypropylene vent must be listed as a ULC-S636 approved system.
Installation of a polypropylene vent system should adhere to the vent manufacturer’s installation instructions supplied with the vent system.
NOTICE
WARNING
Table 3F Approved PolypropyleneTerminations
All vent connections MUST be secured by the vent manufacturer's joint connector (FIG. 3-8).
Insulation should not be used on polypropylene venting materials. The use of insulation will cause increased vent wall temperatures, which could result in vent pipe failure.
IMG00155
Centrotherm InnoFlue SW
Model
51-106
151-211
* These parts are only needed if the sidewall termination assembly is used (see FIG. 4-4B on page 24).
Polypropylene Adapter /
Flue Clamp
ISAG0202 w/IAFC02 IANS02 IATP0202 ISTAGL0202 2PPS-AD w/ PPS-PAC 2PPS-LB 2PPS-HLK ISAG0303 w/IAFC03 IANS03 IATP0303 ISTAGL0303 3PPS-AD w/ PPS-PAC 3PPS-LB 3PPS-HLK
Joint
Connector
Sidewall Retaining
Bracket*
Sidewall
Adapter*
Polypropylene Adapter
JOINT CONNECTOR REQUIRED AT ALL COMPONENT CONNECTIONS OF VENT SYSTEM
POLYPROPYLENE ADAPTER W/FLUE CLAMP
Duravent Polypro
Joint
Connector
Sidewall Kit*
20
3 General venting (continued)
Stainless steel vent
This product has been approved for use with stainless steel using the manufacturers listed in Table 3G.
WARNING
Use only the materials, vent systems, and terminations listed in Tables 3G and 3H. DO NOT mix vent systems of different types or manufacturers. Failure to comply could result in severe personal injury, death, or substantial property damage.
Installation & Operation Manual
NOTICE
Figure 3-9 Near Boiler Stainless Steel Venting
Installation of a stainless steel vent system should adhere to the stainless steel vent manufacturer’s installation instructions supplied with the vent system.
VENT
NOTICE
NOTICE
Table 3G Stainless Steel Vent Pipe and Fittings
Dura Vent (M & G Group) FasNSeal Vent / FasNSeal Flex* Vent Z-Flex (Nova Flex Group) Z-Vent Heat Fab (Selkirk Corporation) Saf-T Vent
The installer must use a specific vent starter adapter at the flue collar connection, supplied by the vent manufacturer to adapt to its vent system. See Table 3H for approved vent adapters. Discard CPVC starter piece.
Installations must comply with applicable national, state, and local codes. Stainless steel vent systems must be listed as a UL-1738 approved system for the United States and a ULC-S636 approved system for Canada.
Approved Stainless Steel Vent Manufacturers
Make Model
3" S.S. ADAPTER
*Use of FasNSeal Flex smooth inner wall vent is to be used in vertical or near vertical sections only, taking precaution to ensure no sagging occurs of the vent system. Connect to the FasNSeal rigid vent using specially designed adapters and sealing method, see manufacturer’s instructions.
Table 3H Approved Stainless Steel (S.S.) Terminations and Adapters
ProTech Heat Fab Z Flex
FasNSeal Saf-T Vent Z-Vent
Model
51 - 211
S.S.
Adapter
300716 (Vent)
300715 (Intake
Air)
Flue
Termination
FSBS3
FSRC3(R.C)
Intake
Air
Termination
303889
S.S.
Adapter
WB50210
(Vent)
9301PVC
(Intake Air)
Flue
Termination
9392
5300CI
Intake
Air
Termination
9314TERM
S.S.
Adapter
2SVSLPVC3
(Vent)
2SVSLA03 (Intake Air)
Flue
Termination
2SVSTP03
2SVSRCX03
Intake Air
Termination
2SVSTEX0390
21
4 Sidewall direct venting
Installation & Operation Manual
Vent/air termination – sidewall
WARNING
WARNING
Determine location
Locate the vent/air terminations using the following guidelines:
1. The total length of piping for vent or air must not exceed the limits given in the General Venting Section on page 16 of this manual.
2. You must consider the surroundings when terminating
the vent and air:
a. Position the vent termination where vapors will not damage nearby shrubs, plants or air conditioning equipment or be objectionable. b. The flue products will form a noticeable plume as they condense in cold air. Avoid areas where the plume could obstruct window views. c. Prevailing winds could cause freezing of condensate and water/ice buildup where flue products impinge on building surfaces or plants. d. Avoid possibility of accidental contact of flue products with people or pets. e. Do not locate the terminations where wind eddies could affect performance or cause recirculation, such as inside building corners, near adjacent buildings or surfaces, window wells, stairwells, alcoves, courtyards, or other recessed areas.
WARNING
f. Do not terminate above any door or window. Condensate can freeze, causing ice formations. g. Locate or guard vent to prevent condensate damage to exterior finishes.
Follow instructions below when determining vent location to avoid possibility of severe personal injury, death, or substantial property damage.
A gas vent extending through an exterior wall shall not terminate adjacent to a wall or below building extensions such as eaves, parapets, balconies, or decks. Failure to comply could result in severe personal injury, death, or substantial property damage.
Sidewall vent and air inlet terminations must terminate in the same pressure zone.
Figure 4-1A PVC/CPVC/Polypropylene Sidewall Termination of Air and Vent
TO BOILER
INTAKE AIR
CONNECTION
FROM BOILER
VENT PIPE
CONNECTION
POSSIBLE ORIENTATIONS
VENT / AIR
TERMINATION
GRADE OR
SNOW LINE
12"
MIN
TO OVER­HANG
12"
MIN
Table 4A Sidewall Vent Kit
Model Kit Number Vent Size
51 - 106 KIT30044 2 inch vent
151 - 211 KIT30045 3 inch vent
If using the alternate sidewall termination:
3. The air piping must terminate in a down-turned elbow as shown in FIG. 4-1B. This arrangement avoids recirculation of flue products into the combustion air stream.
4. The vent piping must terminate in an elbow pointed outward or away from the air inlet, as shown in FIG. 4-1B.
WARNING
Figure 4-1B Alternate PVC/CPVC/ Polypropylene Sidewall Termination of Air and Vent w/Field Supplied Fittings
FROM BOILER
VENT PIPE
CONNECTION
Do not exceed the maximum lengths of the outside vent piping shown in FIG. 4-1B. Excessive length exposed to the outside could cause freezing of condensate in the vent pipe, resulting in potential boiler shutdown.
TO BOILER INTAKE AIR
CONNECTION
BIRD SCREEN
12” MIN
15” MAX
22
TERMINATION
PLATE
BIRD SCREEN
GRADE OR
SNOW LINE
12”
MIN
4 Sidewall direct venting (continued)
Installation & Operation Manual
Vent/air termination – sidewall
Figure 4-1C Alternate Venting Arrangement (if Space Allows) w/Field Supplied Fittings
TO BOILER INTAKE AIR
CONNECTION
FROM BOILER
VENT PIPE
CONNECTION
BIRD
SCREEN
GRADE OR SNOW LINE
ALTERNATE VENTING ARRANGEMENT
(IF SPACE PERMITS)
Figure 4-1D Alternate Venting Arrangement - Typical Stainless Steel Sidewall Termination of Air and Vent w/ Field Supplied Fittings
TO BOILER
INTAKE AIR
CONNECTION
FROM
BOILER
VENT PIPE
CONNECTION
COUPLING
12” MIN 15” MAX
BIRD SCREEN
12”
MIN
12" MIN 15" MAX
Figure 4-2A Clearance to Gravity Air Inlets
12"
MIN.
VENT / AIR
TERMINATION
12"
MIN.
12"
MIN.
Figure 4-2B Alternate Clearance to Gravity Air Inlets w/ Field Supplied Fittings
12”
MIN
BIRD
SCREEN
(TYPICAL)
12”
MIN
12”
MIN
Figure 4-3A Clearance to Forced Air Inlets
BIRD SCREEN
12" MIN
GRADE OR SNOW LINE
5. Maintain clearances as shown in FIG.’s 4-1A thru 4-3B, pages 22 - 23. Also maintain the following:
a. Vent must terminate:
• At least 6 feet from adjacent walls.
• No closer than 12 inches below roof overhang.
• At least 7 feet above any public walkway.
• At least 3 feet above any forced air intake within 10 feet.
• No closer than 12 inches below or horizontally from any door or window or any other gravity air inlet. b. Air inlet must terminate at least 12 inches above grade or snow line; at least 12 inches below the vent termination; and the vent pipe must not extend more than 24 inches vertically outside the building as shown in FIG. 4-1B. Condensate could freeze and block vent pipe. c. Do not terminate closer than 4 feet horizontally from any electric meter, gas meter, regulator, relief valve, or other equipment. Never terminate above or below any of these within 4 feet horizontally.
6. Locate terminations so they are not likely to be damaged by foreign objects, such as stones or balls, or subject to buildup of leaves or sediment.
IF LESS
THAN 10’
VENT / AIR
TERMINATION
7' MIN. ABOVE ANY
PUBLIC WALKWAY
36"
MIN.
FORCED AIR
INLET
Figure 4-3B Alternate Clearance to Forced Air Inlets w/ Field Supplied Fittings
IF LESS
THAN 10’
36”
MIN
FORCED AIR
INLET
BIRD
SCREEN
7’ MIN ABOVE ANY PUBLIC WALKWAY
(TYPICAL)
23
4 Sidewall direct venting
A
Installation & Operation Manual
Prepare wall penetrations
1. Use the factory supplied wall plate as a template to locate the vent and air intake holes and mounting holes.
Air pipe penetration:
a. Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter.
Vent pipe penetration:
a. Cut a hole for the vent pipe. For either combustible or noncombustible construction, size the vent pipe hole with at least a 1/2 inch clearance around the vent pipe outer diameter:
• 3½ inch hole for 2 inch vent pipe
• 4½ inch hole for 3 inch vent pipe Drill 3/16" diameter holes for inserting the plastic anchors
into the wall.
2. For Polypropylene Only: Install the vent and air intake sidewall adapters from Table 3F on page 20 into the vent plate. Slide the sidewall retaining bracket down the sidewall adapters flush to the vent plate (FIG. 4-4B).
3. For PVC/CPVC Only: Install the vent and air intake piping through the wall into the vent plate openings. Use RTV silicone sealant to seal the air pipe. Use the cement/primer listed in Table 3D on page 19 to seal the vent pipe.
4. Mount and secure the vent plate to the wall, using stainless steel screws.
5. Seal all gaps between the pipes and wall. Seal around the plate to the wall assuring no air gaps.
6. Assemble the vent cap to the vent plate (see FIG.'s 4-4A and 4-4B). Insert the stainless steel screws into the vent cap screw hole openings and securely attach the vent cap to the vent plate.
7. Seal all wall cavities.
8. PVC/CPVC terminations are designed to accommodate any wall thickness of standard constructions per the directions found in this manual.
9. Stainless steel terminations are designed to penetrate walls with a thickness up to 9.25 inches of standard construction.
Figure 4-4A PVC/CPVC Sidewall Termination Assembly
VENT
AIR
Figure 4-4B Polypropylene Sidewall Termination Assembly
SIDEWALL ADAPTER
SIDEWALL
DAPTER
(VENT)
GALVANIZED THIMBLE
(AIR)
WALL PLATE
SIDEWALL RETAINING PLATE
IMG00085
VENT PLATE
VENT CAP
Prepare wall penetrations (Alternate ­Field Supplied Option)
1. Air pipe penetration: a. Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter.
2. Vent pipe penetration: a. Cut a hole for the vent pipe. For either combustible or noncombustible construction, size the vent pipe hole with at least a 1/2 inch clearance around the vent pipe outer diameter:
• 3½ inch hole for 2 inch vent pipe
• 4½ inch hole for 3 inch vent pipe b. Insert a galvanized metal thimble in the vent pipe
hole as shown in FIG. 4-4C.
3. Use a sidewall termination plate as a template for correct
location of hole centers.
4. Follow all local codes for isolation of vent pipe when
passing through floors or walls.
5. Seal exterior openings thoroughly with exterior caulk.
Figure 4-4C Alternate Sidewall Termination Assembly w/Field Supplied Fittings
AIR PIPING
VENT PIPING
ELBOW
BIRD SCREEN
VENT PLATE
VENT CAP
CENTERLINE WIDTH
GALVANIZED THIMBLE
SIDEWALL TERMINATION PLATE
ELBOW
BIRD SCREEN
AIR PIPING
VENT PIPING
WALL PLATE
GALVANIZED
THIMBLE
24
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