M&G DuraVent DuraStack User Manual

Installation Instructions

A Modular Double-Wall Positive Pressure Chimney System. Factory Built for Boiler Breeching, Engine Exhaust, and Chimney Stack. Grease Duct (DIS only)

DuraStack

DIS/DAS

A MAJOR CAUSE OF VENT RELATED FIRES IS FAILURE

TO MAINTAIN REQUIRED CLEARANCES (AIR SPACES) TO

COMBUSTIBLE MATERIALS. IT IS OF THE UTMOST IMPORTANCE

THAT POLYPRO® BE INSTALLED ONLY IN ACCORDANCE WITH

THESE INSTRUCTIONS.

WARNING

CARBON MONOXIDE POISONING HAZARD. Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death.

WARNING

Risk of carbon monoxide poisoning or re due to joint separation or pipe breakage.

• Examine all components for possible

shipping damage prior to installation

• Proper joint construction is essential

for a safe installation. Follow these instructions exactly as written.

• This venting system must be free to

expand and contract.

• This venting system must be supported

in accordance with these instructions.

• Check for proper joint construction

when joining pipe to ttings.

• Check for unrestricted vent movement

through, walls, ceilings, and roof penetrations.

• Dierent manufacturers have dierent

joint systems and adhesives. Do not mix pipe, ttings or joining methods from dierent manufacturers.

IMPORTANT

Read through all of these instructions before beginning your installation. Failure to install this product as described in these instructions will void the manufacturer’s warranty, may create a re or other safety hazard, and may aect your homeowner’s insurance and safety listing of your appliance.

Keep these instructions for future reference.

Dear Customer, Installer, or End User:

We welcome any comments regarding matters pertaining to our DuraVent products. We welcome any ideas, input or complaints to help improve our product oering. Send your emails to: president@duravent.com

If you are searching for tech support or product information, please phone us at 800-835-4429. Or email us at: techsupport@duravent.com

Double Wall Construction Positive Pressure Chimney System

For the most up-to-date installation instructions, see www.duravent.com

CONTENTS

INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . 4

TESTING/LISTING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . 4

SECT ION A: GENERAL INFORMATION . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 4

SECT ION B: TEES, EL BOWS, INCRE ASERS. . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . 12

SECTION C: STRUCTURAL SUPPORT AND GUIDING. . . . . . .. . . . . . . . . . . . .16

SECTION D: ROOF AND WALL PENETRATIONS. . . . . . . . . . . . .. . . . . . . . . .. . . .22

SECTION E: TERMINATIONS, STARTING ADAPTORS, DRAIN LENGTH AND

RELIEF VALVE . . . .. . . . .. . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .24

SECT ION F: THERMAL EXPANSION. . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

SECTION G: GREASE DUCT APPLICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

PRODUCT REFERENCE INFORMATION. . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. . . .38

SECTION H: MARKINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

WARRANTY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

DuraStack

DIS/DAS

INTRODUCTION

DuraVent Model DuraStack DIS or DAS Chimney are cylindrical, prefabricated, modular venting systems incorporating a unique extended inner ange designed for both quick assembly and pressure sealing capability. Model DIS incorporates a 2” of mineral ber insulation while DAS is air insulated. The circular cross section and high quality stainless steel inner ue construction provide for a system with high strength-toweight ratio and low friction losses.

TESTING / LISTING INFORMATION

DuraVent model DIS and DAS venting systems are listed with Intertek Testing Services (ETL) to UL/ULC standards: U.S.A.

• UL-103

- 60 in. Positive Pressure Chimney

- Building Heating Appliance Chimney

- 1400°F Chimney

• UL-1978 Grease Duct (DIS only) CANADA

• ULC/ORD C959

- 540°C (1000°F)

- 760°C (1400°F)

• ULC S604

Models DuraStack DIS and DAS are code compliant when installed as per the Installation Instructions with : NFPA211; NFPA31; NFPA37; NFPA96 and CSA-B149

When installed in accordance with it’s installation, Models DuraStack DIS and DAS comply with the following codes:

- NFPA (National Fire Protection Association)

- SBCCI (Southern Building Code Congress International)

- ICBO (International Conference of Building Ocials)

- BOCA (Building Officials and Code Administrators)

- ICC (International Code Congress)

SECTION A  GENERAL INFORMATION

These instructions comprise both general guidelines and special requirements for all parts in the product line. Before specifying a design or beginning an installation please carefully review these instructions.

IMPORTANT

Chimney Cleaning: This applies to cleaning other than standard natural gas chimney applications where minimal maintenance is necessary. Keep your chimney clean. Access should be provided for the inspection and cleaning of all sections of the chimney. Have your chimney cleaned by qualied chimney sweep. It is recommended to use a nylon chimney brush of the correct size. Do not use a brush that will scratch the stainless steel interior of the chimney.

FEATURES

Models DIS and DAS are prefabricated modular venting systems design for industrial and commercial applications. It has a unique extended inner ange for both quick assembly and pressure sealing capability. It is a double wall construction with 2” of mineral ber insulation for DIS and 2” air space for model DAS. The inner ue is made of high quality stainless steel plasma welded.

APPLICATION UL 103 Building Heating Appliance Chimney Listing:

Under this category, models DIS and DAS have been determined suitable for venting ue gases at temperatures not exceeding 538°C (1000°F) under continuous operating conditions from gas, liquid, oil or solid fuel red appliances. Also complies with operation (less than one hour) at temperatures not exceeding 740°C (1400°F) and brief operation (maximum 10 minutes) at temperatures not exceeding 906°C (1700°F). Building Heating Appliance Chimneys are suitable for use with Building Heating

Appliances and Low Heat Appliances as described in the Chimney Selection Chart of National Fire Protection Association (NFPA) Standard NO. 211.

UL 103 1400°F Chimney Listing:

Under this category, models DIS and DAS have been determined suitable for venting ue gases at temperatures not exceeding 760°C (1400°F) under continuous operating conditions from gas, liquid, oil or solid fuel red appliances. Also complies with brief operation (maximum 10 minutes) at temperatures not exceeding 906°C (1700°F). As such, it is suitable for use with ovens and furnaces as described in the Chimney Selection Chart of NFPA No. 211, in addition to other applications.

UL 103 Positive Pressure Listing:

Under this category, models DIS and DAS have been determined suitable for use at a maximum of 60 inch water column internal pressure.

UL 2561 1400°F Chimney Listing

SURROUNDINGS / ENCLOSURE

DuraVent models DIS and DAS chimney are primarily intended to be used in re resistive noncombustible surroundings or installed unenclosed. They are not intended for use in one or two family residences.

CAUTION

Do not enclose this chimney in a chase or passageway of ordinary wood or other combustible material

Where the chimney extends through any zone of a building (outside that in which the heating appliance connected to it is located), it shall be provided with an enclosure having a re resistance rating equal to or greater than that of the oor, wall or roof assemblies through which it passes.

DuraVent models DIS and DIS chimney may penetrate a combustible oor, wall or roof using the appropriate parts and openings sizes. See section D “Roof & Wall Penetration” for more details.

ULC C959 540°C and 760°C Industrial Chimneys Listing:

UL 1978 Grease Ducts Listing (DIS only):

DuraVent model DIS chimney is tested in accordance with UL 1978 Standard and approved for Grease Duct applications when installed in accordance with these installation instructions and National Fire Protection Association standard “NFPA 96, Standard for Ventilation Control and Fire Protection of Commercial Cooking Operations”.

Where, according to local code, no chase enclosure is necessary, models DIS and DAS chimney may be placed adjacent to walls of combustible construction at the clearance specied on each chimney section and in the individual listing; see “CLEARANCES”. Contact local building or re ocials about restrictions and installation inspection requirements in your area.

Grease Ducts (DIS Only)

1. Model DIS grease ducts are primarily

intended for installation in noncombustible surroundings or in unenclosed installations.

2. Where model DIS grease ducts are installed in an open room and an enclosure is not required, the minimum clearance to adjacent combustible walls shall be as shown in this section (see “CLEARANCES”). The ducting may be located in a corner formed by two

walls of combustible construction, if the conditions above are met.

3. Other interior installations in all buildings should be as follows: a) Where a grease duct penetrates a wall or ceiling rated for re resistance, it should be enclosed with a continuous non-combustible enclosure extending from the lowest rerated ceiling or oor above the hood, through any concealed space, to or through the roof so as to maintain the integrity of the re separations required by the applicable building code provisions. The enclosure shall be sealed around the duct at the point of penetration of the lowest re-rated ceiling or oor above the hood, in order to maintain the re resistance rating of the enclosure and shall be extended to the exterior of the building through weather-protected openings. b) A grease duct penetrating a ceiling, oor or wall which does not have a re resistance rating does not require to be enclosed, if the clearances to combustibles are at the correct minimum for unenclosed installations. c) Where model DIS grease ducts extend through any story of a building above the oor on which the connected appliances are located, they shall be enclosed in the upper stories with walls having a re resistance rating of not less than one hour for buildings of two or three stories. If the building is four stories or more, the enclosure wall shall have a re resistance rating of not less than two hours.

4. Combustible roofs or roof-ceiling assemblies may be penetrated as described in Section D – Roof and wall penetrations.

SYSTEM SIZING

IMPORTANT

Do not enclose with combustible materials.

Refer to NFPA 96, “ Standard For Ventilation Control And Fire Protection Of Commercial Cooking Operations”, for

installation and clearances of re-rated enclosures and denitions.

Complete system sizing and capacity information maybe obtained from the “Chimney, Gas Vent, and Fireplace Systems” chapter of the ASHRAE Handbook (go to www.ashrae.org for more information). In spite of these general sizing guidelines, it is most important that the heating appliance, engine or turbine manufacturer’s installation instructions are followed. Not following the equipment manufacturer’s instructions may result in inadequate chimney performance and/or a violation of the equipment manufacturer’s installation requirements.

PART NUMBERS

These instructions identify major model DIS / DAS parts by name and part number.

Table 1

Part Numbers

Example Model Dia. Part Material

DIS 36” length with inside diameter 14” made of ss316 inner ue and ss304 outer casing.

DAS 30° elbow with inside diameter 22” made of ss304 inner ue and galvalume outer casing.

DIS wall support for 8” diameter chimney made of galvalume.

IMPORTANT

Use only factory-supplied components. Failure to do so will void the certication and the warranty of the chimney system.

DIS 14 L36 BC

DAS 22 E30 CE

DIS 8 WS E

EFFECTIVE LENGTH

When assembling two parts together, the joint will overlap 5/8”. So eective length is nominal length minus 5/8”.

Effective Length

Example Material

L36 35 /"

Table 3

DIS Minimum Openings

Model Roof / Floor (C) Wall (C)

Ø5" - Ø10" Inside Ø + 8" Inside Ø + 8"

Ø12" - Ø36" Inside Ø + 8" Not Listed

L24 23 ⁄"

L18 17 /"

L12 11 /"

CLEARANCES DIS

Minimum air space clearance to combustible construction to model DIS Chimney is 1”. For non-combustible construction, maintain clearances as required for installation, access for inspection or per local code.

DAS

Minimum air space clearance to combustible construction to DAS chimney is 4”.

See Table 2.

Table 2

Clearances

Model B.H.A Chimney 1400°F Chimney

DIS 1" 1"

DAS 4" 4"

OPENING THROUGH COMBUSTIBLE CONSTRUCTION

The following table serves to identify the minimum opening required when installing a chimney through a oor, wall or roof made of combustible material. See Table 3 and Figure 1.

Table 4

DAS Minimum Openings

Model Roof / Floor (C) Wall (C)

Ø5" - Ø10" Inside Ø + 12" Inside Ø + 12"

Ø12" - Ø36" Inside Ø + 12" Not Listed

Chimney Outside Diameter

Chimney Inside Diameter

2" Insulation

Clearance Opening

A B C

WARNING

DO NOT INSTALL ANY TYPE OF INSULATION IN THE REQUIRED CLEARANCE SPACES SURROUNDING THE CHIMNEY.

Openings - Minimum opening required when installing a chimney through

a oor, wall or roof made of

combustible material.

Figure 1

CHIMNEY AND FITTING JOINT ASSEMBLY

All components have a male and female end. The installation orientation is indicated on the labeling of each chimney section with an arrow. The arrow indicates the direction of the ow. Clean all inner and outer surfaces of the male and female ends with an appropriate organic solvent, such as acetone, Mek, or other commercial degreaser.

1. Apply a bead of S-650 sealant about 1/8” thick around the male end of chimney and for Grease duct application, add a bead of S-2000 sealant at the edge of the female chimney (see Figure 2). See Table 5 for approved sealants.

2. Insert the female end, of another section of chimney, over male end with sealant (see Figure 3).

3. Insert the assembly band (see Figure

4) around the joint of the two sections

assembled in Step 2. A small bead of S-650 can be applied on the inner groove of the band prior to installation for better leak tightness.

4. Using a phillips screwdriver, connect the two ends of the band as shown in Figure 5.

5. Where the chimney is installed outside, an exterior sealant S-375 must be applied at the upper joint of the band and the outer casing, see Figure 5.

Figure 3

Figure 4

Grease Duct Application: Add a

bead of S-2000 sealant at the edge of the female end.

Apply S-375 sealant here for exterior installation.

Figure 5

Add S-650 sealant here.

Figure 2

Table 5

Sealant Usage

Interior Installation

Sealant

Application

Joints DuraVent S-650 Red 650°F

Inner Flue DuraVent S-2000 White 2000°F

Exterior Installation

Sealant

Application

Joints DuraVent S -650 Red 650°F

Outer Band DuraVent S-375 Gray 375°F

Supplier Model Color

Max.

Temp.

Max.

Temp.

CAUTION

DO NOT ALLOW SCREWS TO PENETRATE THE INNER FLUE. THIS CAN CAUSE CORROSION, GAS LEAKAGE OR EXPANSION FAILURE. NEVER USE SCREWS THROUGH THE OUTER CASING OF AN ADJUSTABLE LENGTH OR EXPANSION JOINT. OBSERVE ADEQUATE SAFETY MEASURES WHEN USING A DEGREASER.

Table 6

Maximum Chimney Heights and Support Method for Model DIS and DAS

Anchor Plate Anchor Plate Ventilated (APV) Wall Support (WS)

Inside Diameter

5 147 133 133 147 61 105

6 128 116 116 128 53 92

8 103 93 93 103 43 74

10 86 78 78 86 35 61

12 73 66 66 73 30 53

14 64 58 58 64 27 46

16 57 52 52 57 24 41

18 53 48 48 53 22 38

20 48 43 43 48 20 34

22 44 40 40 44 18 31

24 37 34 34 37 15 27

26 35 32 32 35 14 25

28 33 30 30 33 13 23

30 31 28 28 31 13 22

32 29 26 26 29 12 21

34 27 25 25 27 11 20

36 26 23 23 26 11 18

Building Metal

Frame

Building Metal

Frame

Building Wood

Frame

Building Metal

Frame

Building Wood

Tee (T)

Frame

SUPPORT METHODS AND HEIGHT LIMITS

1. Several support and guiding methods are

used to anchor a chimney against upward, downward and angular displacement.

2. These supports and guides used with thermal expansion devices, prevent bending stresses on the chimney elbows and joints.

3. Supports and guiding methods and installation are described in Section C. Certain limitations apply for proper installation of supports and guides. See

Tables 6 and 7.

See Dim. "H" Figure 7

and Chimney Guying and Bracing in this section

MVS

Maximum Height - See Table 6

MVS

Termination

Storm Collar

Roof Support

Wall Guide

Floor Guide

Table 7

Support and Guide Spacing for Model

DIS and DAS (dimensions in feet)

Inside Diameter (in.)

5 10 8 10 12

6 10 8 10 12

8 10 8 10 12

10 10 8 10 12

12 10 8 10 12

14 10 8 10 12

16 10 8 10 12

18 10 8 10 12

20 10 8 10 12

22 10 8 10 12

24 10 8 10 12

26 10 8 10 12

28 10 8 10 12

30 10 8 10 12

32 10 8 10 12

34 10 8 10 12

36 10 8 10 12

MVS*

Interior Exterior

H** MHS***

MVS

Wall Support

Figure 6

IMPORTANT

“MVS ” dimension see Table 7 for Maximum Vertical Spacing between two guides or a support and a guide.

IMPORTANT

When the maximum height from Table 6 is exceeded, resupport using another support and expansion joint.

* MVS: Maximum Vertical Spacing between two guides or a support and a guide in a vertical position. ** H: Maximum freestanding Height above the roof. *** MHS: Maximum Horizontal Spacing between two guides or a support and a guide is 12 feet.

THERMAL EXPANSION

Good installation practice requires that any length of exhaust system between two xed points subject to more than 1/4 inch expansion must have an Adjustable Length (LA) or Bellows Joint (LB) to compensate for expansion. Models DIS and DAS will expand approximately 1 inch for every 100°F temperature rise per 100 feet of chimney. To accommodate chimney movements, any wall guide or oor guide must be located

away from the locking band. It is essential that these parts be properly installed and provided with adequate support and guidance to prevent binding or excessive bending forces. (See detailed installation

information contained on page 27, Thermal Expansion).

CHIMNEY WEIGHT

Chimney weight is given in pounds per foot of chimney for each diameter. It is important to know the weight of the chimney section for chimney support or guiding. Chimney weight (Table 8) along with maximum chimney height (Table 6) are necessary to calculate the proper anchor strength needed with wall supports (WS), Anchor Plate (AP) supports and Suspension Bands (SB).

Table 8

CHIMNEY GUYING AND BRACING

1. Proper guying and bracing is essential

for part of the chimney that extends above the roof or parapet wall. The chimney at this point is subject to wind conditions and needs special attention for proper stabilization.

2. If the stack above the roof does not exceed dimension H, no special guying or bracing is required. However, to protect the ashing from lateral movement, a guide must be installed at the roof level. See Figure 7).

3. For stack height above the roof that needs guying or bracing, a support, a small length and a expansion length must be installed near the roof level to absorb the thermal expansion and minimise this eect on the guy wires or brace.

Chimney Weight in lb/ft

Inside Diameter Model DIS Model DAS

5 7 4

6 8 5

8 10 6

10 12 8

12 14 9

14 16 10

16 18 12

18 20 13

20 22 14

22 24 15

24 28 19

26 30 20

28 32 21

30 34 23

32 36 24

34 38 25

36 40 27

Example: Model DIS, 6” diameter section of 25 feet in length from table 8, weight in lb/ft = 8. Total weight 8 x 25 = 200 lbs

Guide

Maximum Height See Table 6

Support

No Guying or Bracing Required

Figure 7

IMPORTANT

If Dimension “H” exceeds the value in table 7, use bracing or cable guying to stabilize chimney section above the roof. See Notes

3, 4, 5 and Figure 8.

Guy Cable * tensioners and roof anchors * (by

others)

See Table 7 for "H" dimensions

Brace

Support

Expansion

Length

Guide

Support

5' Max

Maximum Height

- See Table 6

Figure 8

IMPORTANT

Cables and roof anchors designed for 30 lb. per sq. ft. force on chimney projected area.

feet from any adjacent ridge, wall or parapet, the chimney shall terminate at minimum of 3 feet above the ridge, wall, or parapet.

3. Where chimney terminates at more than 10

feet from ridge, wall, or parapet, a minimum height of 2 feet shall be required above the ridge wall or parapet.

MULTIENGINE EXHAUST SYSTEMS

A common exhaust system for multiple engine or turbine installations is generally not recommended. A separate exhaust system should be provided for each engine or turbine. Check with your engine or turbine manufacturer prior to common exhaust system design. Exhaust gas from operating units tends to ow to non-operating units where condensation may form.

IMPORTANT

Water in engine or turbines at start-up may cause damage. In general, a separate exhaust system should be provided for each engine or turbine.

SECTION B TEES, ELBOWS, INCREASERS

4. When using guy wire, the cable must

be slightly slack or loose to allow thermal expansion.

5. When using rigid bracing, the maximum vertical height between supports must be reduced to 5’ to compensate thermal expansion.

TERMINATION HEIGHT

Chimneys and vents shall terminate above the roof level in accordance with the following requirements:

1. Five feet above the roof level or any adjacent at roof, wall parapet or air intakes, and/or in accordance with the following NFPA 211 requirements.

2. Where chimney terminates at less than 10

90° TEE (T90)

1. Generally used to connect the horizontal

length from the appliance to the vertical length when clean-outs access or drain is required.

2. 90° should not be used for changing ow direction in diesel or turbine exhaust.

3. For supporting the tee, the preferred location is above the tee (see Figure 9).

4. If it is not possible to suspend the tee, it may be supported from the base (see Figure

10). When this is necessary, a short length should be installed between the tee and the tee cap or Drain-Tee Cap for a good clean-out or inspection access.

IMPORTANT

If more than 1/4” of thermal expansion is expected between a stationary point and the tee, the use of an expansion length and a two axis support is recommended to minimize bending moments on the tee (see Figure 11 and Table 9).

Table 9

Maximum Allowable Length Between Two

Fixed Points w/o Expansion Length

Gas Temperature Rise Maximum Length Expansion

200°F 12'0'' 0.25"

300°F 8'0'' 0.25"

400°F 6'0'' 0.25"

500°F 5'0'' 0.25"

600°F 4'0'' 0.25"

700°F 3'6'' 0.25"

800°F 3'0'' 0.25"

900°F 2'6'' 0.25"

1000°F 2'0'' 0.25"

Note: 60°F - 70°F ambient T°

45° TEE T45

1. For systems where ow resistance must

be minimized like engine or turbine exhaust. The use of a 45° tee is suggested. It can be combined with a 45° elbow to make a smooth 90° turn (See Figure 12). To support this tee, use similar method as a 90° tee.

2. When using 45° tee to connect multiple appliances together, thermal expansion must be considered. Thus prepared to prevent bending moments on the tee, an expansion length must be installed between the tees (See Figure 13).

Stationary Support

Suspension

Band

Expansion

Length

Stationary Support

More than ¼" of expected thermal expansion between two

stationary points

Wall

Support

Tee

Tee Cap or Drain Tee Cap

Figure 9

Lengths

Tee

Wall

Support

Short Length

Tee Cap or Drain Tee Cap

Figure 10

Figure 11

Figure 12

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