Modine Manufacturing IFS Installation And Service Manual
INSTALLATION AND SERVICE MANUAL
gas-fired indoor separated combustion duct furnaces
WARNING
1. Improper installation, adjustment, alteration,
service or maintenance can cause property
damage, injury or death, and could cause
exposure to substances which have been
determined by various state agencies to
cause cancer, birth defects or other
reproductive harm. Read the installation,
operating and maintenance instructions
thoroughly before installing or servicing this
equipment.
2. Installing, starting up and servicing heating,
ventilation and air conditioning equipment
poses significant hazards and requires
specialized knowledge of Modine products
and training in performing those services.
Failure to have any service properly
performed by, or making any modification to
Modine equipment without the use of,
qualified service personnel could result in
serious injury to person and property,
including death. Therefore, only qualified
service personnel should work on any
Modine products.
AIR 5-593.10
5H0768550003
May, 2017
model IFS
Approved for use in California by the CEC.
FOR YOUR SAFETY
IF YOU SMELL GAS:
1. Open windows.
2. Don’t touch electrical switches.
3. Extinguish any open flame.
4. Immediately call your gas supplier.
FOR YOUR SAFETY
The use and storage of gasoline or other
flammable vapors and liquids in open
containers in the vicinity of this appliance is
hazardous.
Inspection on Arrival
1. Inspect unit upon arrival. In case of damage, report it
immediately to transportation company and your local
factory sales representative.
2.
Check rating plate on unit to verify that power supply meets
available electric power at the point of installation.
3. Inspect unit upon arrival for conformance with description of
product ordered (including specifications where applicable).
CAUTION
To prevent premature heat exchanger failure
do not locate ANY gas-fired units in areas
where chlorinated, halogenated, or acid
vapors are present in the atmosphere.
PLEASE BE SURE TO LEAVE IT WITH THE OWNER WHEN YOU LEAVE THE JOB.
THIS MANUAL IS THE PROPERTY OF THE OWNER.
SPECIAL PRECAUTIONS / TABLE OF CONTENTS
SPECIAL PRECAUTIONS
THE INSTALLATION AND MAINTENANCE INSTRUCTIONS
IN THIS MANUAL MUST BE FOLLOWED TO PROVIDE SAFE,
EFFICIENT AND TROUBLE-FREE OPERATION. IN ADDITION,
PARTICULAR CARE MUST BE EXERCISED REGARDING
THE SPECIAL PRECAUTIONS LISTED BELOW. FAILURE
TO PROPERLY ADDRESS THESE CRITICAL AREAS COULD
RESULT IN PROPERTY DAMAGE OR LOSS, PERSONAL
INJURY, OR DEATH. THESE INSTRUCTIONS ARE SUBJECT
TO ANY MORE RESTRICTIVE LOCAL OR NATIONAL CODES.
HAZARD INTENSITY LEVELS
1. DANGER: Indicates an imminently hazardous situation
which, if not avoided, WILL result in death or serious injury.
2. WARNING: Indicates a potentially hazardous situation which,
if not avoided, COULD result in death or serious injury.
3. CAUTION: Indicates a potentially hazardous situation which,
if not avoided, MAY result in minor or moderate injury.
4. IMPORTANT: Indicates a situation which, if not avoided,
MAY result in a potential safety concern.
DANGER
Appliances must not be installed where they may be exposed
to a potentially explosive or flammable atmosphere.
WARNING
1. This gas fired heating equipment must be vented - do not
operate unvented.
2. A built-in power exhauster is provided - additional external
power exhausters are not required or permitted.
3. If you are replacing an existing heater, it may be
necessary to resize the venting systems. Improperly
sized venting systems can result in vent gas leakage or
the formation of condensate. Refer to the National Fuel
Gas Code ANSI Z223.1 or CSA B149.1 latest edition.
Failure to follow these instructions can result in injury or
death.
4. Under no circumstances should two sections of double
wall vent pipe be joined together within one horizontal
vent system due to the inability to verify complete seal of
inner pipes.
5. All field gas piping must be pressure/leak tested prior to
operation. Never use an open flame. Use a soap solution or
equivalent for testing.
6. Gas pressure to appliance controls must never exceed 14"
W.C. (1/2 psi).
7. Disconnect power supply before making wiring connections
to prevent electrical shock and equipment damage.
8. All appliances must be wired strictly in accordance with
wiring diagram furnished with the appliance. Any wiring
different from the wiring diagram could result in a hazard
to persons and property.
9. Any original factory wiring that requires replacement must
be replaced with wiring material having a temperature
rating of at least 105°C.
10. To reduce the opportunity for condensation, the minimum
sea level input to the appliance, as indicated on the serial
plate, must not be less than 5% below the rated input, or
5% below the minimum rated input of dual rated units.
11. Ensure that the supply voltage to the appliance, as
indicated on the serial plate, is not 5% greater than the
rated voltage.
12. When servicing or repairing this equipment, use only
factory-approved service replacement parts. A complete
replacement parts list may be obtained by contacting
Modine Manufacturing Company. Refer to the rating plate
on the appliance for complete appliance model number,
serial number, and company address. Any substitution of
parts or controls not approved by the factory will be at the
owner's risk.
CAUTION
1. Installation must conform with local building codes or in the
absence of local codes, with Part 7, Venting of Equipment,
of the National Fuel Gas Code, ANSI Z223.1 (NFPA 54) latest edition. In Canada installation must be in accordance
with CSA B149.1.
2. Purging of air from gas supply line should be performed as
described in ANSI Z223.1 - latest edition “National Fuel
Gas Code”, or in Canada in CAN/CGA-B149 codes.
3. Do not attempt to reuse any mechanical or electrical
controller which has been wet. Replace defective controller.
4. Ensure that the supply voltage to the appliance is not 5%
less than the rated voltage.
1. To prevent premature heat exchanger failure, do not locate
NY gas-fired appliances in areas where corrosive vapors
(i.e. chlorinated, halogenated or acid) are present in the
atmosphere.
2. To prevent premature heat exchanger failure, the input to
the appliance, as indicated on the serial plate, must not
exceed the rated input by more than 5%.
3. To prevent premature heat exchanger failure, observe heat
exchanger tubes by looking at the heat exchanger through
field installed access openings in connecting ductwork.
If the tubes become red while blower and duct furnace are
in operation, additional baffles must be inserted between
blower and duct furnace to assure uniform air flow across
the heat exchanger.
4. To prevent premature heat exchanger failure, with all control
systems, a blower starting mechanism must be provided so
that the blower is running or energized within 45 seconds of
the gas control operation.
5. Start-up and adjustment procedures should be performed by
a qualified service agency.
6. To check most of the Possible Remedies in the
troubleshooting guide listed in Table 24.1, refer to the
applicable sections of the manual.
Table of Contents
Inspection on Arrival .................................................................... 1
Special Precautions ..................................................................... 2
SI (Metric) Conversion Factors .................................................... 3
Unit Location................................................................................ 3
Location Recommendations................................................. 3
Combustible Material and Service Clearances .................... 3
Unit Suspension .......................................................................... 3
Installation ................................................................................... 4
Direction of Airflow ...............................................................4
Duct Installation and Airflow Distribution .............................. 4
Venting ................................................................................. 5
Gas Connections................................................................ 10
Considerations for Elevation .............................................. 11
Electrical Connections........................................................ 12
Start-Up Procedure.................................................................... 12
Pilot Burner and Main Burner Adjustment .......................... 13
Air Shutter Adjustment .......................................................14
Control Operating Sequence.............................................. 14
Variable Air Movement Applications ................................... 15
Gas Control Options........................................................... 16
Performance .............................................................................. 18
Air Temperature and External Static Pressure Limits ......... 18
Pressure Drop Curves........................................................ 18
Dimensionals ............................................................................. 19
Maintenance .............................................................................. 22
Manifold Assembly Removal .............................................. 23
Burner and Pilot Assembly Removal .................................. 23
Service & Troubleshooting....................................................24-25
Replacement Parts Ordering ..................................................... 26
Model Identification.................................................................... 27
Commercial Warranty ...................................................Back Page
IMPORTANT
2
AIR 5-593.9
SI (METRIC) CONVERSION FACTORS / UNIT LOCATION
SI (METRIC) CONVERSION FACTORS
Table 3.1
To Convert Multiply By To Obtain
"W.C. 0.24 kPa
psig 6.893 kPa
°F (°F-32) x 0.555 °C
inches 25.4 mm
feet 0.305 meters
CFM 0.028 m3/min
To Convert Multiply By To Obtain
CFH 1.699 m3/min
Btu/ft3 0.0374 mJ/m
pound 0.453 kg
Btu/hr 0.000293 kW/hr
gallons 3.785 liters
psig 27.7 "W.C.
UNIT LOCATION
DANGER
Appliances must not be installed where they may be exposed
to a potentially explosive or flammable atmosphere.
IMPORTANT
To prevent premature heat exchanger failure, do not locate
ANY gas-fired appliances in areas where corrosive vapors (i.e.
chlorinated, halogenated or acid) are present in the atmosphere.
Location Recommendations
1. When locating the furnace, consider general space and
heating requirements, availability of gas and electrical
supply, and proximity to vent locations.
2. Unit must be installed on the positive pressure side of the
circulating blower.
3. Be sure the structural support at the unit location site is
adequate to support the weight of the unit. For proper
operation the unit must be installed in a level horizontal
position.
4. Do not install units in locations where the flue products can
be drawn into the adjacent building openings such
as windows, fresh air intakes, etc.
5. Be sure that the minimum clearances to combustible
materials and recommended service clearances are
maintained. Units are designed for installation on noncombustible surfaces with the minimum clearances shown
in Figure 3.1 and Table 3.2.
6. Units installed downstream of refrigeration systems, or
exposed to inlet air temperatures of 40°F or less, may
experience condensation. Therefore, provisions should
be made for disposal of condensate. Means have been
provided in the bottom pan of the unit to accommodate a
condensate drain line connection flange.
7. When locating units, it is important to consider that the
combustion air and exhaust vent piping must be connected
to the outside atmosphere, vent terminals should be located
adjacent to one another. The maximum equivalent lengths
are listed in Table 6.1 on page 6.
8. In garages or other sections of aircraft hangars such as
offices and shops that communicate with areas used for
servicing or storage, keep the bottom of the unit at least 7'
above the floor unless the unit is properly guarded to provide
user protection from moving parts. In parking garages, the
unit must be installed in accordance with the standard for
parking structures ANSI/NFPA 88A, and in repair garages
the standard for repair garages NFPA #88B. In Canada,
installation of unit heaters in airplane hangars must be in
accordance with the requirements of the enforcing authority,
and in public garages in accordance with the current CAN/
CGA-B149 codes.
9. Do not install units in locations where gas ignition system is
exposed to water spray, rain, or dripping water.
Figure 3.1 - Combustible Material and Service Clearances
Size
(A)
75 thru 175 1"
3
200 thru 400 2"
j A 3'' minimum clearance to combustible material is required from the vent collar.
Table 3.2 - Recommended Service Clearances
UNIT SUSPENSION
Be sure the means of suspension is adequate to support the
weight of the unit (see Dimensional Data for unit weights).
For proper operation, the unit must be installed in a level
horizontal position. Combustible material and service
clearances as specified in Figure 3.1 and Table 3.2 must be
strictly maintained.
1. Four 1/2" - 13NC tapped holes in top of furnace are
2. NOTE: A pipe hanger adapter kit, shown in Figure 3.2, is
Figure 3.2 - Suspension Methods
AIR 5-593.9
Access
Model
Side
TOP = 3"
j
NON-ACCESS
ACCESS
SIDE = A
Model Size
75 18"
100/125 20"
150/175 25"
200/225 27"
250/300 30"
350/400 41"
Access Side
BOTTOM = 1"
(A)
SIDE = 0
Non-Access
Side (B)
6" 10" 0"
Top
(C)
Bottom
(D)
provided to accept ceiling hangers. To assure that flames
are directed into the center of the heat exchanger tubes,
the furnace must be supported in a vertical position. Use a
spirit level to ensure that unit is suspended correctly.
available as an accessory from the factory. One kit consists
of two drilled 3/4" IPS pipe caps and two 1/2 - 13 x 1-3/4"
capscrews to facilitate threaded pipe suspension. Two kits
are required for mounting all duct furnace models.
C
(Threaded Rod)
(Pipe Adapter Kit)
3
INSTALLATION
Straight
Ductwork
Duct Furnace
Ductwork
Access
Panel
Mounting Holes
Direction of Airflow
Select proper direction of airflow. For models in which the 10th
digit of the model number is an “L” for Low Temperature Rise,
the airflow direction is fully reversible without modification to the
duct furnace. See Airflow Reversal Note.
If the unit is provided with an air distribution baffle (models in
which the 10th digit of the model number is an “H” for High
Temperature Rise), the air baffle must face the air inlet direction
as shown in Figure 4.1. If it is necessary to reverse the airflow
direction, remove the four screws securing the air distribution
baffle, reverse the air distribution baffle to the air inlet side and
replace the screws. See Airflow Reversal Note.
Figure 4.1 - Air Distribution Baffle Location
Baffle location
shown on entering
air side of duct
furnace.
Airflow Reversal Note: If factory installed discharge air options
(thermostat, freeze protection, etc.) were provided, these
options would have to be relocated to the discharge air side of
the duct furnace.
Duct Installation (refer to Figure 4.2)
1. The furnace is designed to accept straight ductwork.
All connections between the ductwork and the furnace
MUST be airtight to prevent air leakage. Seams with
cracks in ductwork should be caulked and/or taped and
be of permanent type.
2. Provide removable access panels on both the upstream
and downstream sides of the ductwork. These openings
should be large enough to view smoke or reflect light inside
the casing to indicate leaks in the heat exchanger and to
check for hot spots on heat exchangers due to poor air
distribution or lack of sufficient air (CFM).
Figure 4.2 - Duct Connections
Airflow Distribution
IMPORTANT
To prevent premature heat exchanger failure, observe heat
exchanger tubes by looking at the heat exchanger through
field installed access openings in connecting ductwork. If
the tubes become red while blower and duct furnace are in
operation, additional baffles must be inserted between blower
and duct furnace to assure uniform air flow across the heat
exchanger.
1. Provide uniform air distribution over the heat exchanger.
Use turning vanes where required (see Figure 4.3) to obtain
uniform air distribution. Avoid installing as in “G”, “H” & “J” of
Figure 4.3.
2. A bottom, horizontal discharge type blower should be
installed at least 12" from the furnace (See “A”, Figure 4.3).
3. A top, horizontal discharge type blower should be installed
at least 24" from the furnace (See “B”, Figure 4.3). Provide
air baffle at top of duct to deflect air down to the bottom of
heat exchanger.
Figure 4.3 - Typical Duct & Airflow Installation
Turning
Vanes
3" Min.
3" Max.
B
B
RECOMMENDED INSTALLATIONS
INSTALLATIONS
NOT RECOMMENDED
4
4
A
SIDE
A
12"
Min.
A
12"
Min.
Air
Baffle
SIDE
24"
Min.
G H J
SIDE
3" Max.
Turning
Vanes
Turning
Vanes
B
Baffle
3" Max.
B
BaffleBaffle
B
SIDE
SIDE
15° Max.
SIDE
Baffle
24"
Min.
Turning
Vanes
3" Max.
Air
Dimensions “B” should never be less than 1/2 of “A”.
3" Min.
Turning
Vanes
3" Min.
12"
Min.
A
12"
Min.
A
No AirNo Air No Air
AIR 5-593.9
B
12"
Min.
12"
Min.
Turning
Vanes
C
TOP
A
15° Max.
FED
Turning
Vanes
TOP
15° Max.
TOP
INSTALLATION - VENTING
W ARNING
1. Gas fired heating equipment must be vented - do not
operate unvented.
2. A built-in power exhauster is provided - additional external
power exhausters are not required or permitted.
3. If you are replacing an existing heater, it may be
necessary to resize the venting systems. Improperly sized
venting systems can result in vent gas leakage or the
formation of condensate. Refer to the National Fuel Gas
Code ANSI Z223.1 or CSA B149.1 latest edition. Failure
to follow these instructions can result in serious injury or
death.
4. Under no circumstances should two sections of double
wall vent pipe be joined together within one horizontal
vent system due to the inability to verify complete seal of
inner pipes.
CAUTION
Installation must conform with local building codes or in the
absence of local codes, with Part 7, Venting of Equipment, of
the National Fuel Gas Code, ANSI Z223.1 (NFPA 54) - latest
edition. In Canada installation must be in accordance with
CSA B149.1.
A3. All heaters come with factory installed vent and combustion
air adapters for attaching the pipe to the heater. The pipe
diameters are 4" for model sizes 75-175 and 6" for model
sizes 200-400. All units are classified as Category III
vented appliances, which defined by ANSI is positive
pressure, non-condensing, and requires the vent system to
be gastight. Attach the vent pipe to the adapter with 3
corrosion resistant screws. (Drill pilot holes through the vent
pipe and adapter prior to screwing in place). Vent pipe must
not be smaller than the connector size. Category III vent
systems listed by a nationally recognized agency and
matching the diameters specified may be used. Different
brands of vent materials may not be intermixed.
A4. Limit the total equivalent vent pipe length to a minimum of
5' and a maximum as shown in Table 5.1, making the vent
system as straight as possible. Total equivalent vent pipe
length must include elbows. The equivalent length of a 4"
elbow is 5' and for a 6" elbow is 7'.
Table 5.1 - Individual Total Equivalent Lengths for
Combustion Air and Exhaust Vent Pipes
Model Size Minimum (ft) Maximum (ft)
75 5 48
100, 125, 150, 175 5 55
200, 225 5 70
250, 300 5 63
350, 400 5 70
Model IFS duct furnaces must be vented with the proper
passageway as described in these instructions to convey flue
gases from the unit or the vent connector to the outside
atmosphere. The heaters must also have a separate
combustion air intake pipe to bring in fresh air for combustion
from the outside atmosphere.
The venting instructions are organized in sections, based on
installation type. The sections are identified as follows:
Section Installation Instructions by Vent System Type
A General Instructions for ALL installations
B VERTICAL 2-PIPE vent systems j
C HORIZONTAL 2-PIPE vent systems j
vent systems j
j The differences between Vertical and Horizontal vent systems in 2-Pipe or
HORIZONTAL AND VERTICAL CONCENTRIC
D
Concentric Vent congurations will be identied in “Section A - General
Instructions – All Units”.
Section A - General Instructions - All Units
A1. If the heater being installed is replacing existing equipment
and using the existing vent system from that equipment,
inspect the venting system for proper size and horizontal
pitch, as required in the National Fuel Gas Code ANSI
Z223.1 or CSA B149.1 Installation Code-latest edition and
these instructions. Determine that there is no blockage or
restriction, leakage, corrosion and other deficiencies, which
could cause an unsafe condition.
A2. The combustion air and vent pipes should be galvanized
steel or other suitable corrosion resistant material. Follow
the National Fuel Gas Code for minimum thickness of vent
material. The minimum thickness for connectors varies
depending on the pipe diameter. Do not vent unit with PVC
or other forms of plastic venting material.
A5. A minimum of 12" straight pipe is recommended from the
flue outlet before turns in the vent pipe.
A6. Horizontal sections of vent and combustion air pipes are to
be installed with a minimum downward slope from the
appliance of 1/4 inch per foot and suspended securely
from overhead structures at points not greater than 3'
apart.
A7. Fasten individual lengths of vent together with at least
three corrosion resistant sheet metal screws.
A8. Keep single wall vent pipe at least 6" from combustible
materials. For double wall vent pipe, follow the vent pipe
manufacturer’s clearances to combustibles. The minimum
distance from combustible materials is based on the
combustible material surface not exceeding 160°F.
Clearance from the vent pipe (or the top of the unit) may
be required to be greater than 6" if heat damage other
than fire could result (such as material distortion or
discoloration).
A9. Avoid venting through unheated space when possible.
When venting does pass through an unheated space or if
the unit is installed in an environment that promotes
condensation, insulate runs greater than 5' to minimize
condensation. Inspect for leakage prior to insulating and
use insulation that is noncombustible with a rating of not
less than 400°F. Install a tee fitting at the low point of the
vent system and provide a drip leg with a clean out cap as
shown in Figure 7.1.
A10. When the vent passes through a combustible INTERIOR
wall or floor, a metal thimble 4" greater than the vent
diameter is necessary. If there is 6' or more of vent pipe in
the open space between the appliance and where the vent
pipe passes through the wall or floor, the thimble need only
be 2" greater than the diameter of the vent pipe. If a
thimble is not used, all combustible material must be cut
away to provide 6" of clearance. Where authorities have
jurisdiction type B vent may be used for the last section of
vent pipe to maintain clearance to combustibles while
passing through wall or floor. See Figure 6.1. Any material
used to close the opening must be noncombustible.
AIR 5-593.9
5
INSTALLATION - VENTING
Figure 6.1 - Venting Through Combustible Roof or Wall
LISTED
CAP
FLASHING
LISTED
Vertical Venting
THIMBLE
SINGLE WALL
Horizontal Venting
ROOF
PIPE
LISTED
THIMBLE
SINGLE WALL
PIPE
MODINE
SPECIFIED
CAP
ROOF
FLASHING
CLEARANCE
SPECIFIED BY
TYPE B VENT
MANUFACTURER
SINGLE WALL
PIPE
CLEARANCE
SPECIFIED BY
TYPE B VENT
MANUFACTURER
j See Instruction A12 for attaching single wall pipe to double wall pipe
A11. All seams and joints of un-gasketed single wall pipe must
be sealed with metallic tape (3M aluminum foil tapes 433
or 363 are acceptable) or silastic suitable for temperatures
up to 400°F. Wrap the tape two full turns around the vent
pipe. One continuous section of double wall vent pipe may
be used within the vent system. Refer to instruction A12 in
“Section A – General Instructions – All Units” for attaching
double wall pipe to single wall pipe.
A12. The following are General Instructions for Double Wall
(Type B) Terminal Pipe Installation. Under no
circumstances should two sections of double wall vent
pipe be joined together within one horizontal vent system
due to the inability to verify complete seal of inner pipes.
How to attach a single wall vent terminal to double
wall (type B) vent pipe:
1. Look for the “flow” arrow on the vent pipe.
2. Slide the vent terminal inside the exhaust end of the
double wall vent pipe.
3. Drill (3) holes through the pipe and the vent terminal.
Using 3/4" long sheet metal screws, attach the cap to
the pipe. Do not over tighten.
How to connect a single wall vent system to double
wall (type B) vent pipe:
1. Slide the single wall pipe inside the inner wall of the
double wall pipe.
2. Drill (3) holes through both walls of the single and
double wall vent pipes. Using 3/4" sheet metal screws,
attach the two pieces of pipe. Do not over tighten.
3. The gap between the single and double wall pipe must
be sealed but it is not necessary to fill the full volume of
the annular area. To seal, run a large bead of 400°F
silastic around the gap.
A13 Do NOT vent this appliance into a masonry chimney.
A14. Do NOT use dampers or other devices in the vent or
combustion air pipes.
A15.
The venting system must be exclusive to a single
appliance, and no other appliance is allowed to be vented
into it.
A16. Precautions must be taken to prevent degradation of
building materials by flue products.
A17. Single wall vent pipe must not pass through any
unoccupied attic, inside wall, concealed space, or floor.
A18. Uninsulated single wall vent pipe must not be used
outdoors for venting appliances in regions where the 99%
winter design temperature is below 32°F.
6
LISTED
CAP
DOUBLE WALL
PIPE
SINGLE WALL
PIPE
MODINE
SPECIFIED
CAP
DOUBLE WALL
PIPE
A19. Long runs of horizontal or vertical combustion air pipes
A20. Vent termination clearances must be maintained:
Table 6.1 - Vent Termination Clearances
j Do not terminate the vent directly above a gas meter or regulator.
k The vent must be at least 6" higher than anticipated snow depth.
A21. Vertical combustion air pipes should be fitted with a tee
A22. In addition to following these General Instructions, specific
Vertical Vent System Determination
• Vertical vent systems terminate vertically (up) (an
• Determine the venting configuration as follows:
> For two building penetrations through the wall or roof
> For a single larger building penetration through the
> For all other cases, proceed to the next section for
Horizontal Vent System Determination
• Horizontal vent systems terminate horizontally
(sideways) (an example is shown in Figure 8.1).
• Determine the venting configuration as follows:
> For two building penetrations through the wall or roof
> For a single larger building penetration through the
AIR 5-593.9
may require insulation in very cold climates to prevent the
buildup of condensation on the outside of the pipe where
the pipe passes through conditioned spaces.
Minimum Clearances for
Forced air inlet within 10 feet 3 feet above
Combustion air inlet of another
appliance
Door, window, gravity air inlet, 4 feet horizontal and below
or any building opening 1 foot above
Electric meter, gas meter, gas 4 feet horizontal (U.S.)
regulator, and relief equipment j 6 feet horizontal (Canada)
Gas regulator
6 feet horizontal (Canada)
Adjoining building or parapet wall 6 feet all directions
Adjacent public walkways 7 feet all directions
Grade (ground level) 3 feet above k
Structure
Vent Terminal Location
6 feet all directions
3 feet horizontal (U.S.)
j
with a drip leg and a clean out cap to prevent against the
possibility of any moisture in the combustion air pipe from
entering the unit. The drip leg should be inspected and
cleaned out periodically during the heating season.
instructions for Vertical and Horizontal vent systems in
2-Pipe or Concentric Vent configurations must also be
followed. The following outlines the differences:
example is shown in Figure 7.1).
(one for the combustion air inlet pipe and one for the
vent pipe), proceed to “Section B - Vertical 2-Pipe
Venting”.
wall or roof, through which both the combustion air
inlet and vent pipes will pass, proceed to “Section D Horizontal and Vertical Concentric Venting”.
Horizontal Vent System Determination.
(one for the combustion air inlet pipe and one for the
vent pipe), proceed to “Section C - Horizontal 2-Pipe
Venting”.
wall or roof, through which both the combustion air
inlet and vent pipes will pass, proceed to “Section D Horizontal and Vertical Concentric Venting”.
INSTALLATION - VENTING
Section B - Vertical 2-Pipe Vent System
Installation
B1. This section applies to vertically vented 2-pipe (one
combustion air inlet pipe and one vent pipe) vent systems
and is in addition to “Section A - General Instructions - All
Units”.
B2. Vertical vent systems terminate vertically (up).
B3. It is recommended to install a tee with drip leg and clean
out cap as shown in Figures 7.1 or 7.2.
B4. The combustion air and vent pipes must be terminated with
(2) Gary Steel Model 1092 caps.
B5. Vertical vents must terminate a minimum horizontal and
vertical distance from roof lines and adjacent walls or
obstructions. These minimum distances are outlined in
Figure 7.1 and Table 7.1 or Figure 7.2.
B6. The vent must terminate at least 1 foot above and 16
inches horizontally from the combustion air inlet.
B7. Once venting is complete, proceed section titled “Installation
- Gas Connections”.
Figure 7.1 - Vertical Venting - 2 Pipes Sloped Roof
16" MIN.
LISTED VENT
TERMINAL
X"
12"
ROOF PITCH = X/12
USE LISTED THIMBLE
THROUGH CEILING
AND ROOF
"H" MIN. *
LISTED AIR
INLET TERMINAL
SEE TABLE 8.1
FOR "H"
DIMENSION
"H" MIN. *
ROOF
FLASHING
* SIZE TO EXPECTED
SNOW DEPTH.
Table 7.1 - Minimum Height from Roof to Lowest
Discharge Opening
Rise X (in) Roof Pitch Min Height H (ft) j
0-6 Flat to 6/12 1.00
6-7 6/12 to 7/12 1.25
7-8 7/12 to 8/12 1.50
8-9 8/12 to 9/12 2.00
9-10 9/12 to 10/12 2.50
10-11 10/12 to 11/12 3.25
11-12 11/12 to 12/12 4.00
12-14 12/12 to 14/12 5.00
14-16 14/12 to 16/12 6.00
16-18 16/12 to 18/12 7.00
18-20 18/12 to 20/12 7.50
20-21 20/12 to 21/12 8.00
j Size according to expected snow depth.
Figure 7.2 - Vertical Venting - 2 Pipes Flat Roof
LISTED VENT
TERMINAL
24" MIN.
TO WALL OR
ADJOINING BUILIDING
12" MIN.
12" MIN. *
* SIZE TO EXPECTED
SNOW DEPTH.
16" MIN.
LISTED AIR
INLET TERMINAL
ROOF FLASING
USE LISTED THIMBLE
THROUGH ROOF
EXHAUST
12" MIN.
RECOMMENDED
COMBUSTION AIR
TEE WITH DRIP LEG
AND CLEANOUT CAP
EXHAUST
COMBUSTION AIR
TEE WITH DRIP LEG
AND CLEANOUT CAP
Section C - Horizontal 2-Pipe Vent System
Installation
C1. This section applies to horizontally vented 2-pipe vent
systems (one combustion air inlet pipe and one vent pipe)
and is in addition to “Section A - General Instructions - All
Units”.
C2. Horizontal vent systems terminate horizontally (sideways).
C3. All horizontal vents must be terminated with a Gary Steel
1092 vent cap. The cap must terminate a minimum
distance from the external wall, as summarized in
Figure 8.1.
C4. The termination of horizontally vented system must extend
12 inches beyond the exterior surface of an exterior wall.
C5. The combustion air pipe must be a minimum of 16 inches
below the vent pipe, and 24 inches from the exterior wall.
C6. Construct the vent system as shown in Figure 8.1.
AIR 5-593.9
7
INSTALLATION - VENTING
COMBUSTION AIR
EXHAUST
24'' MIN.
24'' MIN.
12''
16'' MIN.
SUPPORT BRACKET
(See Fig. 9.2 for detail)
SUPPORT BRACKET
(See Fig. 9.2 for detail)
TERMINAL
TERMINAL
ADJACENT
BUILDING
TEE WITH DRIP
LEG AND
CLEANOUT CAP
AT LOW POINT
OF VENT SYSTEM
PITCH VENT PIPE DOWNWARD
FROM APPLIANCE 1/4" PER FOOT
PITCH COMBUSTION AIR
PIPE DOWNWARD FROM
APPLIANCE 1/4" PER FOOT
MUST USE THIMBLE
THROUGH WALL
Figure 8.1 - Horizontal 2-Pipe Venting
C7. When horizontal vents pass through a combustible wall (up
to 8 inches thick), the vent passage must be constructed
and insulated as shown in Figure 8.2.
C8. The vent must be supported as shown in Figure 8.2.
C9. When condensation may be a problem, the vent system
shall not terminate over public walkways or over an area
where condensate or vapor could create a nuisance or
hazard or could be detrimental to the operation of
regulators, relief openings, or other equipment.
Figure 8.2 - Exhaust Vent Construction Through
Combustible Walls and Support Bracket
METAL FACE
PLATE
45
1"
FIBER GLASS
INSULATION
MIN. 2"
1"
9"
9"
VENT TERMINATION
SUPPORT BRACKET
(where required)
(Make from 1" x 1" steel angle)
VENT PIPE
DIAMETER
2" MIN.
2" MIN.
METAL
SLEEVE
METAL
SLEEVE
For Vertically Vented Units (Refer to Figure 8.3):
j Concentric adapter assembly (same for horizontal and
vertical kits)
k Standard Gary Steel 1092 vent termination
l Specially designed inlet terminal (part #5H75154)
Figure 8.3 - Vertical Concentric Vent Kit Components
Outlet Vent
Combustion Air
Inlet Terminal
Concentric
Vent Adapter
Box
Combustion Air Exhaust
6" Min.
12" Min.*
Termination Cap
* Size according
to expected
snow depth.
Building
Roof / Ceiling
For Horizontally Vented Units (Refer to Figure 8.4):
j Concentric adapter assembly (same for horizontal and
vertical kits)
k Special vent termination cap (part #5H75150)
l Special inlet air guard
Figure 8.4 - Horizontal Concentric Vent Kit
Components
Concentric
Vent Adapter
Box
14" Min.
1" Min.
Outlet Vent
Termination Cap
C10. Maintain a 1/4" per foot downward slope away from the
heater and place a drip leg with clean out near the exit of
the vent as shown in Figure 8.1, or allow the condensate
to drip out the end.
C11. For a vent termination located under an eave, the
distance of the overhang must not exceed 24". The
clearance to combustibles above the exterior vent must
be maintained at a minimum of 12". Consult the National
Fuel Gas Code for additional requirements for eaves that
have ventilation openings.
C12. Once venting is complete, proceed section titled
“Installation - Gas Connections”.
Section D - Concentric Vent System
Installation
D1. This section applies to both horizontally and vertically
vented concentric vent systems as defined in “Section A –
General Instructions – All Units”, and is in addition to the
instructions in that section.
D2. When utilizing the concentric vent option, it should have
been predetermined whether the appliance will be
horizontally or vertically vented. Before proceeding, verify
that the concentric vent kit received contains the correct
components for the installation:
8
The concentric vent adapter box must be installed inside of
the structure or building. Do not install this box on the exterior
of a building or structure.
D3. Once the kit contents have been verified as correct for the
D4. The adapter box is to be mounted on the interior side of the
AIR 5-593.9
Combustion Air
Intake Guard
Building Side Wall
CAUTION
direction of venting, the concentric vent adapter box is to be
installed. Determine the location of the box. Be sure to
maintain all clearances as listed in these instructions.
building. It must not be mounted outside the building. The
adapter box has integral mounting holes for ease of
installation. When horizontal venting multiple units, the
minimum spacing between any sides of the adapter boxes
must be 18" and boxes must not overlap in the vertical
plane (above or below). When condensation may be a
problem, the vent system shall not terminate over public
walkways or over an area where condensate or vapor could
create a nuisance or hazard or could be detrimental to the
operation of regulators, relief openings, or other equipment.
INSTALLATION - VENTING
D5. The adapter box can be mounted flush to the wall (for
horizontal kits) or to the ceiling (for vertical kits). The box
can also be offset from the wall or ceiling by using field
supplied brackets. When mounting the box, consider
serviceability and access to the vent and combustion air
pipes. If the box is to be mounted using field supplied
brackets, these brackets must be strong enough to rigidly
secure the box to the wall or ceiling, and should be made
from corrosion resistant material.
D6. Determine the length of the vent pipe and combustion air
inlet pipe for the selected location. THE VENT PIPE WILL
PASS THROUGH THE CONCENTRIC VENT BOX. THE
LAST SECTION OF VENT PIPE IS A CONTINUOUS
LENGTH OF DOUBLE WALL “B” VENT. See section A12
for attaching and terminating double wall pipe. Begin with
pipe lengths on the concentric pipe side of the adapter box
referring to Figure 9.1. These pipes will extend through
the building wall or roof as well as any added length for
the thickness of the wall and the offset from any field
installed brackets.
For Vertical Concentric Vent Kits
(refer to Figure 8.3):
• The bottom of the combustion air intake pipe must
terminate above the snow line, or at least 12 inches
above the roof, whichever distance is greater.
• The bottom of the vent cap must terminate at least 6
inches above the top of the combustion air intake cap.
For Horizontal Concentric Vent Kits
(refer to Figure 8.4):
• The combustion air intake pipe must terminate at least
1 inch from the wall to prevent water from running down
the wall and into the pipe.
• The back of the vent cap must terminate at least 14
inches from the combustion air intake pipe.
D7. Cut the concentric side vent and combustion air pipes to
the proper length as determined in the previous step. Note
that the vent pipe diameter is 4" and the combustion air
intake pipe diameter is 6" for model sizes 75-175, and 6”
and 8” respectively for model sizes 200-400. The pipes
must be single wall galvanized or stainless steel material,
except for the last section of vent pipe, which must be one
continuous length of double wall B-vent extended through
the concentric vent box and combustion air inlet pipe on
the concentric side of the box.
D8. Allow the concentric side vent pipe to pass through the
concentric vent adapter box, as shown in Figure 9.1.
Attach the double wall vent pipe to the single wall vent
pipe that goes to the unit. Be sure to seal the joint and
the open area around the double wall vent. Seal all joints
and seams using sealant suitable for temperatures up to
400°F.
D9. Slide the combustion air pipe over the vent pipe and
attach to the air inlet of the concentric adapter box, as
shown in Figure 9.1, using at least 3 corrosion resistant
sheet metal screws. Seal the joint and seam using sealant
suitable for temperatures up to 400°F.
D10. Place this assembly (the adapter box, vent pipe and
combustion air pipe) through the wall or roof and verify
that the distance requirements as defined in Step D7 are
met. Securely attach the assembly building.
D11. From outside the building, caulk the gap between the
combustion air intake pipe and the building penetration.
D12. Attach the combustion air intake and vent pipe
terminations as follows:
Figure 9.1 - Adapter Box with Combustion Air Intake
Pipe Attached
Outlet Vent
Pipe Extended
Through Box
A
Combustion Air
Pipe Attached
4.57”
B
Model Sizes A B
75-175 13.33" 18.84"
200-400 17.00" 15.27"
For Vertical Concentric Vent Kits
(refer to Figure 8.3):
• Slide the combustion air cap down over the vent pipe
and fasten it to the combustion air pipe with at least 3
corrosion resistant sheet metal screws.
• Attach the vent cap to the vent pipe using at least 3
corrosion resistant sheet metal screws. Refer to
instruction A12 for connecting terminal to double wall
pipe.
• Caulk the gap between the combustion air cap and the
vent pipe with silicone sealant, or other appropriate
sealants suitable for metal to metal contact and for
temperatures up to 400° F.
For Horizontal Concentric Vent Kits
(refer to Figure 8.4):
• Attach the combustion air intake guard using corrosion
resistant screws at the end of the combustion air intake
pipe to prevent animals and debris from entering.
• Attach the vent cap to the vent pipe using at least 3
corrosion resistant sheet metal screws.
D13. Install vent pipe and combustion air pipe between unit
heater and concentric vent adapter box as outlined in
“Section A – General Instructions – All Units”.
D14. Once venting is complete, proceed to the section titled
“Installation - Gas Connections”.
AIR 5-593.9
9
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