PEERLESS CAST 92 Installation, Operation & Maintenance Manual

CAST 92

Boilers

Peerless

Gas

Installation, Operation & Maintenance Manual

As an ENERGY STAR®Partner, PB Heat, LLC has determined that this product meets the ENERGY STAR guidelines for energy efficiency.

USING THIS MANUAL 1

A. INSTALLATION SEQUENCE . . . . . . . . . . . . .1

B. SPECIAL ATTENTION BOXES . . . . . . . . . . . .1

1. PREINSTALLATION 2

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

B. CODES & REGULATIONS . . . . . . . . . . . . . . .2

C. BOILER LOCATION REQUIREMENTS . . . . . .3

D. CLEARANCE REQUIREMENTS . . . . . . . . . . .4

E. COMBUSTION AIR REQUIREMENTS . . . . . .4

2. BOILER SET-UP 7

A. REMOVE THE BOILER FROM THE CRATE . .7

B. INSTALL THE RELIEF VALVE . . . . . . . . . . . . .7

C. BOILER PIPING – GENERAL . . . . . . . . . . . . .7

3. VENTING & AIR INLET PIPING 9

A. COMMON VENT SYSTEMS . . . . . . . . . . . . .9

B. VENT AND AIR PIPING, GENERAL . . . . . . .10

C. VENT PIPING . . . . . . . . . . . . . . . . . . . . . . . .10

D. AIR PIPING . . . . . . . . . . . . . . . . . . . . . . . . . .10

E. TERMINATIONS . . . . . . . . . . . . . . . . . . . . . .10

F. VENT PIPED THROUGH THE ROOF

(COMBUSTION AIR FROM THE BOILER ROOM) . .10

G. VENT PIPED THROUGH THE ROOF

(AIR PIPED THROUGH SIDE WALL) . . . . . . . . . .11

H. VENT & AIR PIPED THROUGH THE ROOF

(SEPARATE VENT AND AIR TERMINATIONS) . . . .11

I. VENT PIPED THROUGH A SIDE WALL

(SEPARATE VENT AND AIR TERMINATIONS) . . . .12

J. VENT & AIR PIPED THROUGH A

SIDE WALL (SEPARATE VENT AND AIR

TERMINATIONS)

. . . . . . . . . . . . . . . . . . . . . . .12

K. VENT & AIR PIPED THROUGH A

SIDE WALL (CONCENTRIC VENT/AIR

TERMINATION)

. . . . . . . . . . . . . . . . . . . . . . . .13

3A. VENT & AIR PIPING: THROUGH THE ROOF

(COMBUSTION AIR FROM THE BOILER ROOM) 14

A. BOILER VENT CONNECTION . . . . . . . . . . .14

B. VENT PIPING COMPONENTS . . . . . . . . . . .15

C. SUPPORT THE VENT PIPING

COMPLETELY . . . . . . . . . . . . . . . . . . . . . . . .15

D. FLOOR AND WALL PENETRATIONS . . . . .15

E. ROOF PENETRATIONS . . . . . . . . . . . . . . . .15

F. RAIN CAP TERMINATION . . . . . . . . . . . . . .15

G. COMBUSTION AIR OPENINGS . . . . . . . . . .16

H. MULTIPLE BOILER INSTALLATIONS . . . . . .16

3B. VENT & AIR PIPING: THROUGH THE ROOF

(AIR PIPED THROUGH SIDE WALL) 17

A. BOILER VENT CONNECTION . . . . . . . . . . .17

B. VENT PIPING COMPONENTS . . . . . . . . . . .18

C. SUPPORT THE VENT PIPING

COMPLETELY . . . . . . . . . . . . . . . . . . . . . . . .18

D. FLOOR AND WALL PENETRATIONS . . . . .18

E. ROOF PENETRATIONS . . . . . . . . . . . . . . . .18

F. RAIN CAP TERMINATION . . . . . . . . . . . . . .18

G. AIR PIPE CONNECTION . . . . . . . . . . . . . . . .19

H. SUPPORTING AIR PIPING . . . . . . . . . . . . . .19

I. AIR PIPE TERMINATION . . . . . . . . . . . . . . .19

J. MULTIPLE BOILER INSTALLATIONS . . . . . .21

3C. VENT PIPING: THROUGH THE ROOF

(SEPARATE TERMINATIONS) 22

A. BOILER VENT CONNECTION . . . . . . . . . . .22

B. VENT PIPING COMPONENTS . . . . . . . . . . .23

C. SUPPORT THE VENT PIPING

COMPLETELY . . . . . . . . . . . . . . . . . . . . . . . .23

D. FLOOR AND WALL PENETRATIONS . . . . .23

E. ROOF PENETRATIONS . . . . . . . . . . . . . . . .23

F. RAIN CAP TERMINATION . . . . . . . . . . . . . .23

G. AIR PIPE CONNECTION . . . . . . . . . . . . . . . .24

H. SUPPORTING AIR PIPING . . . . . . . . . . . . . .24

I. AIR PIPE TERMINATION . . . . . . . . . . . . . . .24

J. MULTIPLE BOILER INSTALLATIONS . . . . . .25

3D. VENT & AIR PIPING: THROUGH A SIDE

WALL (COMBUSTION AIR FROM THE

BOILER ROOM) 26

A. BOILER VENT CONNECTION . . . . . . . . . . .26

B. VENT PIPING COMPONENTS . . . . . . . . . . .27

C. SUPPORT THE VENT PIPING

COMPLETELY . . . . . . . . . . . . . . . . . . . . . . . .27

D. SIDEWALL TERMINATION . . . . . . . . . . . . . .27

E. COMBUSTION AIR OPENINGS . . . . . . . . . .29

F. MULTIPLE BOILER INSTALLATIONS . . . . . .29

3E. VENT & AIR PIPING: THROUGH A SIDE

WALL (SEPARATE TERMINATIONS) 30

A. BOILER VENT CONNECTION . . . . . . . . . . .30

B. VENT PIPING COMPONENTS . . . . . . . . . . .31

C. SUPPORT THE VENT PIPING

COMPLETELY . . . . . . . . . . . . . . . . . . . . . . . .31

D. AIR PIPE CONNECTION . . . . . . . . . . . . . . . .31

E. SUPPORTING AIR PIPING . . . . . . . . . . . . . .32

F. SIDEWALL TERMINATION ASSEMBLIES . .32

G. MULTIPLE BOILER INSTALLATIONS . . . . . .34

TABLE OF CONTENTS

3F. VENT & AIR PIPING: THROUGH A SIDE

WALL (CONCENTRIC TERMINATION) 35

A. BOILER VENT CONNECTION . . . . . . . . . . .35

B. VENT PIPING COMPONENTS . . . . . . . . . . .36

C. SUPPORT THE VENT PIPING

COMPLETELY . . . . . . . . . . . . . . . . . . . . . . . .36

D. AIR PIPE CONNECTION . . . . . . . . . . . . . . . .36

E. SUPPORTING AIR PIPING . . . . . . . . . . . . . .37

F. SIDEWALL TERMINATION/CONCENTRIC

VENT-AIR ASSEMBLY . . . . . . . . . . . . . . . . .37

G. MULTIPLE BOILER INSTALLATIONS . . . . . .37

4. WATER PIPING & CONTROLS 39

A. BOILER PIPING CONNECTIONS . . . . . . . . .39

B. SYSTEM DESIGN . . . . . . . . . . . . . . . . . . . . .39

C. CIRCULATOR REQUIREMENTS . . . . . . . . . .39

D. ADDITIONAL CONTROLS . . . . . . . . . . . . . .40

E. EXPANSION TANK & AIR SEPARATION . . .40

F. ZONING WITH ZONE VALVES . . . . . . . . . .42

G. ZONING WITH CIRCULATORS . . . . . . . . . .43

H. MULTIPLE BOILERS,

PRIMARY/SECONDARY . . . . . . . . . . . . . . . .44

I. MULTIPLE BOILERS, PARALLEL FLOW . . .45

J. CHILLED WATER SYSTEMS . . . . . . . . . . . .46

5. FUEL PIPING 47

A. CHECK THE GAS TYPE . . . . . . . . . . . . . . . .47

B. GAS SUPPLY COMPONENTS . . . . . . . . . . .47

C. GAS PIPING JOINTS . . . . . . . . . . . . . . . . . .48

D. GAS PIPE SIZING . . . . . . . . . . . . . . . . . . . . .48

E. TEST ALL GAS PIPING FOR LEAKS . . . . . .48

6. CONDENSATE DRAIN PIPING 49

A. FILL THE CONDENSATE TRAP . . . . . . . . . .49

B. CONDENSATE LINE INSTALLATION . . . . . .49

C. CONDENSATE LINE REQUIREMENTS . . . .49

7. ELECTRICAL CONNECTIONS 50

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .50

B. POWER SUPPLY (120 VAC) . . . . . . . . . . . . .50

C. CIRCULATOR WIRING . . . . . . . . . . . . . . . . .50

D. SENSOR WIRING . . . . . . . . . . . . . . . . . . . . .51

E. IAR (INDOOR AIR RESET) WIRING,

WHEN USED . . . . . . . . . . . . . . . . . . . . . . . .52

F. DHW WIRING . . . . . . . . . . . . . . . . . . . . . . . .52

8. BOILER CONTROL: OPERATION 55

A. THE CAST 92 BOILER CONTROL . . . . . . . .55

B. BEFORE CONTROL SETUP . . . . . . . . . . . . .56

C. THE CONTROL DISPLAY . . . . . . . . . . . . . . .56

D. RECOMMENDED SETTINGS . . . . . . . . . . . .57

E. ADJUST SETPOINTS . . . . . . . . . . . . . . . . . .57

F. INDOOR AIR . . . . . . . . . . . . . . . . . . . . . . . . .58

G. OUTDOOR AIR . . . . . . . . . . . . . . . . . . . . . . .58

H. SET THE SYSTEM CLOCK . . . . . . . . . . . . . .59

9. BOILER CONTROL: MULTIPLE BOILERS OVERVIEW 66

9A. MULTIPLE BOILERS – CAST 92 CONTROL 66

9B MULTIPLE BOILERS – (BMS) . . . . . . . . . . . .66

9C MULTIPLE BOILERS – EXTERNAL 4-20MA

CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . .66

9A. BOILER CONTROL: MULTIPLE

BOILERS (CAST 92 CONTROL) 67

A. OVERVIEW: CONTROL SETUP

SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . .67

B. POWER SUPPLY (120 VAC) . . . . . . . . . . . . .67

C. CIRCULATOR WIRING . . . . . . . . . . . . . . . . .67

D. IAR (INDOOR AIR RESET) WIRING,

WHEN USED . . . . . . . . . . . . . . . . . . . . . . . .68

E. SENSOR WIRING . . . . . . . . . . . . . . . . . . . . .69

F. DHW WIRING . . . . . . . . . . . . . . . . . . . . . . . .69

G. EXTERNAL INTERLOCKS . . . . . . . . . . . . . .72

H. OVERRIDES – CONTROL PRIORITIES . . . . .72

I. SET TERMINATION DIP SWITCHES . . . . . .72

J. SET CONTROL PARAMETERS ON

KEYPADS . . . . . . . . . . . . . . . . . . . . . . . . . . .73

K. START-UP BOILERS

L. CONNECT NETWORK CABLES . . . . . . . . . .73

M. MASTER BOILER CABLE . . . . . . . . . . . . . . .73

N. MEMBER BOILER CABLES . . . . . . . . . . . . .74

O. CHECK THE NETWORK . . . . . . . . . . . . . . . .74

P. START THE SYSTEM . . . . . . . . . . . . . . . . . .74

9B. BOILER CONTROL: MULTIPLE

BOILERS BUILDING MANAGEMENT CONTROL (BMS) 75

A. OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . .75

B. MODBUS REGISTERS . . . . . . . . . . . . . . . . .75

C. BACNET OR LONWORKS PROTOCOLS . . .76

D. WIRING AND SET-UP . . . . . . . . . . . . . . . . .76

E. CONNECT THE BMS CABLE . . . . . . . . . . . .76

F. VERIFY BMS/HEATNET OPERATION . . . . .76

9C. BOILER CONTROL: MULTIPLE BOILERS

EXTERNAL 4–20MA CONTROL 77

A. OVERVIEW — CONTROL SETUP

SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . .77

B. CONNECT 4-20MA WIRING . . . . . . . . . . . .77

C. POWER SUPPLY (120 VAC) . . . . . . . . . . . . .77

D. CIRCULATOR WIRING . . . . . . . . . . . . . . . . .77

E. 4-20MA OPERATION . . . . . . . . . . . . . . . . . .79

F. IAR (INDOOR AIR RESET) WIRING –

APPLY ONLY IF USING SPACE HEATING

OVERRIDE MODE . . . . . . . . . . . . . . . . . . . .79

G. SENSOR WIRING . . . . . . . . . . . . . . . . . . . . .79

H. DHW WIRING – ONLY IF USING DHW

OVERRIDE MODE . . . . . . . . . . . . . . . . . . . .79

I. OVERRIDES – CONTROL PRIORITIES . . . . .79

TABLE OF CONTENTS

J. SET CONTROL PARAMETERS ON

KEYPADS . . . . . . . . . . . . . . . . . . . . . . . . . . .82

K. START-UP BOILERS . . . . . . . . . . . . . . . . . . .82

L. START THE SYSTEM . . . . . . . . . . . . . . . . . .82

10. FILL AND TEST THE SYSTEM 83

A. CLOSED SYSTEMS ONLY . . . . . . . . . . . . . .83

B. HARD WATER CONDITIONS . . . . . . . . . . . .83

C. PREVENT OXYGEN CORROSION . . . . . . . .83

D. FLUSH AND CLEAN THE SYSTEM . . . . . . .83

E. PURGE AIR FROM THE SYSTEM . . . . . . . .83

F. ADD A CHEMICAL INHIBITOR . . . . . . . . . . .83

G. WATER PH . . . . . . . . . . . . . . . . . . . . . . . . . .84

H. ANTIFREEZE . . . . . . . . . . . . . . . . . . . . . . . . .84

I. SYSTEM PRESSURE . . . . . . . . . . . . . . . . . .84

J. FINAL CHECKS . . . . . . . . . . . . . . . . . . . . . . .85

11. START-UP PROCEDURE 86

A. START-UP CHECKLIST . . . . . . . . . . . . . . . . .86

B. LIGHTING & OPERATING PROCEDURES . .89

C. TURN THE BOILER OFF . . . . . . . . . . . . . . . .90

D. CHECK IGNITION . . . . . . . . . . . . . . . . . . . . .90

E. INSERT COMBUSTION ANALYZER

PROBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90

F. CHECK HIGH FIRE OPERATION . . . . . . . . .90

G. ADJUST GAS VALVE THROTTLE

SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

H. VERIFY GAS INLET PRESSURE . . . . . . . . .91

I. TO METER GAS INPUT (NATURAL

GAS ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . .92

J. CHECK LOW FIRE OPERATION . . . . . . . . . .92

K. WHEN IS LOW FIRE ADJUSTMENT

REQUIRED? . . . . . . . . . . . . . . . . . . . . . . . . .92

L. REMOVING THE BOILER JACKET TOP . . . .92

M. ADJUSTING THE LOW-FIRE SETTING . . . .93

N. REPLACE THE BOILER JACKET TOP . . . . .93

O. MEASURE FLAME CURRENT . . . . . . . . . . .93

P. CHECK BOILER MODULATION . . . . . . . . . .93

Q. TEST FLAME FAILURE MODES . . . . . . . . .94

R. TEST CONTROL & INTERLOCK

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . .94

S. FILL OUT THE COMBUSTION TEST

RECORD . . . . . . . . . . . . . . . . . . . . . . . . . . . .94

12. TROUBLESHOOTING 95

13. MAINTENANCE 97

A. READ BEFORE PROCEEDING . . . . . . . . . . .97

B. HANDLING CERAMIC FIBER AND

FIBERGLASS MATERIALS . . . . . . . . . . . . . .97

C. CLEANING THE AIR FILTER . . . . . . . . . . . . .97

D. ACCESSING THE ELECTRODE

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . .98

E. ACCESSING THE BURNER . . . . . . . . . . . . .99

F. ANNUAL START-UP OVERVIEW . . . . . . . .100

G. ANNUAL START-UP CHECKLIST . . . . . . . .100

14. REPAIR PARTS 102

15.BOILER RATINGS & SPECIFICATIONS 108

APPENDIX A. SUGGESTED WIRING 109

IAR (INDOOR AIR RESET) WIRING, WHEN USED WIRING FOR 3-WIRE ZONE VALVES

WITHOUT A ZONE CONTROLLER . . . . . . . . .109

IAR (INDOOR AIR RESET) WIRING, WHEN USED WIRING FOR CIRCULATOR RELAYS (RELAYS MUST HAVE 24VAC COMMON

TERMINALS) . . . . . . . . . . . . . . . . . . . . . . . . . .110

IAR (INDOOR AIR RESET) WIRING, WHEN USED WIRING FOR TYPICAL ZONE

CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . .111

APPENDIX B. COMBUSTION TEST RECORD 113

TABLE OF CONTENTS

1

A. INSTALLATION SEQUENCE

Follow the installation instructions provided in this manual in the order shown. The order of these instructions has been set in order to provide the installer with a logical sequence of steps that will minimize potential interferences and maximize safety during boiler installation.

B. SPECIAL ATTENTION BOXES

Throughout this manual special attention boxes are provided to supplement the instructions and make special notice of potential hazards. The definition of each of these categories, in the judgement of PB Heat, LLC are as follows:

USING THIS MANUAL

Indicates special attention is needed, but not directly related to potential personal injury or property damage.

NOTICE

Indicates a condition or hazard which will or can cause minor personal injury or property damage.

CAUTION

DANGER

Indicates a condition or hazard which will cause severe personal injury, death or major property damage.

Indicates a condition or hazard which may cause severe personal injury, death or major property damage.

WARNING

USING THIS MANUAL

2

PREINSTALLATION

A. GENERAL

1. Cast 92 boilers are supplied completely assembled as packaged boilers. The package should be inspected for damage upon receipt and any damage to the unit should be reported to the shipping company and wholesaler. This boiler should be stored in a clean, dry area.

2. Carefully read these instructions and be sure to understand the function of all connections prior to beginning installation. Contact your PB Heat, LLC Representative for help in answering questions.

3. This boiler must be installed by a qualified contractor. The boiler warranty may be voided if the boiler is not installed correctly.

4. A hot water boiler installed above radiation or as required by the Authority having jurisdiction, must be provided with a low water fuel cut-off device either as part of the boiler or at the time of installation.

B. CODES & REGULATIONS

1. Installation and repairs are to be performed in strict accordance with the requirements of state and local regulating agencies and codes dealing with boiler and gas appliance installation.

2. In the absence of local requirements the following should be followed:

a. ASME Boiler and Pressure Vessel Code, Section

IV - “Heating Boilers”

b. ASME Boiler and Pressure Vessel Code, Section

VI - “Recommended Rules for the Care and Operation of Heating Boilers”

c. ANSI Z223.1/NFPA 54 - “National Fuel Gas Code”

d. ANSI/NFPA 70 - “National Electrical Code”

e. ANSI/NFPA 211 - “Chimneys, Fireplaces, Vents

and Solid Fuel Burning Appliances”

3. Where required by the authority having jurisdiction, the installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1.

**Please read if installing in Massachusetts**

Massachusetts requires manufacturers of Side Wall Vented boilers to provide the following information from the Massachusetts code:

·

A hard wired carbon monoxide detector with an alarm and battery back-up must be installed on the floor level where the gas equipment is to be installed AND on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment.

·

In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.

·

Detector(s) must be installed by qualified licensed professionals.

·

APPROVED CARBON MONOXIDE DETECTORS: Each carbon monoxide detector shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.

·

SIGNAGE: A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.

·

EXEMPTIONS to the requirements listed above:

°

The above requirements do not apply if the exhaust vent termination is seven (7) feet or more above finished grade in the area of the venting, including but not limited to decks and porches.

°

The above requirements do not apply to a boiler installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes.

·

This boiler installation manual shall remain with the boiler at the completion of the installation.

See the latest edition of Massachusetts Code 248 CMR for complete verbage and also for additional (non-vent related) requirements (248 CMR is available online).

If your installation is NOT in Massachusetts, please see your authority of jurisdiction for requirements that may be in effect in your area. In the absence of such requirements, follow the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CAN/CSA B149.1, Natural Gas and Propane Installation Code.

1. PREINSTALLATION

Liquefied Petroleum (LP) Gas or Propane is heavier than air and, in the event of a leak, may collect in low areas such as basements or floor drains. The gas may then ignite resulting in a fire or explosion.

WARNING

3

C. BOILER LOCATION REQUIREMENTS

1. Indoor Installation Only:

a. Do not install the boiler outside or in an area that

would expose the boiler or its gas or electrical components to rain or dripping or spraying water.

b. Do not install the boiler in a location that would

subject the boiler to freezing. Where freeze protection is needed, follow the guidelines in this manual.

2. Flooring:

a. The boiler can be installed on combustible

flooring, but must not be installed on carpeting.

b. The floor must be structurally sound and capable

of supporting the weight of the boiler.

c. The boiler must be leveled front to back and side

to side. Use metal shims if necessary.

3. Accessibility: Jacket parts will have to be removed for some service

procedures. Ensure that the location provides a reasonable means for service and operation of the boiler.

4. System Piping, Fuel and Electrical Supply:

a. The boiler must be located such that piping for

water, gas, vent and air can reasonable be connected.

b. There must be a reasonable means of providing

electrical supply to the boiler.

5. Adjacent Construction: Locate the boiler in an area that will prevent water

damage to adjacent construction should a leak occur or during routine maintenance.

6. Combustion Air:

a. Do not place the boiler in a location that would

restrict the flow of combustion air into the air intake or subject the boiler to a negative air pressure in the space when using air from the boiler room.

b. Provide required combustion air openings to the

boiler room and the building (when required) when using air from the boiler room for combustion (see Section C, “Combustion Air Requirements”). If air is piped to the boiler air intake connection, combustion air openings are not required unless other appliances share the same room.

c. Buildings will require the installation of a fresh air

duct or other means of providing make-up air if the intake air option isn't used. Any building utilizing other gas burning appliances, a fireplace, wood stove or any type of exhaust fan must be checked for adequate combustion air when all of these devices are in operation at one time. Sizing of an outside air duct must be done to meet the requirements of all such devices.

d. The boiler must be supplied with combustion air

in accordance with Section 5.3, "Air for Combustion and Ventilation," of the latest revision of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and all applicable local building codes. Canadian installations must comply with

CSA B149.1 or .2 Installation Code for Gas Burning Appliances and Equipment, or applicable

provisions of the local building codes.

7. Negative Room Pressure: Never operate the boiler in an environment subjected

to a negative pressure unless it is Direct Vented. Failure to comply with this warning can result in excessive levels of carbon monoxide.

8. Combustion Air Contamination:

a. Combustion air contaminated with fluorocarbons

or other halogenated compounds such as cleaning solvents and refrigerants will result in the formation of acids in the combustion chamber. These acids will cause premature failure of the boiler.

b. Construction Dust

: If the boiler is operated while the building is under construction it must be protected from wood, concrete, sheet rock and other types of dust. Failure to properly protect the boiler from construction dust will damage the boiler.

c. If the boiler has been operated with contaminated

air, it must be thoroughly inspected. Where possible, boiler components must be cleaned, following instructions provided in this manual and/or supplementary instructions from PB Heat. Where cleaning is not possible, the boiler may have to be replaced.

d. Never store combustible materials, gasoline or any

product containing flammable vapors or liquids in the vicinity of the boiler.

9. Clearances: a. All installations must provide the minimum

clearances to combustible materials given in Section B, “Clearance Requirements”.

b. The installation should provide the minimum

service clearances given in Section B, “Clearance Requirements”, when possible. If these clearances cannot be met, then:

Ensure that boiler components can be accessed for operation/start-up/maintenance as required in this manual.

PREINSTALLATION

Do not install the boiler unless the location meets all of the requirements in Sections 1 through 9 below. Failure to comply could result in severe personal injury, death or substantial property damage.

WARNING

4

PREINSTALLATION

D. CLEARANCE REQUIREMENTS

1. Clearances to Combustible Surfaces:

2. Clearances for Service and Operation:

E. COMBUSTION AIR REQUIREMENTS

1. Air Ducted to Boiler Air Intake: a. If air is ducted from outside to the boiler air

intake, follow instructions in Section 3, “Venting & Air Inlet Piping”.

b. If the boiler is located in a small room (clearances

less than the recommended SERVICE/OPERATION clearances given in Figure 1.2):

All installations must provide the minimum clearances to combustible materials and surfaces given in Table 1.1. Failure to comply could result in a fire hazard, causing severe personal injury, death or substantial property damage.

WARNING

Table 1.1: Minimum Clearances to Combustible

Materials/Surfaces for ALL Installations (Figure 1.1)

From Inches Millimeters

To p 6 153

Back 6 153

Left side 6 153

Right side 6 153

Front 6 153

Rear 6 153

Vent piping 2 51

System water piping 1 25.4

If the boiler is located in a closed room, the room must be provided with ventilation openings even if air is ducted to the boiler. See Figure 1.1. Size the openings with a free area no less than 1 square inch per BTUH input of all Cast 92 boilers in the room.

EXCEPTION: Ventilation openings are not required if the boiler room provides at least the minimum SERVICE/OPERATION clearances given in Table 1.2. Failure to provide adequate ventilation could result in overheating of the boiler components or the room, potentially causing severe personal injury, death or substantial property damage.

WARNING

The installation must provide reasonable access and clearance for service and operation of the boiler. Table 2 gives recommended minimum clearances for service and operation. The boiler may be installed in a space that does not provide these recommended clearances provided it is accessible for the service and operation procedures required in this manual.

Flame observation port — The flame observation port on the LEFT side of the boiler must be accessible to view the combustion chamber during boiler start-up. Make sure that the installation allows serviceman access to the left side for this purpose.

WARNING

Table 1.2: Recommended Minimum Clearances for

Service/Operation (Figure 1.2)

From Inches Millimeters

To p 24 610

Back 24 610

Left side 24 610

Right side 24 610

Front 36 914

Rear 18 457

Figure 1.1: Clearance to Combustibles Materials

Figure 1.2: Service/Operation Clearance References

5

PREINSTALLATION

i. No Other Appliances in the Room: Provide

two ventilation openings through one of the enclosure walls. Each opening must be sized for a free area of at least 1 square inch per 1,000 BTUH input of the Cast 92 boilers in the room. One opening must be within 12 inches of the ceiling, the other within 12 inches of the floor.

ii. Other Appliances in the Same Room: The room

must have combustion air openings sized for the other appliances. Increase the free area of the air openings by one square inch per 1,000 BTUH of the Cast 92 boilers located in the room.

2. Air From Boiler Room: When the Boiler Draws Combustion Air from the

Boiler Room:

i. If the room volume is at least 50 cubic feet per

BTUH of the combined input of all appliances in the room, no special openings are needed UNLESS the building is of tight construction (see definition). If the building is of tight construction, provide openings to the building in accordance with all applicable codes.

ii. If the boiler is in a space smaller than 50 cubic

feet volume per BTUH input, provide air openings using one of the methods in Figure 1.3.

3. Definitions:

a. Free Area

: Louvers or grilles reduce the area of an opening. Free area is the area remaining with the louver or grille in place. If the free area of a louver is unknown, use the following:

i. Metal Louver: Multiply required free area of

the opening times 1.7 to determine actual area of the required opening.

ii. Wood Louver: Multiply required free area of

the opening times 5 to determine actual area of the required opening.

b. Tight Construction

: When a building is extensively sealed to prevent air infiltration, it cannot provide enough air for combustion unless openings are provided to the outside. The National Fuel Gas Code defines such buildings as having all of the following:

i. Walls and ceilings exposed to the outside

atmosphere have a continuous water vapor retarder with a rating of 1 perm or less with openings gasketed.

ii. Weather-stripping has been added on

openable windows and doors.

iii. Caulking or sealants are applied to areas such

as joints around windows and door frames, between sole plates and floors, between wallceiling joints, between wall panels, at penetrations for plumbing, electrical, and gas lines, and in other openings.

4. Conversion Factors: In

2

/1,000 BTUH to cm2/kw — Multiply In2/1,000

BTUH times 22 In

2

/2,000 BTUH to cm2/kw — Multiply In2/2,000

BTUH times 11 In

2

/3,000 BTUH to cm2/kw — Multiply In2/3,000

BTUH times 7.4 In

2

/4,000 BTUH to cm2/kw — Multiply In2/4,000

BTUH times 5.5

5. Air Opening Options for Combustion Air

Drawn from Boiler Room:

Upper openings (U) must be within 12 inches of the ceiling. Lower openings (L) must be within 12 inches of the floor.

Option 1 – Air Openings Through Interior Wall:

When air is supplied to the boiler room through openings in an interior wall (air supply from inside the building), size each opening to provide minimum free area of:

1 in

2

per 1,000 BTUH of all Cast 92 boilers in the

room.

Figure 1.3: Air opening options for combustion air

drawn from boiler room

If other appliances are located in the same room as the boiler, increase the size of air openings to provide the free area required for the other appliances in addition to the air required for the Cast 92 boiler(s).

WARNING

6

PREINSTALLATION

Option 2 – Air Openings Through Outside Wall:

When air is supplied to the boiler room through openings in an outside wall (air supply from outside the building), size each opening to provide minimum free area of:

1 in

2

per 4,000 BTUH of all Cast 92 boilers in the

room.

Option 3 – Horizontal Ducts to Outside Wall:

When air is supplied to the boiler room through horizontal ducts to an outside wall (air supply from outside the building), size each opening to provide minimum free area of:

1 in

2

per 3,000 BTUH of all Cast 92 boilers in the

room.

Option 4 – Openings to Attic/Crawl Space:

Air openings can be connected to a ventilated attic or crawl space. The upper opening must be to the attic. The lower opening can be a vertical duct from the attic or an opening in the floor from the crawl space. Size each opening to provide minimum free area of:

1 in

2

per 3,000 BTUH of all Cast 92 boilers in the

room.

Option 5 – Single Opening (not shown):

A single opening directly connected to the outdoors through a wall or a vertical or horizontal duct can be used if the installation provides the clearances of Figure 1.2, and the top of the opening is within 12 inches of the ceiling. Size the opening to provide minimum free area of:

1 in

2

per 3,000 BTUH of all Cast 92 boilers in the

room.

7

A. REMOVE THE BOILER FROM THE CRATE

1. Remove the crate from the skid. But leave the boiler on the skid to move the boiler near its location.

2. Inspect the boiler thoroughly for any possible damage that may have occurred in shipping or handling.

3. Slide the boiler off of the skid into position.

4. Use a spirit level to check whether the boiler sides and front are vertically plumb. If not, slide metal shims under the base until the boiler is level.

B. INSTALL THE RELIEF VALVE

Check Relief Valve Pressure Setting:

Inspect the boiler relief valve before installing to ensure it is set at the pressure required for the system. You should also verify that all water system components are rated for at least the pressure setting of the relief valve to avoid component damage due to excess pressure.

2. Connecting the Relief Valve: Connect 3/4" NPT black iron pipe and fitting so the relief valve as shown in Figure 2.1. Follow all instructions provided in the relief valve manufacturer’s instructions and labeling.

C. BOILER PIPING — GENERAL

Piping Guidelines:

• All installations must be installed by a qualified technician in accordance with the latest revision of the ANSI/ASME Boiler and Pressure Vessel Code, Section IV.

• Where required, the installation must comply with ANSI/ASME CSD-1, Standard for Controls and Safety Devices for Automatically Fired Boilers.

2. BOILER SET-UP

Never install any type of valve between the boiler and the relief valve, or in the relief discharge piping. An explosion could occur, causing severe personal injury, death or substantial property damage. General piping requirements.

WARNING

Improper piping of the boiler will void the manufacturer’s warranty, and can cause boiler failure, resulting in possible severe personal injury, death or substantial property damage.

WARNING

Figure 2.1: Relief valve piping

Cold weather handling — The boiler jacket includes plastic parts. If the boiler has been in a cold environment (below 0°F), allow the boiler to warm to room temperature before handling.

CAUTION

Do not drop the boiler or allow the jacket to bump against the floor or wall when handling.

CAUTION

The boiler maximum allowable working pressure is 100 psig (700 kPa). The relief valve must never have a setting greater than 100 psig. Using a higher pressure relief valve could result in an explosion, causing possible severe personal injury, death or substantial property damage.

WARNING

Install a shut-off valve in the boiler supply and return connections to allow isolation of the boiler for servicing when necessary.

NOTICE

BOILER SET-UP

8

• All applicable local codes and ordinances must also be followed.

• A minimum clearance of 1" (25 mm) must be maintained between heating system pipes and all combustible construction.

• All heating system piping must be supported by suitable hangers — not by the boiler.

• The thermal expansion of the system must be considered when supporting the system.

• A minimum system pressure of 12 psig (84 kPa) must be maintained.

BOILER SET-UP

9

When a Cast 92 boiler replaces a boiler that shared a common vent system, follow the guidelines below to check operation of the remaining appliance(s).

A. COMMON VENT SYSTEMS

If an existing boiler is removed from a common venting system, the common venting system may then be too large for the proper venting of the remaining appliances connected to it. 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.

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

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

3. Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhaust, so they will operate at maximum speed. Do not operate a summer exhaust fan for a boiler installation. Close fireplace dampers.

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

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

6. After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas-burning appliance to their previous condition of use.

3. VENTING & AIR INLET PIPING

DO NOT install a Cast 92 boiler on a common vent system. All Cast 92 boilers must be individually vented. Failure to comply could result in improper operation of any of the appliances on the vent system, resulting in possible severe personal injury, death or substantial property damage.

WARNING

VENTING & AIR INLET PIPING

Heat-fab EZ Seal Joint Assembly

10

7. 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. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Appendix F in the National Fuel Gas Code, ANSI Z223.1/ NFPA 54 and or CSA B149 Installation Codes.

B. VENT AND AIR PIPING, GENERAL

1. Pages 9 through 13 are a brief overview of the options for vent and air piping configurations and give a summary and brief list of requirements for each of the vent/air configuration options.

2. When air is taken from the boiler room (no air pipe connected to the boiler air inlet fitting), follow the instructions in this manual to ensure the boiler room has proper openings for combustion air and ventilation.

C. VENT PIPING

1. Category II & IV Venting Only: All Cast 92 boilers require vent piping listed for use in pressurized, condensing operation. Use only the materials specified in this manual. When venting category II the flue pipe must be increased to 5 inch for the 92-2 and 6 inch for the 92-4.

2. Vent Pipe Options: Use only Heat-fab Saf-T Vent

®

EZ Seal or Z-Flex

®

Z-Vent vent pipe and components. You will find specific component information for each configuration in this manual.

3. Vent Pipe Joint Assembly: EZ Seal and Z-Vent vent piping use a silicon rubber ring-style gasket in each joint. Joints are secured using metal tabs that wrap around a ring on the adjacent piping component for Heat-fab vent pipe, or gear clamps for Z-Flex vent pipe. Never use screws in the vent piping. Screws are only applied to the air piping portion of Heat-fab SC concentric vent, used for concentric vent/air sidewall terminations.

D. AIR PIPING

1. Air Options: Combustion air can be piped through the side wall or through the roof of the building. Sidewall air intake can be done with either through-the-roof or sidewall venting.

2. Air Piping Materials: The best choices for air piping are PVC, CPVC or ABS. These materials are easy to work with and yield a clean final appearance. Joint sealing is easier than other methods because it only requires use of the standard joint sealant for the type of plastic pipe used. And there are not horizontal seams requiring sealing like on metal air piping.

Other materials suitable for combustion air venting are galvanized pipe, aluminum pipe and flexible aluminum pipe. All joints, including the seams, of these piping materials must be sealed with silicone adhesive sealant, such as Dow Corning 732.

E. TERMINATIONS

1. Through-the-roof Terminations: Both vent and air piping must terminate with a Heatfab or Z-Flex rain cap.

2. Sidewall Terminations: Vent and air pipes can be individually terminated using Heat-fab or Z-Flex termination elbows with built-in screen, or concentrically terminated using Heat-fab type SC concentric vent/air pipe (only when using Heat-fab vent piping) Termination components as given in this manual.

F. VENT PIPED THROUGH THE ROOF

(COMBUSTION AIR FROM THE BOILER ROOM)

VENTING & AIR INLET PIPING

Vent Components

92-2 92-4

Heat-Fab Z-Flex Heat-Fab Z-Flex

Vent Piping/Components (Incl. Supports, Thimbles, etc.)

EZ-Seal3"Z-Vent3"EZ-Seal4"Z-Vent

4"

Boiler Adapter (Adapts from EZ-Seal to Z-Vent Piping)

Not

Required

2SVSHTA03

Not

Required

2SVSHTA04

Rain Cap Vent Termination 5300CI 2SVSRCF03 5400CI 2SVSRCF04

Joint Sealant, as Needed GE RTV106 or Equivalent

11

G. VENT PIPED THROUGH THE ROOF

(AIR PIPED THROUGH SIDE WALL)

H. VENT & AIR PIPED THROUGH THE ROOF

(SEPARATE VENT AND AIR TERMINATIONS)

Vent Components

92-2 92-4

Heat-Fab Z-Flex Heat-Fab Z-Flex

Vent Piping/Components (Incl. Supports, Thimbles, etc.)

EZ-Seal

3"

Z-Vent

3"

EZ-Seal

4"

Z-Vent

4"

Boiler Adapter (Adapts from EZ-Seal to Z-Vent Piping)

Not

Required

2SVSHTA03

Not

Required

2SVSHTA04

Rain Cap Vent Termination

5300CI 2SVSRCF03 5400CI 2SVSRCF04

Joint Sealant, as Needed

GE RTV106 or Equivalent

Air Components Heat-Fab Z-Flex Heat-Fab Z-Flex

Termination Elbow 9314TERM 2SVSTEX0390 9414TERM 2SVSTEX0490

Termination Pipe Section (1 ft)

9302 2SVEPWCF0301 9402 2SVEPWCF0401

Termination Thimble 9393S 2SVSWTE03 9493S 2SVSWTE04

Gear Clamp (Nose Clamp)

3" Clamp 7HS44XX 4" Clamp 7HS64XX

Air Piping/Components (Incl. Supports, Thimbles, etc.)

3" PVC, CPVC, ABS,

Galvanized or Aluminum

4" PVC, CPVC, ABS,

Galvanized or Aluminum

Vent Components

92-2 92-4

Heat-Fab Z-Flex Heat-Fab Z-Flex

Vent Piping/Components (Incl. Supports, Thimbles, etc.)

EZ-Seal

3"

Z-Vent

3"

EZ-Seal

4"

Z-Vent

4"

Boiler Adapter (Adapts from EZ-Seal to Z-Vent Piping)

Not

Required

2SVSHTA03

Not

Required

2SVSHTA04

Rain Cap Vent Termination

5300CI 2SVSRCF03 5400CI 2SVSRCF04

Joint Sealant, as Needed

GE RTV106 or Equivalent

Air Components Heat-Fab Z-Flex Heat-Fab Z-Flex

Rain Cap Termination 5300CI 2SVSRCF03 5400CI 2SVSRCF04

Termination Pipe Section (3 ft)*

9307 2SVEPWCF0303 9407 2SVEPWCF0304

*Note: Standard air piping termination pipe section is 3 feet. A longer length can be

used if needed.

Air Piping/Components (Incl. Supports, Thimbles, etc.)

3" PVC, CPVC, ABS,

Galvanized or Aluminum

4" PVC, CPVC, ABS,

Galvanized or Aluminum

VENTING & AIR INLET PIPING

12

I. VENT PIPED THROUGH A SIDE WALL

(COMBUSTION AIR FROM THE BOILER ROOM)

J. VENT & AIR PIPED THROUGH A SIDE WALL

(SEPARATE VENT AND AIR TERMINATIONS)

Vent Components

92-2 92-4

Heat-Fab Z-Flex Heat-Fab Z-Flex

Vent Piping/Components (Incl. Supports, Thimbles, etc.)

EZ-Seal

3"

Z-Vent

3"

EZ-Seal

4"

Z-Vent

4"

Boiler Adapter (Adapts from EZ-Seal to Z-Vent Piping)

Not

Required

2SVSHTA03

Not

Required

2SVSHTA04

Joint Sealant, as Needed GE RTV106 or Equivalent

Termination Elbow 9314TERM 2SVSTEX0390 9414TERM 2SVSTEX0490

Termination Pipe Section (1 ft)

9302 2SVEPWCF0301 9402 2SVEPWCF0401

Termination Thimble 9393S 2SVSWTE03 9493S 2SVSWTE04

Gear Clamp (Nose Clamp)

3" Clamp 7HS44XX 4" Clamp 7HS64XX

Vent Components

92-2 92-4

Heat-Fab Z-Flex Heat-Fab Z-Flex

Vent Piping/Components (Incl. Supports, Thimbles, etc.)

EZ-Seal

3"

Z-Vent

3"

EZ-Seal

4"

Z-Vent

4"

Boiler Adapter (Adapts from EZ-Seal to Z-Vent Piping)

Not

Required

2SVSHTA03

Not

Required

2SVSHTA04

Termination Elbow 9314TERM 2SVSTEX0390 9414TERM 2SVSTEX0490

Termination Pipe Section (1 ft)

9302 2SVEPWCF0301 9402 2SVEPWCF0401

Termination Thimble 9393S 2SVSWTE03 9493S 2SVSWTE04

Gear Clamp (Nose Clamp)

3" Clamp 7HS44XX 4" Clamp 7HS64XX

Joint Sealant, as Needed GE RTV106 or Equivalent

Air Components Heat-Fab Z-Flex Heat-Fab Z-Flex

Termination Elbow Same as Vent Termination Same as Vent Termination

Air Piping/Components (Incl. Supports, Thimbles, etc.)

3" PVC, CPVC, ABS,

Galvanized or Aluminum

4" PVC, CPVC, ABS,

Galvanized or Aluminum

VENTING & AIR INLET PIPING

13

VENTING & AIR INLET PIPING

K. VENT & AIR PIPED THROUGH A SIDE WALL

(CONCENTRIC VENT/AIR TERMINATION)

Vent Components

92-2 92-4

Heat-Fab Heat-Fab

Vent Piping/Components (Incl. Supports, Thimbles, etc.)

EZ-Seal, 3" Piping

Saf-T Vent SC Fittings for

Termination Assembly

EZ-Seal, 4" Piping

Saf-T Vent SC Fittings for

Termination Assembly

Termination Assembly:

• Single-wall Adapter

• Air Intake Tee

• 6" Straight Section

• 12" Straight Section

• Wall Plate (2 Required)

• Termination Adapter

• Mitered Termination

SC03ADEZ SC03TAD3

SC0366

SC03L12

SC03FS

SC03HT

9390

SC04ADEZ SC04TAD3

SC0466

SC04L12

SC04FS

SC04HT

9490

Joint Sealant, as Needed GE RTV106 or Equivalent

Air Components Heat-Fab Heat-Fab

Air Piping/Components (Also Supports, Thimbles, etc.)

3" PVC, CPVC, ABS,

Galvanized or Aluminum

4" PVC, CPVC, ABS,

Galvanized or Aluminum

14

A. BOILER VENT CONNECTION

1. The vent connection at the boiler is for Heat-Fab EZSeal vent piping only. To use Z-Flex Z-Vent venting you must install the Z-Vent adapter, part number 2SVSHTA03 (92-2) or 2SVSHTA04 (92-4).

2. EZ-Seal Connection: Insert EZ-Seal pipe male end into the boiler connection. Make sure the locking tabs slide under the EZ-Seal locking ring. Bend back locking tabs to complete the joint. Follow EZ-Seal instructions to complete the vent piping installation.

3. Z-Vent adapter Installation: Insert male end of adapter into boiler vent connection. Make sure the locking tabs slide under the gear clamp on the adapter. Bend back the locking tabs (as in left illustration above). Then tighten the adapter gear clamp to finish the connection. Follow Z-Vent instructions to connect ZVent piping.

The vent piping operates with positive pressure. The vent piping must be completely sealed and securely supported.

Use only the vent components listed in this manual. Use of any other materials could result in vent system failure.

Exposed vent pipe poses a potential burn hazard to people and pets. Insulate or shield the pipe where necessary to prevent risk.

Never drill through, or install screws into, the vent pipe or vent components.

Failure to properly install the vent piping could result in flue gas leakage, causing possible severe personal injury, death or substantial property damage.

WARNING

Terminate the vent following the guidelines in this manual. Avoid vent termination locations likely to be affected by winds, snowdrifts, people and pets. Protect building materials and vegetation from degradation caused by the flue gases and condensation.

WARNING

Code compliance – Follow all applicable local codes when installing the vent system. Where codes differ from this manual, follow code requirements. Contact PB Heat if you have any questions regarding the installation.

NOTICE

Figure 3A.1: Vertical Venting

EZ-Seal Vent Attachment Z-Vent Adapter

Attachment

3A. VENT & AIR PIPING: THROUGH THE

ROOF

(COMBUSTION AIR FROM THE BOILER ROOM)

VENT & AIR PIPING: THROUGH THE ROOF

15

4. Slope horizontal runs toward the boiler. All horizontal runs of vent pipe must slope continuously at least 1/4" per foot (21 mm per meter) to ensure condensate drains completely back to the boiler. DO NOT install the vent piping with any sections that could trap condensate.

B. VENT PIPING COMPONENTS

1. See Table 3A.1 for acceptable vent components. NO OTHER vent materials are acceptable.

2. Carefully follow the instructions supplied by the vent piping manufacturer.

3. The vent joints seal with elastomer rings in the pipe and fittings. Avoid damaging these seals.

4. Cutting Z-Vent Pipe (Z-Vent only — DO NOT cut EZ- Seal Pipe): Length adjustments with Z-Vent pipe can be made by cutting the pipe, following the Z-Vent instructions. Be sure to cut the pipe squarely and to file the cut edge smooth after cutting. Rough pipe ends will damage the seals. Support the pipe when cutting to avoid making the pipe out of round.

5. Adjustable Lengths of EZ-Seal Pipe: Length adjustments with EZ-Seal piping are made with slip-fit adjustable length sections, not by cutting the pipe. Make sure the adjustable length does not jut into elbows or terminations. This could block flue gas and condensate flow.

6. Maximum Vent Piping Length: See the table in Figure 3A.1 for the maximum allowable length. Each elbow causes the same pressure drop as 10 feet of vent pipe, so the allowable length reduces 10 feet for each elbow used in the piping. When 45° elbows are used, two 45° elbows are equivalent to one 90° elbow.

7. Insulate the vent piping where it passes through unheated areas to prevent condensate freeze-up.

8. If the pipe passes through an occupied space, install a chase around the pipe, following the vent pipe instructions and applicable codes.

9. Clearance from Combustible Materials: Provide minimum clearance to all combustible materials of at least 2 inches (51 mm).

10. Using an Existing Chimney as a Chase: The vent piping can be routed through an existing UNUSED and STRAIGHT chimney. DO NOT vent directly into the chimney. Install the vent piping so it can be inspected after installation. Follow vent pipe manufacturer’s instructions for chimney-as-chase installations.

C. SUPPORT THE VENT PIPING

COMPLETELY

1. DO NOT use the boiler vent connection to support the vent piping. Provide support straps from the ceiling or noncombustible saddle or pedestal supports from the floor. This is required on ALL installations, regardless of the length of the horizontal piping connected to the boiler.

2. Vent piping cannot be supported from above (such as relying on roof jack sections). You must install supports on the horizontal piping before the vent turns upward.

3. Install at least one support on every horizontal run. For horizontal runs longer than 5 feet (1.5 m), install a support every 3 feet (0.9 m).

4. Follow the vent pipe manufacturer’s instructions for placement and installation of supports.

D. FLOOR AND WALL PENETRATIONS

1. Follow applicable codes and the vent pipe instructions to install fire stops, thimbles or other devices at all floor and wall penetrations.

2. Provide minimum 2 inches (51 mm) clearance to all combustible construction.

E. ROOF PENETRATIONS

Follow applicable codes and the vent pipe instructions to install a roof jack, flashing and support. Long extensions of vent pipe above the roof may require the use of guy supports as specified in the vent pipe instructions.

F. RAIN CAP TERMINATION

1. Use only the rain caps listed in Table 3A.1.

2. The rain cap exhaust opening must be at least 2 feet (0.6 m) above the highest roof point within 10 feet, as shown in Figure 3A.1. See the National Fuel Gas Code, ANSI/NFPA 54 for details on pitched roof applications.

3. See Figure 3A.2 for additional minimum clearances.

VENT & AIR PIPING: THROUGH THE ROOF

Table 3A.1: Vent and Air System Components

Vent Components

92-2 92-4

Heat-Fab Z-Flex Heat-Fab Z-Flex

Vent Piping/Components (Incl. Supports, Thimbles, etc.)

EZ-Seal3"Z-Vent3"EZ-Seal4"Z-Vent

4"

Boiler Adapter (Adapts from EZ-Seal to Z-Vent Piping)

Not

Required

2SVSHTA03

Not

Required

2SVSHTA04

Rain Cap Vent Termination 5300CI 2SVSRCF03 5400CI 2SVSRCF04

Joint Sealant, as Needed GE RTV106 or Equivalent

Figure 3A.2: Vent Termination Minimum

Clearances

16

G. COMBUSTION AIR OPENINGS

Combustion air must be supplied from the boiler room as shown in Figure 1.1. Make sure the installation provides air openings as required by applicable codes and this manual.

H. MULTIPLE BOILER INSTALLATIONS

1. Each boiler must be individually vented. DO NOT use combined venting.

2. Install multiple vents through the roof following all guidelines for single-vent installations.

3. Install the vents so they are no closer than 12 inches on centers.

VENT & AIR PIPING: THROUGH THE ROOF

17

A. BOILER VENT CONNECTION

1. The vent connection at the boiler is for Heat-Fab EZSeal vent piping only. To use Z-Flex Z-Vent venting you must install the Z-Vent adapter, part number 2SVSHTA03 (92-2) or 2SVSHTA04 (92-4).

2. EZ-Seal Connection: Insert EZ-Seal pipe male end into the boiler connection. Make sure the locking tabs slide under the EZ-Seal locking ring. Bend back locking tabs to complete the joint. Follow EZ-Seal instructions to complete the vent piping installation.

3. Z-Vent Adapter Installation: Insert male end of adapter into boiler vent connection. Make sure the locking tabs slide under the gear clamp on the adapter. Bend back the locking tabs (as in left illustration above). Then tighten the adapter gear clamp to finish the connection. Follow Z-Vent instructions to connect ZVent piping.

VENT & AIR PIPING: THROUGH THE ROOF

The vent piping operates with positive pressure. The vent piping must be completely sealed and securely supported.

Use only the vent components listed in this manual. Use of any other materials could result in vent system failure.

Exposed vent pipe poses a potential burn hazard to people and pets. Insulate or shield the pipe where necessary to prevent risk.

Never drill through, or install screws into, the vent pipe or vent components.

Failure to properly install the vent piping could result in flue gas leakage, causing possible severe personal injury, death or substantial property damage.

WARNING

Terminate the vent and air piping following the guidelines in this manual. Avoid vent termination locations likely to be affected by winds, snowdrifts, people and pets. Protect building materials and vegetation from degradation caused by the flue gases and condensation.

WARNING

Code compliance – Follow all applicable local codes when installing the vent system. Where codes differ from this manual, follow code requirements. Contact PB Heat if you have any questions regarding the installation.

NOTICE

Figure 3B.1: Vertical Venting/Sidewall Air

EZ-Seal Vent Attachment Z-Vent Adapter

Attachment

3B. VENT & AIR PIPING: THROUGH THE

ROOF

(AIR PIPED THROUGH SIDE WALL)

18

VENT & AIR PIPING: THROUGH THE ROOF

4. Slope horizontal runs toward the boiler. All horizontal runs of vent pipe must slope continuously at least 1/4" per foot (21 mm per meter) to ensure condensate drains completely back to the boiler. DO NOT install the vent piping with any sections that could trap condensate.

B. VENT PIPING COMPONENTS

1. See Table 3B.1 for acceptable vent components. NO OTHER vent materials are acceptable.

2. Carefully follow the instructions supplied by the vent piping manufacturer.

3. The vent joints seal with elastomer rings in the pipe and fittings. Avoid damaging these seals.

4. Cutting Z-Vent Pipe (Z-Vent only — DO NOT cut EZ- Seal Pipe): Length adjustments with Z-Vent pipe can be done by cutting the pipe, following the Z-Vent instructions. Be sure to cut the pipe squarely and to file the cut edge smooth after cutting. Rough pipe ends will damage the seals. Support the pipe when cutting to avoid making the pipe out of round.

5. Adjustable Lengths of EZ-Seal Pipe: Length adjustments with EZ-Seal piping are done with slip-fit adjustable length sections, not by cutting the pipe. Make sure the adjustable length does not jut into elbows or terminations. This could block flue gas and condensate flow.

6. Maximum Vent Piping Length: See the table in Figure 3B.1 for the maximum allowable length. Each elbow causes the same pressure drop as 10 feet of vent pipe, so the allowable length reduces 10 feet for each elbow used in the piping. When 45° elbows are used, two 45° elbows are equivalent to one 90° elbow.

7. Insulate the vent piping where it passes through unheated areas to prevent condensate freeze-up.

8. If the pipe passes through an occupied space, install a chase around the pipe, following the vent pipe instructions and applicable codes.

9. Clearance from Combustible Materials: Provide minimum clearance to all combustible materials of at least 2 inches (51 mm).

10. Using an Existing Chimney as a Chase: The vent piping can be routed through an existing STRAIGHT chimney. DO NOT vent directly into the chimney. Install the vent piping so it can be inspected after installation. Follow vent pipe manufacturer’s instructions for chimney-as-chase installations.

C. SUPPORT THE VENT PIPING

COMPLETELY

1. DO NOT use the boiler vent connection to support the vent piping. Provide support straps from the ceiling or noncombustible saddle or pedestal supports from the floor. This is required on ALL installations, regardless of the length of the horizontal piping connected to the boiler.

2. Install at least one support on every horizontal run. For horizontal runs longer than 5 feet (1.5 m), install a support every 3 feet (0.9 m).

3. Vent piping cannot be supported from above (such as relying on roof jack sections). You must install supports on the horizontal piping before the vent turns upward. Provide a support on the horizontal piping within 6 inches of every upturned elbow to support the vertical run.

4. Follow the vent pipe manufacturer’s instructions for placement and installation of supports.

D. FLOOR AND WALL PENETRATIONS

1. Follow applicable codes and the vent pipe instructions to install fire stops, thimbles or other devices at all floor and wall penetrations.

2. Provide minimum 2 inches (51 mm) clearance to all combustible construction.

E. ROOF PENETRATIONS

Follow applicable codes and the vent pipe instructions to install a roof jack, flashing and support. Long extensions of vent pipe above the roof may require the use of guy supports as specified in the vent pipe instructions.

F. RAIN CAP TERMINATION

1. Use only the rain caps listed in Table 3B.1.

2. The rain cap exhaust opening must be at least 2 feet (0.6 m) above the highest roof point within 10 feet, as shown in Figure 3B.1. See the National Fuel Gas Code, ANSI/NFPA 54 for details on pitched roof applications.

3. See Figure 3B.2 for additional minimum clearances.

Table 3B.1: Vent and Air System Components

Vent Components

92-2 92-4

Heat-Fab Z-Flex Heat-Fab Z-Flex

Vent Piping/Components (Incl. Supports, Thimbles, etc.)

EZ-Seal

3"

Z-Vent

3"

EZ-Seal

4"

Z-Vent

4"

Boiler Adapter (Adapts from EZ-Seal to Z-Vent Piping)

Not

Required

2SVSHTA03

Not

Required

2SVSHTA04

Rain Cap Vent Termination

5300CI 2SVSRCF03 5400CI 2SVSRCF04

Joint Sealant, as Needed

GE RTV106 or Equivalent

Air Components Heat-Fab Z-Flex Heat-Fab Z-Flex

Termination Elbow 9314TERM 2SVSTEX0390 9414TERM 2SVSTEX0490

Termination Pipe Section (1 ft)

9302 2SVEPWCF0301 9402 2SVEPWCF0401

Termination Thimble 9393S 2SVSWTE03 9493S 2SVSWTE04

Gear Clamp (Nose Clamp)

3" Clamp 7HS44XX 4" Clamp 7HS64XX

Air Piping/Components (Incl. Supports, Thimbles, etc.)

3" PVC, CPVC, ABS,

Galvanized or Aluminum

4" PVC, CPVC, ABS,

Galvanized or Aluminum

19

G. AIR PIPE CONNECTION

1. Before installing the air piping, install the air pipe sidewall termination assembly (Item D, Figure 3B.1). See instructions following.

2. Construct the air piping from PVC, CPVC or ABS plastic, or galvanized or aluminum metallic pipe (including flexible aluminum duct if desired).

3. Attach the air piping to the boiler air connection, preferably using silicone RTV to seal the connection. If the boiler room air is free of contaminants you can use metallic duct tape to seal the joints. With age, however, duct tape adhesives can loosen, so duct tape is not as reliable as silicone RTV.

4. If the installation is required to meet direct vent (sealed combustion) requirements, seal all joints withe silicone RTV. The air pipe installation must be air-tight and water-tight.

5. Maximum air piping length: See the table in Figure 3B.1, for the maximum allowable length. Each elbow causes the same pressure drop as 10 feet of vent pipe, so the allowable length reduces 10 feet for each elbow used in the piping. When 45° elbows are used, two 45° elbows are equivalent to one 90° elbow.

H. SUPPORTING AIR PIPING

1. DO NOT use the boiler air connection to support the air piping. Provide support straps from the ceiling or install wall brackets.

2. Provide at least one support on all air pipe installations.

3. Provide a support every 3 feet for air pipe lengths greater than 5 feet horizontally.

4. Provide a support on the horizontal piping within 6 inches of every upturned elbow to support the vertical run.

I. AIR PIPE TERMINATION

1. See Table 3B.1 for part numbers of the sidewall termination components required for Z-Vent and EZSeal air pipe installations. The air piping termination must be constructed using the stainless steel vent materials listed in Table 3B.1 to ensure the configuration is correct. DO NOT terminate the air piping with any other method.

2. Termination Assembly Components:

a. Wall Thimble

: Use only the thimble listed in Table 3B.1. The hole in the thimble will prevent the pipe length (B) from being pushed inward. The raised portion of the pipe female end is too large to pass through the hole in the thimble. Follow the vent pipe manufacturer’s instructions supplied with the thimble. If the wall thimble isn’t long enough for the application, follow the vent manufacturer’s instructions to add an extension.

Alternate Construction

: The air pipe can be inserted through a hole without using a thimble. For this option, attach a storm collar on both the inside and outside walls at the penetration. Before attaching the collars, seal around the air pipe thoroughly with silicone RTV to prevent air leakage or insect access. The storm collar tightens around the vent pipe with a gear clamp. This prevents movement of the finished assembly. You will still need to use the length of vent pipe and the termination elbow described below.

b. Length of Vent Pipe

: Use a 1-foot length of vent pipe as listed in Table 3B.1 unless the wall penetration requires a longer length. If a longer length is required, use a length of EZ-Seal or ZVent long enough for the application.

Insert the pipe from OUTSIDE, male end first. The pipe will stop at the raised section of the female end.

VENT & AIR PIPING: THROUGH THE ROOF

COMBUSTION AIR MUST BE UNCONTAMINATED

Construction dust: If the boiler is operated while the building is under construction it must be protected from wood, concrete, sheet rock and other types of dust. Failure to properly protect the boiler from construction dust will damage the boiler.

Combustion air contaminated with fluorocarbons or other halogenated compounds, such as laundry products, cleaning solvents and refrigerants will result in the formation of acids in the combustion chamber and vent piping. These acids will cause premature failure of the boiler and vent, causing possible severe personal injury, death or substantial property damage.

If the boiler room, or any room through which the air piping travels, may contain contaminants as listed above, you MUST seal air pipe joints with silicone RTV to prevent contaminants from entering the boiler combustion air. The finished air piping installation must be air-tight and water-tight.

WARNING

Figure 3B.2: Termination Minimum Clearances

When using metallic piping, seal all of the longitudinal seam joints in addition to the component joints.

NOTICE

20

VENT & AIR PIPING: THROUGH THE ROOF

c. Gear Clamp: Use a hose clamp or a gear clamp

manufactured by the vent manufacturer (see Table 3B.2).

Slide the clamp over the male end of the pipe after the pipe has been inserted from outside.

From the inside, pull the pipe so it is firmly against the outside plate.

Push the gear clamp against the inside plate and tighten securely. This will prevent the termination assembly from being pushed outward.

d. Termination Elbow

: Use only the termination elbow listed in Table 3B.2. The elbow must be pointed downward.

Before inserting the male end of the elbow into the pipe, apply a bead of silicone RTV and spread around the end.

Insert the termination elbow and secure using the vent pipe manufacturer’s joint assembly procedure.

Termination Location

: Install the air pipe termination where it meets the minimum clearances shown in Figure 3B.4.

Appliance exhaust outlets: Install the air intake at least 2 feet below and 5 feet horizontally from any appliance vent outlet.

Exiting below grade or minimum height: See Figure 3B.5. When the air pipe must exit the building below grade or below the minimum height for the termination elbow, install vertical piping as necessary for the termination elbow to be high enough to meet the minimum clearances of Figure 3B.4. Make sure to support the piping using wall brackets available from the vent pipe manufacturer.

Figure 3B.1: Vertical Venting/Sidewall Air

(Partially Repeated from Page 17)

Figure 3B.4: Minimum Clearances to Air

Termination

Figure 3B.2: Sidewall Air Pipe Termination

Assembly

21

J. MULTIPLE BOILER INSTALLATIONS

1. Venting Multiple Boilers: a. Each boiler must be individually vented. DO NOT

use combined venting.

b. Install multiple vents through the roof following all

guidelines for single-vent installations.

c. Install the vents so they are no closer than 12

inches on centers.

2. Air Piping for Multiple Boilers: a. Air for each boiler must be individually piped. DO

NOT use combined air piping.

b. Install multiple air pipes through the side wall

following all guidelines for single-air pipe installations.

c. Install the terminations so they are no closer than

12 inches on centers.

VENT & AIR PIPING: THROUGH THE ROOF

Figure 3B.2: Using External Piping to Raise the

Termination

22

A. BOILER VENT CONNECTION

1. The vent connection at the boiler is for Heat-Fab EZSeal vent piping only. To use Z-Flex Z-Vent venting you must install the Z-Vent adapter, part number 2SVSHTA03 (92-2) or 2SVSHTA04 (92-4).

2. EZ-Seal Connection: Insert EZ-Seal pipe male end into the boiler connection. Make sure the locking tabs slide under the EZ-Seal locking ring. Bend back locking tabs to complete the joint. Follow EZ-Seal instructions to complete the vent piping installation.

3. Z-Vent Adapter Installation: Insert male end of adapter into boiler vent connection. Make sure the locking tabs slide under the gear clamp on the adapter. Bend back the locking tabs (as in left illustration above). Then tighten the adapter gear clamp to finish the connection. Follow Z-Vent instructions to connect Z-Vent piping.

The vent piping operates with positive pressure. The vent piping must be completely sealed and securely supported.

Use only the vent components listed in this manual. Use of any other materials could result in vent system failure.

Exposed vent pipe poses a potential burn hazard to people and pets. Insulate or shield the pipe where necessary to prevent risk.

Never drill through, or install screws into, the vent pipe or vent components.

Failure to properly install the vent piping could result in flue gas leakage, causing possible severe personal injury, death or substantial property damage.

WARNING

Terminate the vent and air piping following the guidelines in this manual. Avoid vent termination locations likely to be affected by winds, snowdrifts, people and pets. Protect building materials and vegetation from degradation caused by the flue gases and condensation.

WARNING

Code compliance – Follow all applicable local codes when installing the vent system. Where codes differ from this manual, follow code requirements. Contact PB Heat if you have any questions regarding the installation.

NOTICE

Figure 3C.1: Vertical Venting

VENT & AIR PIPING: THROUGH THE ROOF

3C. VENT PIPING: THROUGH THE ROOF

(SEPARATE TERMINATIONS)

EZ-Seal Vent Attachment Z-Vent Adapter

Attachment

23

4. Slope horizontal runs toward the boiler. All horizontal runs of vent pipe must slope continuously at least 1/4" per foot (21 mm per meter) to ensure condensate drains completely back to the boiler. DO NOT install the vent piping with any sections that could trap condensate.

B. VENT PIPING COMPONENTS

1. See Table 3C.1 for acceptable vent components. NO OTHER vent materials are acceptable.

2. Carefully follow the instructions supplied by the vent piping manufacturer.

3. The vent joints seal with elastomer rings in the pipe and fittings. Avoid damaging these seals.

4. Cutting Z-Vent Pipe (Z-Vent only — DO NOT cut EZ- Seal Pipe): Length adjustments with Z-Vent pipe can be done by cutting the pipe, following the Z-Vent instructions. Be sure to cut the pipe squarely and to file the cut edge smooth after cutting. Rough pipe ends will damage the seals. Support the pipe when cutting to avoid making the pipe out of round.

5. Adjustable Lengths of EZ-Seal Pipe: Length adjustments with EZ-Seal piping are done with slip-fit adjustable length sections, not by cutting the pipe. Make sure the adjustable length does not jut into elbows or terminations. This could block flue gas and condensate flow.

6. Maximum Vent Piping Length: See the table in Figure 3C.1 for the maximum allowable length. Each elbow causes the same pressure drop as 10 feet of vent pipe, so the allowable length reduces 10 feet for each elbow used in the piping. When 45° elbows are used, two 45° elbows are equivalent to one 90° elbow.

7. Insulate the vent piping where it passes through unheated areas to prevent condensate freeze-up.

8. If the pipe passes through an occupied space, install a chase around the pipe, following the vent pipe instructions and applicable codes.

9. Clearance from combustible materials: Provide minimum clearance to all combustible materials of at least 2 inches (51 mm).

10. Using an existing chimney as a chase: The vent piping and air piping can be routed through an existing UNUSED and STRAIGHT chimney. DO NOT vent directly into the chimney. Install the vent piping so it can be inspected after installation. Follow vent pipe manufacturer’s instructions for chimney-as-chase installations.

C. SUPPORT THE VENT PIPING

COMPLETELY

1. DO NOT use the boiler vent connection to support the vent piping. Provide support straps from the ceiling or noncombustible saddle or pedestal supports from the floor. This is required on ALL installations, regardless of the length of the horizontal piping connected to the boiler.

2. Install at least one support on every horizontal run. For horizontal runs longer than 5 feet (1.5 m), install a support every 3 feet (0.9 m).

3. Vent piping cannot be supported from above (such as relying on roof jack sections). You must install supports on the horizontal piping before the vent turns upward. Provide a support on the horizontal piping within 6 inches of every upturned elbow to support the vertical run.

4. Follow the vent pipe manufacturer’s instructions for placement and installation of supports.

D. FLOOR AND WALL PENETRATIONS

1. Follow applicable codes and the vent pipe instructions to install fire stops, thimbles or other devices at all floor and wall penetrations.

2. Provide minimum 2 inches (51 mm) clearance to all combustible construction.

E. ROOF PENETRATIONS

Follow applicable codes and the vent pipe instructions to install a roof jack, flashing and support. Long extensions of vent pipe above the roof may require the use of guy supports as specified in the vent pipe instructions.

F. RAIN CAP TERMINATION

1. Use only the rain caps listed in Table 3C.1.

2. The rain cap exhaust opening must be at least 2 feet (0.6 m) above the highest roof point within 10 feet, as shown in Figure 3C.1. See the National Fuel Gas Code, ANSI/NFPA 54 for details on pitched roof applications.

Table 3C.1: Vent System Components

VENT & AIR PIPING: THROUGH THE ROOF

Vent Components

92-2 92-4

Heat-Fab Z-Flex Heat-Fab Z-Flex

Vent Piping/Components (Incl. Supports, Thimbles, etc.)

EZ-Seal

3"

Z-Vent

3"

EZ-Seal

4"

Z-Vent

4"

Boiler Adapter (Adapts from EZ-Seal to Z-Vent Piping)

Not

Required

2SVSHTA03

Not

Required

2SVSHTA04

Rain Cap Vent Termination

5300CI 2SVSRCF03 5400CI 2SVSRCF04

Joint Sealant, as Needed

GE RTV106 or Equivalent

Air Components Heat-Fab Z-Flex Heat-Fab Z-Flex

Rain Cap Termination 5300CI 2SVSRCF03 5400CI 2SVSRCF04

Termination Pipe Section (3 ft)*

9307 2SVEPWCF0303 9407 2SVEPWCF0304

*Note: Standard air piping termination pipe section is 3 feet. A longer length can be

used if needed.

Air Piping/Components (Incl. Supports, Thimbles, etc.)

3" PVC, CPVC, ABS,

Galvanized or Aluminum

4" PVC, CPVC, ABS,

Galvanized or Aluminum

24

3. See Figure 3C.2 for additional minimum clearances. The vent must always terminate at least 4 feet (1.2 m) above the air intake termination.

G. AIR PIPE CONNECTION

1. Construct the air piping from PVC, CPVC or ABS plastic, or galvanized or aluminum metallic pipe (including flexible aluminum duct if desired).

2. Attach the air piping to the boiler air connection, preferably using silicone RTV to seal the connection. If the boiler room air is free of contaminants you can use metallic duct tape to seal the joints. With age, however, duct tape adhesives can loosen, so duct tape is not as reliable as silicone RTV.

3. If the installation is required to meet direct vent (sealed combustion) requirements, seal all joints with silicone RTV. The air pipe installation must be air-tight and water-tight.

4. The air piping connects to the stainless steel pipe section attached to the air intake rain cap termination (Item F, Figure 3C.1). See instructions following.

5. Maximum air piping length: See the table in Figure 3C.1 for the maximum allowable length. Each elbow causes the same pressure drop as 10 feet of vent pipe, so the allowable length reduces 10 feet for each elbow used in the piping. When 45° elbows are used, two 45° elbows are equivalent to one 90° elbow.

H. SUPPORTING AIR PIPING

1. DO NOT use the boiler air connection to support the air piping. Provide support straps from the ceiling or install wall brackets.

2. Provide at least one support on all air pipe installations.

3. Provide a support every 3 feet for air pipe lengths greater than 5 feet horizontally.

4. Provide a support on the horizontal piping within 6 inches of every upturned elbow to support the vertical run.

I. AIR PIPE TERMINATION

1. See Table 3C.1 for part numbers of the vertical termination components required for Z-Vent and EZSeal air pipe installations. The air piping termination must be constructed using the stainless steel vent materials listed in Table 3C.1 to ensure the configuration is correct. DO NOT terminate the air piping with any other method.

2. Termination Assembly Components:

a. Rain Cap

: Use only the rain cap listed in Table 3C.1, the same cap as used on the vent termination.

Install the rain cap so it meets the minimum clearances shown in Figure 3C.2.

b. Length of Vent Pipe

: Use a 3-foot length of vent pipe as listed in Table 3C.1 unless the roof penetration requires a longer length to meet minimum clearances. If a longer length is required, use a length of EZ-Seal or Z-Vent long enough for the application.

Attach the air piping to the male end (bottom end) of the stainless steel pipe.

c. Roof penetration components: Use the same

components as used for the vent penetration.

VENT & AIR PIPING: THROUGH THE ROOF

COMBUSTION AIR MUST BE UNCONTAMINATED

Construction dust: If the boiler is operated while the building is under construction it must be protected from wood, concrete, sheet rock and other types of dust. Failure to properly protect the boiler from construction dust will damage the boiler.

Combustion air contaminated with fluorocarbons or other halogenated compounds, such as laundry products, cleaning solvents and refrigerants will result in the formation of acids in the combustion chamber and vent piping. These acids will cause premature failure of the boiler and vent, causing possible severe personal injury, death or substantial property damage.

If the boiler room, or any room through which the air piping travels, may contain contaminants as listed above, you MUST seal air pipe joints with silicone RTV to prevent contaminants from entering the boiler combustion air. The finished air piping installation must be air-tight and water-tight.

WARNING

When using metallic piping, seal all of the longitudinal seam joints in addition to the component joints.

NOTICE

Figure 3C.2: Termination Minimum Clearances

25

J. MULTIPLE BOILER INSTALLATIONS

1. Venting Multiple Boilers: a. Each boiler must be individually vented. DO NOT

use combined venting.

b. Install multiple vents through the roof following all

guidelines for single-vent installations.

c. Install the vents so they are no closer than 12

inches on centers.

d. Provide minimum 5 feet between the center line

of any vent termination and any air intake termination.

2. Air Piping for Multiple Boilers: a. Air for each boiler must be individually piped. DO

NOT use combined air piping.

b. Install multiple air pipes through the side wall

following all guidelines for single-air pipe installations.

c. Install the terminations so they are no closer than

12 inches on centers.

d. Provide minimum 5 feet between the center line

of any vent termination and any air intake termination.

VENT & AIR PIPING: THROUGH THE ROOF

26