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UTICA BOILERS
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UBSSC-100

UTICA BOILERS UBSSC-050, UBSSC-075, UBSSC-100, UBSSC-150, UBSSC-200 Installation, Operation & Maintanance Manual

Models
UBSSC- 1 00 UBSSC- 1 50 UBSSC-200
WALL MOUNTED
GAS BOILER
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
An ISO 9001-2008 Certified Company
Manufacturedby:
ECRInternational,Inc.
2201 Dwyer Avenue, Utica NY 13504-4729 web site: www.ecrinternational.com
H
P/N# 240008845, Rev. C [06/2011]
FIGURE 1-1 Dimensions
DIMENSIONS
(D)
Wall Hanging
Bracket
(D)
Vent Connector
Safety Relief Valve Connection (¾ NPT)
(F)
Combustion Air
(A)
(B)
Models
Width (A)
Height (B)
Depth (C)
Bracket (D)
Water
Connections
Gas
Connection
Condensate Drain
Connection (H)
Weight
Vent Connector
Table 1 : Physical Data
050/075/100 150/200
20"
(508mm)
31"
(787mm)
14"
(356mm)
28"
(711mm)
Location
(I)
Size (E) 1-1/4" NPT
Location
(J)
Size (G)
Shipping
Unit
2"
(51mm)
4-1/2"
(114mm)
1/2"
NPT
3/4" NPT
111 lb
(50 kg)
91 lb
(41 kg)
2"
(51mm)
23"
(584mm)
42"
(1092mm)
16.0"
(406mm)
40"
(1016mm)
2"
(51mm)
1-1/4" NPT
4-1/2"
(114mm)
3/4"
NPT
3/4" NPT
~182 lb (83 kg)
~157 lb (71 kg)
3"
(76mm)
(C)
(I)
(J)
Supply Water (E)
Gas Connection (G)
Return Water (E)
Condensate Drain Connection (H)
2
TABLE OF CONTENTS
1 - Introduction ............................................................................................................................... 4
2 - Important Safety Information .................................................................................................... 5
3 - Component Listing .....................................................................................................................6
4 - Locating Boiler ...........................................................................................................................9
5 - Hydronic Piping ........................................................................................................................11
5.2 Special Conditions ................................................................................................................... 11
5.3 Safety Relief Valve and Air Vent .... ............................................................................................11
5.4 Trim Piping ............................................................................................................................. 12
5.5 System Piping ......................................................................................................................... 12
6 - Combustion Air And Vent Piping ............................................................................................... 17
6.2 Removal of Existing Boiler From Common Vent System..................................................................17
6.3 Materials ............................................................................................................................... 17
6.4 Pipe Installation ...................................................................................................................... 18
6.5 Termination ............................................................................................................................ 18
6.6 Condensate Piping ................................................................................................................... 24
7 - Gas Supply Piping ....................................................................................................................25
8 - Electrical Connections .............................................................................................................. 27
8.3 Line Voltage Connections .......................................................................................................... 27
8.4 External Connections ............................................................................................................... 27
9 - Start Up Procedure ................................................................................................................... 29
9.6 CSD-1 Compliance Test.............................................................................................................32
10 - Operating Instructions ........................................................................................................... 33
11 - General Maintenance And Cleaning ........................................................................................ 34
12 - Ratings And Capacities ........................................................................................................... 38
13 - Troubleshooting .....................................................................................................................39
14 - Wiring Diagram ......................................................................................................................53
15 - Glossary .................................................................................................................................55
Appendix A - Control Module ......................................................................................................... 57
1.1 Front Panel Status Indicators .................................................................................................... 57
2.1 Introduction ........................................................................................................................... 58
2.2 Operation ............................................................................................................................... 58
2.3 Status Indication ..................................................................................................................... 58
2.4 Sequence of Operation ............................................................................................................. 59
2.5 Theory of Operation................. ............................................................................................... 61
Check our website frequently for updates: www.ecrinternational.com
Information and specifi cations outlined in this manual in effect at the
time of printing of this manual. ECR International reserves the right to
discontinue, change specifi cations or system design at any time without
notice and without incurring any obligation, whatsoever.
3
1 - INTRODUCTION
1.1 Designated Use
Hot water heating boiler.• Indoor installation.• Closet or alcove installation.• Direct vent boiler.• For use with natural gas or liquefi ed petroleum gases •
(LP/propane).
1.2 The unit MUST NOT:
• Directly heat potable water. Indirect heating is acceptable.
• Heat water with non-hydronic heating system chemicals present (example, swimming pool water).
Exceed 50 psig (344 kPa) system pressure.• Exceed 195°F (90.5°C) system design temperature.•
1.3 Operational Features
Modulating: 20-100%.• Integral Dual Limit.• Integral Low Water Cutoff (with test button).• Outdoor Temperature Reset.• Integral Multiple Boiler Control.•
4
!
This is the safety alert symbol. Symbol alerts you to potential personal injury hazards. Obey all safety messages following this symbol to avoid possible injury or death.
2.2
Become familiar with symbols identifying
potential hazards.
2 - IMPORTANT SAFETY INFORMATION
2.1 General
Boiler installation shall be completed by qualifi ed agency. See glossary for additional information.
WARNING
!
Fire, explosion, asphyxiation and electrical shock hazard. Improper installation could result in death or serious injury. Read this manual and understand all requirements before beginning installation.
2.2
Become familiar with symbols identifying
potential hazards.
This is the safety alert symbol. Symbol alerts you to potential personal injury hazards. Obey all safety messages following this symbol to avoid possible injury or death.
!
DANGER
Indicates a hazardous situation which, if not avoided, WILL result in death or serious injury
2.3 Installation shall conform to requirements of authority having jurisdiction or in absence of such requirements:
National Fuel Gas Code, ANSI Z223.1/NFPA 54• National Electrical Code, NFPA 70.•
2.4 Where required by authority having
jurisdiction, installation shall conform to Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1.
Additional manual reset low water cutoff may be required.
2.5 Requirements for Commonwealth of Massachusetts:
Boiler installation must conform to Commonwealth of Massachusetts code 248 CMR which includes but is not
limited to:
Installation by licensed plumber or gas fi tter.•
.
!
WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
!
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE
Used to address practices not related to personal injury.
5
3 - COMPONENT LISTING
Return Water From Heating System (In)
(see
page 8)
-
Connection supplied at bottom of boiler.
Low Voltage Terminal Strip
(see page 8) -
Connection of all low voltage wiring, including thermostat. See section
8.
Heat Exchanger Pump
Gas Shutoff Valve
- Fuel supply isolation
during servicing. See section 7
Combustion Air Blower
- Delivers proper quantity of combustion air, receives fuel from gas valve, mixes air and fuel sending mixture to burner for combustion.
Gas (Control) Valve
- Delivers proper quantity of fuel to Combustion Air Blower. See section 7.
High Temperature Supply Switch
Low Water Cutoff
Senses inadequate quantity of water. Turns off boiler before damage can occur.
8
Gas Connection
See section 7.
Control Module
3.1 Component Listing
User Interface
1.
information regarding boiler condition. Allows adjustment of boiler operating parameters. NOTE: Does not replace thermostat used to control central heating space.
2.
Combustion Air Inlet (2"/3")
Return Water From Heating System (In)
3.
page 8)
Low Voltage Terminal Strip
4.
Connection of all low voltage wiring, including thermostat. See section
Igniter
5.
Flame Sensor
6.
Sight Glass
7.
burner fl ame.
-
Connection supplied at bottom of boiler.
(see page 8)
(see Appendix A) - Displays
(see page 7 & 8)
(see
(see page 8) -
8.
(see page 8)
(see page 8) - Permits observation of
Gas (Control) Valve
20.
proper quantity of fuel to Combustion Air Blower. See section 7.
High Temperature Supply Switch
21.
Low Water Cutoff
22.
quantity of water. Turns off boiler before damage can occur.
Safety Relief Valve
23.
supplied, Field installed. See section 5.
High Voltage Junction Box
24.
connection of 120V components. See section
Vent Connector
25.
Gas Connection
26.
Wall Hanging Support Bracket
27.
Integral to boiler. Allows wall mounting when used with supplied wall mounting bracket. See section 4.
(see page 8)
(see page 8) --
(see pages 7 & 8) - Factory
(see page 8) - For
(see pages 7 & 8) - See section 6. (see page 8)
- Delivers
(see page 8)
Senses inadequate
See section 7.
(see page 7) -
8.
Burner
8.
Heat Exchanger
9.
Condensate Collector
10.
Return Temperature Sensor
11.
Drain Valve
12.
Heat Exchanger Ball Valve
13.
Supply Water Outlet to Heating System (Out)
14.
(see page 8) - Connections supplied for connecting from bottom of boiler. See section 5.
Vent Temperature Sensor
15.
Condensate Drain
16.
a liquid (condensate) as a by-product of combustion. Condensate must be piped to appropriate drain. See section 6.
Heat Exchanger Pump
17.
(see page 35)
(see page 8)
(see page 8)
(see page 8)
(see page 12)
(see page 8)
(see page 8)
(see page 8) - Boiler produces
(see page 8)
Air Vent
28.
Control Module
29.
Lower Jacket Panel
30.
then forward to access.
Transformer
31.
water cutoff.
Pressure Test Port
32.
Combustion Analysis Test Port
33.
Return Water Sensor -
34.
User Interface -
35.
(see page 7 & 8)
(see page 8)
(see page 7) - Gently pull upward
(see page 8) - Supplies 24V power to low
- (see page 8)
(see page 8)
(see page 8)
- (see page 8)
Gas Shutoff Valve
18.
during servicing. See section 7
Combustion Air Blower
19.
proper quantity of combustion air, receives fuel from gas valve, mixes air and fuel sending mixture to burner for combustion.
(see page 8)
(see page 8)
- Fuel supply isolation
- Delivers
6
3 - COMPONENT LISTING
SAFETY RELIEF VALVE
AIR VENT
WALL HANGING
SUPPORT BRACKET
FIGURE 3-1 Boiler Components (Viewed from Back of Boiler)
VENT CONNECTOR
COMBUSTION
AIR INLET
WALL HANGING
SUPPORT BRACKET
AIR VENT
SAFETY RELIEF VALVE
NOTE:
See Section 5-3
For Safety Relief
Valve Piping Instructions
FIGURE 3-2 Lower Jacket (Viewed from front of boiler)
Disconnect connector
Lower Jacket
Connector to User
Interface
before removing Lower
Jacket
FIGURE 3-3 Upper and Lower Jacket Latch
(Viewed from front of boiler)
Upper and Lower
Jacket Latch
Lift Jacket up,
engage jacket with chasis
push down.
7
3 - COMPONENT LISTING
GAS SHUTOFF
VALVE
COMBUSTION
AIR
BLOWER
GAS (CONTROL)
VALVE
LOW WATER
CUTOFF
SAFETY RELIEF VALVE
AIR VENT
HEAT EXCHANGER
PUMP
HEAT
EXCHANGER
RETURN WATER
FROM HEATING
SYSTEM (IN)
SUPPLY WATER TO
HEATING SYSTEM
(OUT)
LOW VOLTAGE
TERMINAL STRIP
IGNITER
SIGHT GLASS
GAS CONNECTION
CONDENSATE
DRAIN
COMBUSTION
ANALYSIS TEST
PORT
HIGH VOLTAGE JUNCTION BOX
HEAT EXCHANGER
BALL VALVE
USER INTERFACE
3 - COMPONENT LISTING
FIGURE 3-4 Boiler Components (View from Front of Boiler)
AIR VENT
HIGH TEMPERATURE
SUPPLY SWITCH
LOW WATER
CUTOFF
GAS (CONTROL)
VALVE
SAFETY RELIEF VALVE
VENT CONNECTOR
NOTE:
See Section 5
For Piping
Instructions
COMBUSTION
AIR INLET
IGNITER
FLAME
SENSOR
SIGHT GLASS
COMBUSTION
AIR
BLOWER
GAS SHUTOFF
VALVE
(SHOWN IN OPEN
POSITION)
HEAT EXCHANGER
PUMP
COMBUSTION
ANALYSIS TEST
PORT
VENT
TEMPERATURE
SENSOR
CONDENSATE
COLLECTOR
LOW VOLTAGE
TERMINAL STRIP
PRESSURE
TEST PORT
USER INTERFACE
CONTROL
MODULE
Fuse and
Holder
HEAT
EXCHANGER
TRANSFORMER
RETURN WATER
SENSOR (Located
behind piping)
CONDENSATE
DRAIN
HIGH VOLTAGE JUNCTION BOX
SUPPLY WATER TO
HEATING SYSTEM
(OUT)
HEAT EXCHANGER
BALL VALVE
RETURN WATER
FROM HEATING
SYSTEM (IN)
GAS CONNECTION
8
4 - LOCATING BOILER
4.1 Boiler Location Considerations
Ambient room temperature always above 32°F (0°C) to • prevent freezing of liquid condensate.
Approved for installation in closets.• Protect gas ignition system components from water •
(dripping, spraying, rain, etc.) during operation and service (circulator replacement, condensate trap, control replacement, etc.).
Wall mounting. •
Wall must be plumb and capable of supporting boiler • weight plus 60 lbs (28 kg). See Table 1.
Wall mounting. See section 4.2.•
Access to outdoors to meet minimum and maximum • pipe lengths for combustion air and vent piping. See section 6.
Disposal of condensate. See section 6.• Drainage of water (or water - antifreeze solution) during •
boiler service or from safety relief valve discharge. See section 5.
Access to system water piping, gas supply, and electrical • service. See sections 5, 7 and 8.
FIGURE 4-1 Clearance to Combustible Materials
A
B
F
A
C
F
FLOOR
A
E
Clearances to combustible materials and service • clearances. See Table 2 and fi gure 4-1.
Multiple Boilers can be wall mounted, placed side by • side, or back to back.
TABLE 2: BOILER CLEARANCES
Dimension
Left Side (B)
Right Side (C)
Front (D)
Bottom (F)
Combustion Air/Vent
Hot Water Piping
(1)
Required distances measured from boiler.
(2)
Service, proper operation clearance recommendation.
Model
Top (A)
Back (E)
piping
E
F
Combustible
Materials
050/075/100/
150/200
0" (0 cm) 14" (36 cm) 0" (0 cm) 0" (0 cm) 0" (0 cm) 0" (0 cm) 0" (0 cm) 6" (16 cm) 0" (0 cm) 0" (0 cm) 0" (0 cm) 12" (32 cm)
0" (0 cm)
½" (1.3 cm) 6" (16 cm)
(1)
Service
050/075/100/
150/200
6" (16 cm)
D
F
FLOOR
(1)(2)
9
4 - LOCATING BOILER
!
FIGURE 4-2 Wall Mount Bracket Engaged with Bracket on Boiler
Center brackets. Avoid
overhang on sides of wall
mount bracket.
4 Slots for attaching Wall
Mount Bracket to Studs
4.2 Prepipe supply and return water connections with factory fi ttings before wall mounting.
4.3 Wall Mounting
Mount boiler on wall using wall mounting bracket included with unit.
Structure must be capable of supporting boiler weight • plus 60 lbs (28 kg). See Table 1, page 2.
Wall mount bracket has 4 slots allowing mounting on • two (2) wall studs spaced at 11½" to 16½" on center. See fi gure 4-2.
Boiler includes (4) 3/8" x 3" lag screws and (4) washers • for attaching wall mount bracket to wood studs. Field source appropriate fasteners for other wall constructions (masonry, concrete).
Attach wall mount bracket level on wall.• Boiler must engage with wall mount bracket. • Avoid overhang on sides of wall mount bracket. Verify •
boiler bracket is centered on wall bracket. See fi gure 4-2.
!
CAUTION
Boiler weight exceeds 75 pounds (34 kg). Do not lift boiler onto wall without assistance.
10
5 - HYDRONIC PIPING
5.1 General
Install piping in accordance with authority having jurisdiction.•
NOTICE
Use two (2) wrenches when tightening and fi tting to pipe boiler's threaded fi ttings. Boiler's internal piping can be damaged if subjected to excessive torque.
Support system piping and safety relief valve discharge • piping. Boiler's internal piping and wall mount bracket can be damaged if subjected to excessive weight.
Size central heating pump (and domestic hot water pump, • if used) for system requirements only. Heat exchanger pump compensates for pressure drop through boiler internal piping and heat exchanger.
Thoroughly clean and fl ush system before connecting to • boiler.
5.2 Special Conditions
System piping exposed to freezing conditions: Use • inhibited proplyene glycol solutions certifi ed by fl uid manufacturer for use with closed water heating system. Do not use automotive or ethylene glycol.
!
WARNING
Poison hazard. Ethylene glycol is toxic. Do not use • ethylene glycol.
Never use automotive or standard glycol antifreeze, • even ethylene glycol made for hydronic systems.
Ethylene glycol can attack gaskets and seals used in • hydronic systems.
Use only inhibited proplyene glycol solutions certifi ed • by fl uid manufacturer as acceptable for use with closed water heating system.
Thoroughly clean and fl ush any system that used glycol • before installing new Boiler.
Provide user with Material Safety Data Sheet (MSDS) • on fl uid used.
NOTICE
Do not expose boiler and condensate piping to freezing temperatures.
Boiler installed above radiation level (or as required by • authority having jurisdiction). Integral low water cutoff provided in boiler. See page 6.
Boiler used in connection with refrigeration system. • Install piping in parallel with boiler, with appropriate valves to prevent chilled medium from entering boiler.
System piping connected to heating coils located in air • handling unit exposed to refrigerated air circulation. Install fl ow control valves or other automatic means to prevent gravity circulation of boiler water during cooling cycle.
5.3 Safety Relief Valve and Air Vent
NOTICE
Boiler rated at 50 psig (345 kPa) maximum allowable working pressure. Boiler provided with 30 psig (206 kPa) safety relief valve. Field source safety relief valve for system pressures greater than 30 psig (206 kPa). Temperature Pressure Gauge and Air Vent satisfactory for 30-50 psig (206-345 kPa) operation.
FIGURE 5-1 Safety Relief Valve & Air Vent (View from front of boiler)
Safety Relief
Valve
Air Vent
3/4"F x 3/4"M
NPT Tee
3/4 NPT
3/4" x 1/4" NPT
90° Elbow
3/4" NPT
Close Nipple
Install safety relief valve and air vent using pipe fi ttings • provided with boiler. See fi gure 5-1
Install safety relief valve with spindle in vertical position.• Do not install shutoff valve between boiler and safety •
relief valve. Install discharge piping from safety relief valve. See •
Position Air Vent and Safety Relief Valve
to provide space for discharge piping.
11
5 - HYDRONIC PIPING
!
WARNING
Burn and scald hazard. Safety relief valve could discharge steam or hot water during operation. Install discharge piping per these instructions.
FIGURE 5-2 Safety Relief Valve Discharge Piping
Safety Relief Valve
5.4 Trim Piping
fi gure 5-2.
Use ¾" or larger pipe.• Use pipe suitable for temperatures of 375°F (191°C) •
or greater. Individual boiler discharge piping shall be independent •
of other discharge piping. Size and arrange discharge piping to avoid reducing •
safety relief valve relieving capacity below minimum relief valve capacity stated on rating plate.
Run pipe as short and straight as possible to location • protecting user from scalding and properly drain piping.
Install union, if used, close to safety relief valve outlet.• Install elbow(s), if used, close to safety relief valve •
outlet and downstream of union (if used). Terminate pipe with plain end (not threaded).•
Temperature - Pressure Gauge. Install temperature • pressure gauge using nipple, tee and bushing provided with boiler. See fi gure 5-3.
Check Local Codes
For Maximum
Distance To Floor
FIGURE 5-3 Temperature Pressure Gauge and Drain Valve Installations
Gas Supply
Drain Valve. Install drain valve using nipple, tee and • bushing provided with boiler. See fi gure 5-3.
5.5 System Piping
Systems with automatic fi ll valves require back fl ow • prevention device.
Single boiler system. See fi gures 5-4, 5-5, 5-6, 5-7 for • general guidance. Additional considerations:
Control system designed for single central heating • pump. Installer responsible for integration of multiple central heating pumps.
Control system allows domestic hot water • prioritization. Function could be lost if central heating pump not directly connected to control system.
Multiple boiler system. See fi gure 5-8 for general • guidance. Additional considerations:
Control system requires equivalent water • temperatures entering each boiler to properly sequence and adjust system supply temperature.
Install multi boiler sensor kit. See "Parts, Kits & • Optional Accessories" manual for part number.
Temperature Pressure
Gauge shown at
System Supply
Connection
Drain Valve shown
at System Return
Connection to Boiler
12
5 - HYDRONIC PIPING
NOTICE
Illustrations are meant to show system piping concept only. Installer responsible for all equipment and detailing required by authority having jurisdiction.
FIGURE 5-4 System Piping
Safety Relief Valve
Piping Legend
Check Local Codes
For Maximum
Distance To Floor
System
Supply
FLOOR
System
Return
13
5 - HYDRONIC PIPING
5-5 TWO-PIPE ZONED SYSTEM WITH VALVES
DHW Pump
CH/System
Pump
Heat exchanger
ball valve open
(as shipped)
5-6 TWO-PIPE ZONED SYSTEM WITH PUMPS
DHW Pump
Zone
Pump
3/8"/10mm
Open End
Wrench
Heat exchanger
ball valve open
(as shipped)
3/8"/10mm
Open End
Wrench
14
5 - HYDRONIC PIPING
5-7A SINGLE BOILER USING PRIMARY/SECONDAY PUMPING
12"/305mm Max. apart
12"/305mm Max. apart
CH/System
Existing closely spaced tees
in primary system loop
Limit length
Pump
Heat exchanger
ball valves closed
5-7B SINGLE BOILER USING PRIMARY/SECONDAY PUMPING
to
5'/1.6 m
3/8"/10mm Open
End Wrench
12"/305mm Max. apart
12"/305mm Max. apart
CH/System
Pump
Heat exchanger
ball valve open
Existing closely spaced tees
in primary system loop
Limit length
to
5'/1.6 m
3/8"/10mm Open
End Wrench
15
5 - HYDRONIC PIPING
5-8 TYPICAL MULTIPLE BOILER PIPING - (See Multiple Boiler Guide)
DHW Pump
CH/
System
Pump
12"/305mm Max. apart
System
T emperature
Sensor
Size common piping
according to
maximum heat
capacity of
entire system
Up to 16
boilers
All heat exchanger
ball valves closed
3/8"/10mm Open
End Wrench
(See Multiple Boiler Guide)
16
6 - COMBUSTION AIR AND VENT PIPING
6.1 General
This boiler requires a dedicated direct vent system. Install combustion air and vent piping in accordance with these instructions, authority having jurisdiction, and
National Fuel Gas Code, ANSI 223.1/NFPA 54.
Vent connections serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems operating under positive pressure.
Install vent system in accordance with these instructions.
6.2 Removal of Existing Boiler From Common Vent System
When existing boiler is removed from common venting system, common venting system is likely to be too large for proper venting of appliances remaining connected to it.
After removal of existing boiler, following steps shall be followed with each appliance remaining connected to common venting system placed in operation, while other appliances remaining connected to common venting system are not in operation:
Seal any unused openings in common venting system.• Visually inspect venting system for proper size and •
horizontal pitch. Determine there is no blockage or restrictions, leakage, corrosion and other defi ciencies which could cause an unsafe condition.
When practical, close all building doors, windows, and • all doors between space in which appliances remaining connected to common venting system are located and other spaces of building. Turn on clothes dryer and any appliance not connected to common venting system. Turn on exhaust fans, such as range hoods and bath­room exhaust so they will operate at maximum speed. Do not operate summer exhaust fan. Close fi replace dampers.
Turn on appliance being inspected. Follow lighting • instructions. Adjust thermostat so appliances will operate continuously.
Any improper operation of common venting system • should be corrected so installation conforms with National Fuel Code, ANSI Z223.1/NFPA 54. When re-sizing any portion of common venting system, common venting system should be re-sized to approach minimum size as determined using appropriate tables in Chapter 13 of the National Fuel Gas Code, ANSI Z223.1/NFPA 54.
6.3 Materials
See Table 3•
Table 3 - Combustion air and vent pipe fi ttings
must conform with the following:
Item Material Standards
PVC schedule 40 ANSI/ASTM D1785
PVC - DWV ANSI/ASTM D2665
CPVC schedule 40
Vent Pipe
and Fittings
Pipe
Cement/
Primer
IPEX is approved vent manufacturer in Canada listed • to ULC-S636.
IPEX System 636 Cements and Primers are approved • in Canada listed to ULC-S636.
SDR-21 & SDR-26 PVC ANSI/ASTM D2241
ABS-DWV ANSI/ASTM D2661
Schedule 40 ANSI/ASTM F628
PVC ANSI/ASTM D2564
CPVC ANSI/ASTM F493
Schedule 40 ABS ANSI/ASTM D2235
DO NOT USE CELLULAR (FOAM) CORE PIPE
ANSI/ASTM D1784/
F441
Test for spillage at draft hood relief opening after 5 • minutes of main burner operation. Use fl ame of match or candle, smoke from cigarette, cigar or pipe.
Determine each appliance remaining connected to • common venting system properly vents when tested as outlined above. Then return doors, windows, exhaust fans and any other gas-burning appliance to their previous condition of use.
!
WARNING
Use of cellular core PVC for venting fl ue gas could result in death, serious injury.
17
6 - COMBUSTION AIR AND VENT PIPING
6.4 Pipe Installation
Minimum and maximum combustion air and vent pipe • lengths listed in Table (3). Pipe length counted from combustion air connector to termination.
Install fi eld-sourced 2" to 3" transition, if used, in vertical • section at combustion air inlet and vent connector.
90° elbows equivalent to 5.0 ft (1.6 m). 45° elbows • equivalent to 3.5 ft (1.1 m). 2" to 3" transition has no equivalent length.
Slope vent pipes minimum 1/4" per foot (21 mm/m) • back toward boiler. Support horizontal sections to prevent sags capable of accumulating condensate.
Support piping in accordance with pipe manufacturer's • instruction and authority having jurisdiction. In absence of manufacturer's instruction use pipe hooks, pipe straps, brackets, or hangers of adequate and strength located at intervals of 4 ft (1.2m) or less. Allow for expansion/contraction of pipe.
Combustion air and vent piping must be air tight and • water tight.
Certifi ed vent system components must NOT be inter-• changed with other vent systems or unlisted pipe/fi ttings.
6.5 Termination
Terminate combustion air and vent pipes with fi ttings or • concentric vent kit.
See "Parts, Kits and Optional Accessories" manual • for concentric vent kit part numbers.
Use horizontal pipe for vent and 90° elbow for • combustion air termination when using fi ttings.
Terminate combustion air and vent pipes in same • atmospheric pressure zone through exterior sidewall or roof.
Locate combustion air termination as far as possible • from swimming pool, swimming pool pump house, and other sources of airborne chlorine.
Locate combustion air and vent terminals as required by • authority having jurisdiction.
!
WARNING
Vent extending through exterior wall shall not terminate adjacent to wall or below building extensions such as eaves, balconies, parapets or decks. Failure to comply could result in death or serious injury.
Table 4 - Combustion Air and Vent Piping Length
Combustion Air and Vent Pipe Equivalent Length
2” Pipe 3” Pipe
Model 050 075/100 075/100 150/200
Min.
Max.
6 ft.
(1.8 m)
100 ft.
(30.5 m)
6 ft.
(1.8 m)
50ft.
(15.2 m)
6 ft.
(1.8 m)
100 ft.
(30.5 m)
6 ft.
(1.8 m)
100 ft.
(30.5 m)
1 - 90° elbow = 5 ft (1.6 m) 1 - 45° elbow = 3.5 ft (1.1 m) 1- 2" x 3" adapter = 0 ft (0 m)
Note: Concentric Vent Kit=5 ft (1.6m) equivalent length
For Example: Boiler can be installed on outside wall and vented with 1-90° elbow and 1 ft (0.30 m) of vent pipe.
18
6 - COMBUSTION AIR AND VENT PIPING
FIGURE 6-1
12" (30 cm)
Minimum
8" (21 cm)
Minimum
Vent Combustion
12" (30 cm) Minimum above
anticipated snow line
FIGURE 6-2
3" (8 cm) Maximum
Air
15" (38 cm)
Maximum
Roof Line
Roof
Terminations
3" (8 cm) Maximum horizontal separation between combustion air intake and vent of same appliance.
8" (21 cm) Minimum vertical separation between combustion air intake and vent of different appliances.
15" (38 cm) Maximum horizontal length of vent.
Maximum vent/intake between different appliances 12" (30cm).
Maximum allowable total vertical vent length with outside exposure is 10 ft.(3.05m).
Abandoned unused masonry chimney may be used as chaseway for combustion air and vent. Both combustion air and vent pipe must exit above top of chimney with clearances as shown in fi gure 6-1.
12" (30 cm)
Minimum from
overhang
See snow & ice
page 23
FIGURE 6-3
3" (8 cm) Maximum
separation
12" (30 cm) Separation
between bottom of
combustion air intake
and bottom of vent
Vent
Combustion Air
12" (30cm)
Minimum
separation
Side Wall
Terminations
3" (8 cm) Minimum horizontal separation between combustion air intake and vent terminations.
8" (21 cm) Minimum vertical separation between combustion air intake and vent terminations.
12" (30 cm) Separation between bottom of combustion air intake and bottom of vent.
Multiple terminations as shown in 6-1, 6-2, and 6-3 must be a minimum of 12” (30 cm) horizontally between vent of one termination and air intake of next appliance.
Maximum allowable total outside exposure vent length equals 10 ft. (3.05m).
Maintain a pitch of 1/2" per ft. (42mm/m) outside exposure back to boiler to ensure proper condensate drainage for horizontal runs.
See snow & ice
page 23
Combustion Air
Vent
19
6 - COMBUSTION AIR AND VENT PIPING
FIGURE 6-4
Combustion
Air
1" (2.54cm) Maximum
1"(2.54cm) Maximum
Vent
FIGURE 6-7
FIGURE 6-5
1" (2.54cm) Maximum
* See Note Below
Combustion
Air
*Must be less than 4" or greater than 24" Horizontal dis­tance between end bells of each air intake to prevent fl ue gas recirculation.
Note: Securing strap must be fi eld installed to prevent movement of termination kit in side wall
Roof overhang
12" (30cm) Minimum
36"(0.9m) Minimum
Maintain 12"(30cm)
Vent
clearance above
clearance above highest
highest anticipated
anticipated snow level or
snow level or grade
Maintain 12"
grade
OD 3½" ( OD 4½" (11.4cm) - 3" (7.6cm) kit
Combustion Air
Elbow fi eld supplied
** Note Overall length may be modifi ed by cutting or extending both combustion air and vent pipes. 12" is minimum allowable length and 60" is maximum allowable length for this dimension. SDR-26 PVC (D2241) only may be used for extending pipes. Do not use Schedule 40 PVC or use couplings to extend pipes. Dimension will change if intake/vent pipes are lengthened or shortened.
8.9cm)
- *2" (
5.0cm)
kit
**See
Note
*2 or 3" (5.0 or 7.6cm) Diameter
PVC intake/combustion air
*2" (
5.0cm)
Diameter = 41" Length (1.0m))
46-3/4" (1.2 m)
3" (7.6cm) Diameter = 47" Length (1.2m)
Combustion Air
Vent
1"(2.54cm) Maximum
* Note: 2" For use with models 050/075/100. 3" For use with models 075/100/150/200
20
6 - COMBUSTION AIR AND VENT PIPING
Concentric
Vent Roof
Terminations
Glue inner vent pipe to prevent recirculation.
Maintain 12" (30 cm) minimum clearance above highest anticipated snow level. Maximum of 24"(0.61m) above roof.
Support must be fi eld installed to secure termination kit to structure.
Elbow, roof boot/fl ashing fi eld supplied.
Allowed Wall/Roof thickness 1/2"-30" (1.2 - 76cm).
Vertical concentric vent system can be installed in unused masonry chimney.
Contact Technical Support for questions regarding installation or use.
FIGURE 6-6
Combustion Air
Roof boot/fl ashing (fi eld supplied)
Note: Support must be fi eld installed to secure termination kit to structure
Vent
Vent
Maintain 12"(30cm)
clearance above highest
anticipated snow level
24" above roof
Support (fi eld supplied)
Combustion Air
21
6 - COMBUSTION AIR AND VENT PIPING
Forced Air
Inlet
12"
(30.5cm m)
Minimum
Less than 10' (3 m)
Minimum
Termination must be 12" (30.5 cm)
from or below doors,
windows or gravity
inlet.
Termination
Termination
3' (0.9 m) [If located within 10' (3 m) of forced air inlet]
Doors &
Windows
Condensate
Forced Air
Inlet
Combustion air and vent termination must be 12" (300mm) from or below doors, windows or gravity inlet.
Vent gas may condense, forming moisture, may be corrosive. Protect building materials at vent from exhaust of vent gas.
Terminate venting system 3’ (0.9 m) above and 10' (3.0 m) from any forced air inlet (except boiler’s combustion air inlet).
3' (0.9 m)
Minimum
Grade, Snow
& Ice
"L"
Corner
Terminate vent system bottom, minimum 12" (300 mm) above highest anticipated snow level.
Avoid locations where snow may drift and block vent and combustion air. Ice or snow may cause boiler to shut down if vent or combustion air becomes obstructed.
Vent termination shall NO T be installed closer than 3' (0.9 m) from inside corner of “L” shaped structure.
22
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