Velocity Phantom PHNTM135CB, Phantom PHNTM150CB, Phantom PHNTM180CB Installation, Operating And Service Instructions

Page 1

Installation, Operating and Service Instructions for

Residential

 Condensing  High Efficiency  Direct Vent  Gas-Fired  Combi Boilers

9700609

As an ENERGY STAR® Partner, Velocity Boiler Works has determined that the PHANTOM™ Combi boilers meet the ENERGY STAR® guidelines for energy efficiency established by the United States Environmental Protection Agency (EPA).

WARNING

Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury, or loss of life. For assistance or additional information, consult a qualified installer, service agency or the gas supplier. This boiler requires a special venting system. Read these instructions carefully before installing.

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IMPORTANT INFORMATION - READ CAREFULLY

NOTE: The equipment shall be installed in accordance with those installation regulations enforced in the area where the installation is to be made. These regulations shall be carefully followed in all cases. Authorities having jurisdiction shall be consulted before installations are made.

All wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code and/or local regulations.

All wiring on boilers installed in Canada shall be made in accordance with the Canadian Electrical Code and/or local regulations.

The City of New York requires a Licensed Master Plumber supervise the installation of this product.

The Commonwealth of Massachusetts requires this product to be installed by a Licensed Plumber or Gas Fitter.

The following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important information concerning product life.

DANGER

Indicates an imminently

hazardous situation which, if not avoided, will result in death, serious injury or substantial property damage.

WARNING

Indicates a potentially hazardous situation which, if not avoided, could result in death, serious injury or substantial property damage.

DANGER

Explosion Hazard. DO NOT store or use gasoline or other flammable vapors or liquids

in the vicinity of this or any other appliance.

If you smell gas vapors, DO NOT try to operate any appliance - DO NOT touch any electrical switch or use any phone in the building. Immediately, call the gas supplier from a remotely located phone. Follow the gas supplier’s instructions or if the supplier is unavailable, contact the fire department.

WARNING

This boiler must only be serviced and repaired by skilled and experienced service technicians.

•

If any controls are replaced, they must be replaced with identical models.

•

Read, understand and follow all the instructions and warnings contained in all the sections of this manual.

•

If any electrical wires are disconnected during service, clearly label the wires and assure that the wires are reconnected properly.

•

Never jump out or bypass any safety or operating control or component of this boiler.

•

Assure that all safety and operating controls and components are operating properly before placing the boiler back in service.

•

Annually inspect all vent gaskets and replace any exhibiting damage or deterioration.

CAUTION

Indicates a potentially hazardous situation which, if not avoided, may result in moderate or minor injury or property damage.

NOTICE Indicates special instructions on installation, operation, or maintenance which are important but not related to personal injury hazards.

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WARNING

Asphyxiation Hazard. Fire Hazard. Explosion Hazard. This boiler requires regular

maintenance and service to operate safely. Follow the instructions contained in this manual.

WARNING

Asphyxiation Hazard. Fire Hazard. Explosion Hazard. This boiler requires regular maintenance and service to operate safely. Follow the instructions contained in this manual.

•

Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Read and understand the entire manual before attempting installation, start-up operation, or service. Installation and service must be performed only by an experienced, skilled, and knowledgeable installer or service agency.

•

This boiler must be properly vented.

•

This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate combustion and ventilation air.

•

Asphyxiation Hazard. The interior of the venting system must be inspected and cleaned before the start of the heating season and should be inspected periodically throughout the heating season for any obstructions. A clean and unobstructed venting system is necessary to allow noxious fumes that could cause injury or loss of life to vent safely and will contribute toward maintaining the boiler’s efficiency.

•

Installation is not complete unless a safety relief valve is installed in the supply piping. - See the System Piping Section of this manual for details.

•

This boiler is supplied with safety devices which may cause the boiler to shut down and not re-start without service. If damage due to frozen pipes is a possibility, the heating system should not be left unattended in cold weather; or appropriate safeguards and alarms should be installed on the heating system to prevent damage if the boiler is inoperative.

•

Burn Hazard. This boiler contains very hot water under high pressure. Do not unscrew any pipe fittings nor attempt to disconnect any components of this boiler without positively assuring the water is cool and has no pressure. Always wear protective clothing and equipment when installing, starting up or servicing this boiler to prevent scald injuries. Do not rely on the pressure and temperature gauges to determine the temperature and pressure of the boiler. This boiler contains components which become very hot when the boiler is operating. Do not touch any components unless they are cool.

•

Respiratory Hazard. Boiler materials of construction, products of combustion and the fuel contain alumina, silica, heavy metals, carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which can cause death or serious injury and which are known to the state of California to cause cancer, birth defects and other reproductive harm. Always use proper safety clothing, respirators and equipment when servicing or working nearby the appliance.

•

Failure to follow all instructions in the proper order can cause personal injury or death. Read all instructions, including all those contained in component manufacturers manuals which are provided with the boiler before installing, starting up, operating, maintaining or servicing.

•

All cover plates, enclosures and guards must be in place at all times.

DANGER

Explosion Hazard. Electrical Shock Hazard. Burn Hazard. This boiler uses flammable

gas, high voltage electricity, moving parts, and very hot water under high pressure. Assure that all gas and electric power supplies are off and that the water temperature is cool before attempting any disassembly or service.

Do not attempt any service work if gas is present in the air in the vicinity of the boiler. Never modify, remove or tamper with any control device.

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WARNINGS FOR THE HOMEOWNER

FOLLOW ALL INSTRUCTIONS and warnings printed in this manual and posted on the boiler.

INSPECT THE BOILER ANNUALLY. To keep your boiler safe and efficient, have a service technician follow the Service checklist near the end of this manual.

IF YOU ARE NOT QUALIFIED to install or service boilers, do not install or service this one.

THE BOILER MAY LEAK WATER at the end of its useful life. Be sure to protect walls, carpets, and valuables from water that could leak from the boiler.

PROTECT YOUR HOME IN FREEZING WEATHER. A power outage, safety lockout, or component failure will prevent your boiler from lighting. In winter, your pipes may freeze and cause extensive property damage. Do not leave the heating system unattended during cold weather unless alarms or other safeguards are in place to prevent such damage

DO NOT BLOCK AIR FLOW into or around the boiler. Insufficient air may cause the boiler to produce carbon monoxide or start a fire.

KEEP FLAMMABLE LIQUIDS AWAY from the boiler, including paint, solvents, and gasoline. The boiler may ignite the vapors from the liquids causing explosion or fire.

KEEP CHILDREN AND PETS away from hot surfaces of the boiler, boiler piping, vent piping and vent terminals.

CARBON MONOXIDE (CO) is an odorless, deadly gas that may be introduced into your home by any malfunctioning fuel-burning product or vent system failure. Consider installing CO alarms near bedrooms in all levels of the building to warn you and your family of potential CO exposure.

DANGER

• Water temperature over 125°F (52°C) can cause severe burns instantly or death from scalds.

• Children, disabled and elderly are at highest risk of being scalded.

• Feel water before bathing or showering.

• Installation of an ASSE 1017 or ASSE 1070 certied tempering valve is REQUIRED as part of this boiler’s installation. Consult Sections X and XIII for details on valve installation and temperature adjustment.

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WARNINGS FOR THE INSTALLER

READ THIS ENTIRE MANUAL before attempting installation, start-up, or service. Improper installation, adjustment, alteration, service, or maintenance may cause serious property damage, personal injury, or death.

DO NOT DISCONNECT PIPE FITTINGS on the boiler or in the heating system without first verifying that the system is cool and free of pressure and that your clothing will protect you from a release of hot water or steam. Do not rely solely on the boiler’s temperature and pressure gage when making this judgment.

USE PROPER PERSONAL PROTECTION EQUIPMENT when servicing or working near the boiler. Materials of construction, flue products, and fuel contain alumina, silica, heavy metals, carbon monoxide, nitrogen oxides, and/or other toxic or harmful substances that can are hazardous to health and life and that are known to the State of California to cause cancer, birth defects, and other reproductive harm.

INSTALL ALL GUARDS, cover plates, and enclosures before operating the boiler.

SIZE THE BOILER PROPERLY relative to the design heat load or, if using domestic hot water priority, the peak hot water load, whichever is larger. A grossly oversized boiler will cycle excessively and this will lead to premature failure of the boiler and its components. Our warranty does not apply to damage from excessive cycling.

ADHERE TO ALL LOCAL CODE REQUIREMENTS. Contact your local code inspector prior to installation. In the absence of a local code, adhere to the National Fuel Gas

Code ANSI Z223.1/NFPA 54 or CAN/CSA B149.1, Natural Gas and Propane Installation Code.

ALL WIRING must comply with the National Electrical Code ANSI/NFPA 70 (in the USA) or

the Canadian Electrical Code CSA C22.1 (in Canada) and any local regulations.

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Table of Contents

I. Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

II. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

III. Before Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

IV. Locating The Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

V. Mounting The Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

VI. Air For Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

VII. Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

A. Vent System Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

B. Design Requirements Unique to Horizontal Twin Pipe Venting

Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

C. Design Requirements Unique to Vertical Venting Systems . . . . . . . . 28

D. Design Requirements Unique to Split Vent Systems . . . . . . . . . . . . . 36

E. Assembly of CPVC/PVC Vent Systems . . . . . . . . . . . . . . . . . . . . . . .44

F. Assembly of DuraVent PolyPro Vent Systems . . . . . . . . . . . . . . . . . . 51

G. Assembly of Selkirk Polyflue Vent Systems . . . . . . . . . . . . . . . . . . . . 56

H. Assembly of Centrotherm InnoFlue Vent Systems . . . . . . . . . . . . . .60

I. Assembly of Stainless Steel Vent Systems . . . . . . . . . . . . . . . . . . . . 64

J. Condensate Trap and Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

K. Removing An Existing Boiler From Common Chimney . . . . . . . . . . .67

VIII. Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

IX. System Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

A. General System Piping Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . .70

B. Standard Piping Installation Requirements . . . . . . . . . . . . . . . . . . . . .71

C. Near Boiler Piping Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

D. Piping For Special Situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

X. Domestic Hot Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

XI. Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

XII. Start-Up and Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94

XIII. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102

XIV. Service and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

XV. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

XVI. Repair Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Appendix A: Instructions for High Altitude Installation Above 2,000 ft. . 154

Appendix B: Special Requirements For Side-Wall Vented Appliances

In The Commonwealth of Massachusetts . . . . . . . . . . . . . 157

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I. Product Description

This boiler is a stainless steel gas fired condensing boiler designed for use in forced hot water heating systems requiring supply water temperatures of 180°F or less. In addition to providing water for space heat, this boiler also generates domestic hot water (DHW). This boiler may be vented vertically or horizontally with combustion air supplied from outdoors. It is not designed for use in gravity hot water systems or systems containing significant amounts of dissolved oxygen.

II. Specifications

SEE TABLE 2.4

OUTSIDE

OF WALL

"A"

INSIDE

OF WALL

VENT

CONNECTION

RELIEF

VALVE

AIR INTAKE

CONNECTION

ACCESS

TEMPERATURE/

PRESSURE GAUGE

(INSIDE CABINET)

BOILER SUPPLY WATER

CONNECTION

BOILER RETURN WATER

CONNECTION

DOMESTIC HOT WATER OUTLET DOMESTIC COLD WATER INLET

CONDENSATE

CONNECTION

GAS CONNECTION

DOOR

CONDENSATE TRAP

CLEANOUT

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Figure 2.1: General Configuration

Page 8

Model

Size

Fig 2.1 Dim

“A”, (in)

Connection Size (NPT Male)

Boiler Water

Content,

(Gal.)

Net Weight,

(lbs.)

Supply/Re-

turn Hot/Cold Gas

135 15 1 3/4 1/2 0.53 109

150 19 1 3/4 1/2 0.79 126

180 19 1 3/4 1/2 0.79 126

II. Specifications (continued)

Model

Size

Nominal

Vent/Intake

Size (in.)

Min. Vent

Length (in.)

Max Vent

Length (ft.)

Approx. Derate

at Max Vent (%)

135 3 12 135 7

150 3 52 135 7

180 3 52 135 9

Table 2.2: Performance Specifications

Space Heating Ratings Domestic Hot Water (DHW) Ratings

Hot Water Draw Limits, GPM

Input, MBH

Model Number

Min Max Min Max

PHNTM135CB 12 120 112 97 95.0 12 135 3.3 3.0 2.6 0.5

PHNTM150CB 15 150 142 123 95.0 15 150 3.9 3.7 3.1 0.5

PHNTM180CB 18 180 169 147 95.0 18 180 4.5 4.1 3.5 0.5

Notes:

1. DHW ratings are not AHRI certified.

2. The Net AHRI Water Ratings shown are based on a piping and pickup allowance of 1.15. The manufacturer should be consulted before selecting a boiler for installations having unusual piping and pickup requirements, such as intermittent system operation, extensive piping systems, etc.

3. Maximum draw rates shown are at sea level and minimum vent length. Under other conditions draw rates will be reduced proportionally to the reduction in input. See Table 2.4 and Appendix A for input de-rate information.

4. Minimum flow rate shown is that required through the boiler to initiate a call for DHW. A higher flow rate may be required through the fixture due to mixing at the tempering valve and fixture itself.

Heating

Capacity,

MBH

Net AHRI

Water,

MBH

AFUE, %

Input, MBH

70°F 77°F 90°F

Rise Rise Rise

Max.

Table 2.3: Physical Specifications

Min.

Table 2.4: Vent Lengths

III. Before Installing

1. Safe, reliable operation of this boiler depends upon installation by a professional heating contractor in strict accordance with this manual and the requirements of the authority having jurisdiction.

• In the absence of an authority having jurisdiction, installation must be in accordance with this manual

and the National Fuel Gas Code, ANSI Z223.1. In Canada, installation must be in accordance with the B149.1 Installation Code.

• Where required by the authority having jurisdiction, this installation must conform to the Standard for

Controls and Safety Devices for Automatically Fired Boilers (ANSI/ASME CSD-1).

2. Read Section VII to verify that the maximum combustion air and exhaust pipe lengths will not be exceeded in the planned installation. Also verify that the vent terminal can be located in accordance with Section VII.

3. Make sure that the boiler is correctly sized:

• For heating systems employing convection radiation (baseboard or radiators), use an industry

accepted sizing method such as the I=B=R Guide RHH published by the Air-Conditioning, Heating and Refrigeration Institute (AHRI).

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III. Before Installing (continued)

• For new radiant heating systems, refer to the radiant tubing manufacturer’s boiler sizing guidelines.

• For system which includes an indirect water heater, make sure the boiler has the output called for by the indirect water heater manufacturer’s instructions.

4. All boilers are shipped from the factory configured for use with natural gas. They may be converted for use with LP gas (“propane”) using a proper conversion kit per Table 3.1. Use a combustion analyzer and follow all instructions supplied with conversion kit.

Table 3.1: LP Conversion Kit

Model Size LP Conversion Kit PN

135, 150 107874-01

180 107875-01

WARNING

Do not attempt to operate this boiler on LP gas without converting it using the proper conversion kit.

• Do not attempt to convert this boiler to LP gas without the use of a combustion analyzer.

•

Failure to follow the conversion instructions will result in operation of the boiler at unsafe Carbon Monoxide (CO) levels and may result in personal injury or loss of life. Improper conversion may also result in unreliable operation, resulting in property damage.

• Before attempting to operate this boiler at altitudes above 2000 ft., follow instructions shown in Appendix A of this manual.

NOTICE This product must be installed by a licensed plumber or gas fitter when installed within the Commonwealth of Massachusetts. See Appendix C for additional important information about installing this product within the Commonwealth of Massachusetts.

IV. Locating the Boiler

1. Observe the minimum clearances shown in Figure 4.1. These clearances apply to combustible construction as well as non-combustible walls, floors, ceilings and doors.

2. Note the recommended service clearances in Figure 4.1. These service clearances are recommended, but may be reduced to the combustible clearances provided:

a. Access to the front of the boiler is provided through a door. b. Access is provided to the condensate trap located beneath the boiler.

Note that servicing the boiler will become increasingly difficult as these service clearances are reduced.

3. Observe the following clearances from piping to combustible construction:

Non-concentric vent (exhaust): ¼” Air intake piping: 0” Hot water piping: ¼”

4. The relief valve must be installed in the location shown in Figure 2.1 and must be in the same space as the boiler.

5. The boiler should be located so as to minimize the length of the vent system.

6. The combustion air piping must terminate where outdoor air is available for combustion and away from areas that will contaminate combustion air. Avoid areas near chemical products containing chlorine, chloride based salts, chloro/fluoro carbons, paint removers, cleaning solvents and detergents.

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IV. Locating the Boiler (continued)

Figure 4.1: Minimum Clearances To Combustible Construction

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V. Mounting The Boiler

A. Wall Mounting

CAUTION

This boiler weighs as much as 126 pounds:

• Two people are required to safely lift this boiler onto the wall mounting hook.

• Make sure that wall mounting hook is anchored to a structure capable of supporting the weight of the boiler and attached piping when filled with water. Jurisdictions in areas subject to earthquakes may have special requirements for supporting this boiler. These local requirements take precedence over the requirements shown below.

1. If the boiler is installed on a framed wall, minimum acceptable framing is 2 x 4 studs on 16” centers. The boiler mounting holes are on 16” centers for installation between two studs at the standard spacing. In cases where the boiler cannot be centered between the studs, or where the studs are spaced closer than 16” apart, the boiler may be anchored to ¾” plywood or horizontal 2 x 4’s anchored to the studs.

2. 5/16” x 2” lag screws and washers are provided for mounting this boiler. These lag screws are intended for mounting the boiler directly onto studs covered with ½” sheathing. When the boiler is attached to other types of construction, such as masonry, use fasteners capable of supporting the weight of the boiler and attached piping in accordance with good construction practice and applicable local codes.

3. Make sure that the surface to which the boiler is mounted is plumb.

4. Before mounting the boiler, make sure that wall selected does not have any framing or other construction that will interfere with the vent pipe penetration.

5. Once a suitable location has been selected for the boiler, and any needed modifications have been made to the wall, use Figure 5.1 to locate holes “A” and “B”. Make sure that the horizontal center line of these holes is level. Holes “C” and “D” may also be drilled at this time or after the boiler is hung on the wall. If the 5/16” x 2” lag screws are used, drill 3/16” pilot holes.

6. The wall mounting hook is used to secure the boiler to the shipping pallet. Remove this hook from the pallet and secure to the wall using the 5/16” x 2” lag screws and washers, or other suitable anchors as appropriate (Figure 5.2). Make sure the hook is level.

7. Hang the boiler on the wall hook as shown in Figure 5.2.

8. If not already done in Step (5) locate and drill holes “C” and “D” using the ob-round slots in the bottom mounting flange. Secure the bottom flange to the wall using the 5/16”x 2” lag screws, or other fasteners as appropriate (Figure 5.2).

9. Verify that the front of the boiler is plumb. If it is not, install washers at holes “C” and “D” between the bottom mounting flange and the wall to adjust.

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Figure 5.1 Wall Layout/Mounting Hole Location

V. Mounting The Boiler (continued)

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Figure 5.2 Boiler Mounting Bracket Installation / Boiler Wall Mounting

V. Mounting The Boiler (continued)

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VI . Air for Ventilation

WARNING

Outdoor combustion air must be piped to the air intake. Never pipe combustion air from areas containing contaminates such as swimming pools and laundry room exhaust vents. Contaminated combustion air will damage the boiler and may cause property damage, personal injury or loss of life.

Air for combustion must always be obtained directly from outdoors (see Section VII for intake piping). Although combustion air must always be obtained directly from outdoors, ventilation openings may still be required to prevent overheating of boiler components if the boiler is installed in a small space, such as a closet.

• If the recommended service clearances shown in Figure 4.1 can be maintained (with all doors to the room closed), no ventilation openings are required for this boiler.

• If the above service clearances cannot be maintained, provide two openings into the room, one near the floor and one near the ceiling. The top edge of the upper opening must be within 12” of the ceiling and the bottom edge of the lower opening within 12” of the floor. Each of these openings must have a free area of at least 100 square inches. The “free area” takes into account the blocking effect of mesh grilles and louvers. Where screens are used they must be no finer than ¼” (4 x 4) mesh.

• If this boiler is installed in a room with other appliances, provide adequate air for combustion and/or ventilation in accordance with the other appliance manufacturer’s installation manual or applicable code. In cases where such provisions require two openings in excess of 100 square inches, no additional opening area is required for this boiler.

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VII. Venting

WARNING

Asphyxiation Hazard. Failure to vent this boiler in accordance with these instructions

could cause products of combustion to enter the building resulting in severe property damage, personal injury or death.

•

Do not interchange vent systems or materials unless otherwise speciﬁed. Read, understand and follow all the instructions and warnings contained in all the sections of this manual.

•

The use of thermal insulation covering vent pipe and ﬁttings is prohibited.

•

Do not use a barometric damper, draft hood or vent damper with this boiler.

•

Any CPVC vent materials supplied with this boiler do not comply with B149.1.S1-07 and are not approved for use in Canadian jurisdictions that require vent systems be listed to ULC S636-2008. In these jurisdictions, vent this boiler using a listed ULC S636 Class IIB venting system.Annually inspect all vent

gaskets and replace any exhibiting damage or deterioration.

•

Do not locate vent termination where exposed to prevailing winds. Moisture and ice may form on surface around vent termination. To prevent deterioration, surface must be in good repair (sealed, painted, etc.).

•

Do not locate air intake vent termination where chlorine, chloroﬂuorocarbons (CFC’s), petroleum distillates, detergents, volatile vapors or other chemicals are present. Severe boiler corrosion and failure will result.

•

The use of cellular core PVC (ASTM F891), cellular core CPVC or Radel (polyphenolsulfone) is prohibited.

•

Do not locate vent termination under a deck.

•

Do not reduce speciﬁed diameters of vent and combustion air piping.

•

When installing vent pipe through chimney, as a chase, no other appliance can be vented into the chimney.

A. Vent System Design

There are three basic ways to vent this boiler:

• Horizontal (“Side Wall”) Twin Pipe Venting (Figure 7.0a) - Vent system exits the building through an outside wall. Combustion air and flue gas are routed between the boiler and the terminal(s) using separate pipes for at least part of the way. A summary of Horizontal Twin Pipe venting options is shown in Table 7.5.

• Vertical Twin Pipe Venting (Figure 7.0b) - Vent system exits the building through a roof. Combustion air and flue gas are routed between the boiler and the terminal(s) using separate pipes for at least part of the way. A summary of Vertical Twin Pipe venting options is shown in Table 7.13

• Split Venting (Figure 7.0c) - Exhaust system exits the building through a roof, and combustion air is drawn from a terminal mounted on the side wall. A summary of split venting options is shown in Table 7.21

All of these systems are considered “direct vent” because the air for combustion is drawn directly from the outdoors into the boiler. One of the vent option columns in Tables 7.5, 7.13, 7.21 must match the planned vent and air intake system exactly.

Design details applying to all vent systems are shown in this section. Observe all design requirements in this section, as well as those unique to the type of system being installed:

• B - Design Requirements Unique to Horizontal Twin Pipe Vent Systems

• C - Design Requirements Unique to Vertical Twin Pipe Vent Systems

• D - Design Requirements Unique to Split Vent Systems

1. Approved Vent Systems and Materials – The following materials and vent systems may be used to vent this

boiler:

• CPVC – Use only CPVC listed to ASTM F441. In Canada, this pipe must also be listed to ULC S636.

• PVC – PVC may be used only as permitted in this manual. All PVC must be listed to ASTM D2665. At least 30” of CPVC pipe, and at least one CPVC elbow, must be installed between the boiler’s vent connection and the PVC pipe. Use of foam core PVC is not permitted for venting. PVC vent pipe may not be used to vent this boiler in Canada.

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VII. Venting A. Vent System Design (continued)

Figure 7.0a: Horizontal Twin Pipe

Figure 7.0b: Vertical Twin Pipe

Figure 7.0c: Split Venting

BOILER

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VII. Venting A. Vent System Design (continued)

• DuraVent PolyPro - ULC S636 listed Polypropylene special gas vent system.

• Selkirk Polyflue - ULC S636 listed Polypropylene special gas vent system.

• Centrotherm InnoFlue SW - ULC S636 listed Polypropylene special gas vent system.

• DuraVent FasNSeal Flex - UL 1738 listed Stainless Steel special gas vent system.

Use PVC and/or CPVC for the air intake system. PVC may be used for all air intake piping between the intake

terminal and the boiler.

When CPVC and/or PVC pipe is used, it must be joined using primer and cement that is listed for use with the

pipe material being joined (PVC, CPVC, or CPVC to PVC).

2. Vent Kit Available for Use with this Boiler - The following vent kit is available for CPVC/PVC vent systems installed with this boiler in the USA:

• 107039-02 - 3” CPVC/PVC Vent Kit

These kit include the following:

(1) 30” CPVC Straight Pipe

(1) 90 degree short bend CPVC Elbow

(1) Straight PVC Coupling (for exhaust terminal)

(1) 90 degree PVC Elbow (for intake termination)

(2) Rodent screens

The CPVC Pipe and elbow supplied with these kits are not listed to ULC S636 and may not be used in Canada.

3. Maximum Vent and Air Intake Lengths - The maximum length of the vent air intake piping depends upon the vent option selected and the boiler size. See Tables 7.5, 7.13 or 7.21 for the maximum vent lengths. These maximum lengths apply to both the vent and intake piping (e.g. Option 1 may have up to 135ft of intake and 135ft of vent piping). For all vent systems, the lengths shown in Tables 7.5, 7.13 and 7.21 are in addition to the first 90° elbow. If more elbows are desired, the maximum allowable vent length must be reduced by the amount shown in Table

7.1 for each additional elbow used. Termination fittings are never counted.

It is recommended that all field supplied PVC or CPVC elbows be “1/4 Bend” (Sanitary 90° Elbow) or “Long

Sweep 1/4 Bend” type elbows (Figure 7.2). In this manual “sanitary” and “long sweep” elbows are treated as having the same equivalent length.

Example: A 3” twin pipe horizontal CPVC/PVC vent system is planned for a horizontally vented 135 MBH model which has

the following components in the vent system:

• 1 ft CPVC Straight Pipe

• 90 CPVC Elbow (short bend)

• 1-1/2 ft CPVC Straight Pipe

• Coupling

• 10 ft PVC Straight Pipe

• 90 PVC Elbow (Sanitary Elbow Design)

• 15 ft PVC Straight Pipe

• PVC Coupling Terminal

The Vent Option #1 column in Table 7.5 describes a horizontal direct vent system using 3” CPVC and PVC pipe. From this column, we see that the boiler may have a vent length of up to 135ft. The first CPVC 90 degree elbow is not considered. From Table 7.1, we see that the equivalent length of the 90 PVC elbow is 4ft and that the equivalent length of the coupling is 0ft. The total equivalent length of the planned venting system is therefore:

1ft (Straight CPVC) + 0ft (first short bend CPVC 90 Elbow) + 1.5ft (Straight CPVC) + 0ft (Coupling) + 10ft (Straight PVC) + 4ft (PVC 90 Sanitary Elbow) + 15ft (Straight PVC) + 0ft (Coupling Terminal) = 31.5ft.

Since Table 7.1 shows a maximum allowable vent length of 135ft, the planned vent system length is acceptable.

The flex venting used on some of the Vertical Twin Pipe and Split Vent Options also reduces the maximum allowable vent length. See Sections VII-C or VII-D for details.

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Page 18

VII. Venting A. Vent System Design (continued)

NOTICE Do not exceed maximum vent/combustion air system length. Refer to Tables 7.1B, 7.5, 7.13, and

7.21 in this section for maximum vent/combustion air system length.

Use only vent and combustion air terminals and terminal locations shown in Tables 7.1B, 7.5, 7.13 and 7.21.

4. Vent Side Noise Attenuator - This boiler comes with a vent side noise attenuator. If equivalent vent length is less than 70 equivalent ft., install noise attenuator as described below. Attenuator is not required on size 135 at altitudes above 2000ft. Refer to Figure 7.1A.

a. To properly install attenuator, insert approximately a 9” length CPVC pipe in vent adaptor. b. Fit a 3” CPVC coupling on length of pipe. Glue coupling to pipe using a field supplied cement and

primer that is listed for use with materials being joined (CPVC and/or PVC).

c. Insert attenuator in length of pipe. Ensure attenuator tube is pointing down and sits inside 3” CPVC

coupling.

d. Install remaining venting as described in this manual. If using one of the polypropylene or stainless

steel vent systems listed described in this manual, use a listed adapter to adapt from CPVC to be the other vent system.

Figure 7.1A: Installation of Vent Side Attenuator

NOTICE Indicates special instructions on installation, operation, or maintenance which are important but not related to personal injury hazards.

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Page 19

VII. Venting A. Vent System Design (continued)

NOTICE Do not exceed maximum vent/combustion air system length. Refer to Tables 7.1B, 7.5, 7.13, and

7.21 in this section for maximum vent/combustion air system length.

Use only vent and combustion air terminals and terminal locations shown in Tables 7.5, 7.13 and 7.21.

5. Minimum Vent and Air Intake Lengths - Observe the minimum vent lengths shown in Tables 7.5, 7.13 and 7.21.

6. Clearances to Combustibles - Maintain the following clearances from the vent system to combustible construction:

• Vent - 1/4” (also observe clearances through both combustible and non-combustible walls - see 9)

• Air Intake - 0”

• Concentric Portion of Concentric Terminals - 0”

7. Pitch of Horizontal Vent Piping - Pitch all horizontal vent piping so that any condensate which forms in the piping will run towards the boiler.

• Pitch CPVC/PVC vent piping 1/4” per foot.

• Pitch Polypropylene vent piping 5/8” per foot.

Table 7.1B: Vent/ Air Intake Fitting Equivalent Length

CPVC/PVC Fitting

3” 90° Elbow (“Sanitary Bend”) 4.0 3” 90° Elbow 8.7

3” 45° Elbow 2.0 3” 45° Elbow 4.6

3” 90° Elbow (“Short Bend”) 10.0

3” Coupling 0.0

Equivalent Length (ft)

PolyPro, Polyflue

or InnoFlue

Vent Fitting

Equivalent Length (ft)

FasNSeal Vent Fitting

3” 90° Elbow 4.0

3” 45° Elbow 2.0

3” Straight Tee 18.0

3” Boot Tee 8.0

Equivalent Length (ft)

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Figure 7.2: CPVC and PVC Elbows

Page 20

VII. Venting A. Vent System Design (continued)

8. Supporting Pipe - Vertical and horizontal sections of pipe must be properly supported. Maximum support spacing is as follows:

• Support CPVC/PVC horizontally and vertically every 4 feet.

• Support DuraVent PolyPro horizontally near the female end of each straight section of pipe and vertically

every 10 feet.

• Support Centrotherm InnoFlue horizontally every 39 inches with additional supports at elbows and vertically

every 78”.

• Support 3” Polyflue horizontally every 39”. Support vertical runs of 3” Polyflue every 16 ft.

• Support DuraVent FasNSeal horizontally every 6ft or less. Support vertical runs at the base and every 12ft or

less.

Les instructions d´installation du système d´évacuation doivent préciser que les sections horizontales

doivent être

supportées pour prévenir le fléchissement. Les méthodes et les intervalles de support doivent être

spécifiés. Les

instructions divent aussi indiquer les renseignements suivants:

• les chaudières de catégories II et IV doivent être installées de façon à empêcher l´accumulation de

condensat: et

• si nécessaire, les chaudières de catégories II et IV doivent être pourvues de dispositifs d´évacuation du

condensat.

9. Allowing for Thermal Expansion -

• For CPVC/PVC pipe design, the vent system shall allow 3/8” of thermal expansion for every 10ft of CPVC/

PVC pipe. The boiler will always act as an anchor to one end of the vent system. If at all possible, select and install hangers and wall thimbles so that the vent system can expand towards the terminal. When a straight run of pipe exceeds 20ft and must be restrained at both ends, an offset or expansion loop must be provided (Figures 7.3a, 7.3b). When a straight horizontal run of pipe exceeds 20ft and is restrained at one end with an elbow at the other, avoid putting a hanger or guide less than “Y” inches from the elbow in the adjoining straight section (Figure 7.3c). Thermal expansion fittings are not permitted.

• When properly assembled, expansion of PolyPro, Polyflue and InnoFlue vent systems is accommodated at

the joints. See Section VII - F, G & H of this manual for details.

• Stainless steel vent systems must be free to expand and contract in accordance with manufacturer’s

installation instructions.

10. Running PVC Vent Pipe Inside Enclosures and Through Walls - PVC vent pipe must be installed in a manner that permits adequate air circulation around the outside of the pipe:

• Do not enclose PVC venting - Use CPVC in enclosed spaces, even if PVC is installed upstream.

• PVC venting may not be used to penetrate combustible or non-combustible walls unless all of the following

conditions are met: a. The wall penetration is at least 66 inches from the boiler as measured along the vent. b. The wall is 12” thick or less c. An airspace of at least that shown in Figure 7.4 is maintained around the OD of the vent.

If any of these conditions cannot be met, use CPVC for the wall penetration.

11. Vent Manufacturer’s Instructions – The vent system manufacturer may have additional vent system design requirements. Read and follow the vent manufacturer’s instructions in addition to those shown here. Where a conflict arises between the two sets of instructions, the more restrictive requirements shall govern.

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Page 21

VII. Venting A. Vent System Design (continued)

Figure 7.3a

Figure 7.3c

Figure 7.3b

Figure 7.3: Expansion Loops for CPVC/PVC Pipe

Figure 7.4: Wall Penetration Clearances for PVC Vent Pipe

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Page 22

VII. Venting B. Design Requirements Unique to Horizontal Twin Pipe Venting Systems (continued)

B. Design Requirements Unique to Horizontal Twin Pipe Venting Systems

Table 7.5 summarizes all horizontal twin pipe vent options. Illustrations of horizontal twin pipe vent systems

are shown in Figures 7.6 – 7.10. In addition to the requirements in Section VII - A, observe the following design requirements:

1. Permitted Terminals for Horizontal Venting:

Terminal Option A: Fittings (Acceptable for Vent Options 1-4) – Vent terminates in a plain end (coupling for PVC,

bell end for PolyPro, Polyflue and plain end pipe for InnoFlue). Intake terminates in a PVC 90 sweep elbow pointing down. Outer edge of both terminals must be within 10” of the wall surface (Figures 7.6, 7.9). The section of DuraVent PolyPro, Centrotherm InnoFlue or Selkirk Polyflue exposed to the outdoors must be UV resistant.

Use of rodent screens (not supplied) is generally recommended for both terminations. These can be fabricated from 2 x 2 (1/2” mesh) stainless steel screen. Rodent screens and are installed as shown in Figure 7.28. Rodent screens (“bird guards”) for PolyPro, InnoFlue and Polyflue are as follows:

Size/Vent System Rodent Screen (“Bird Guard”) 3” PolyPro DuraVent # 3PPS-BG 3” Polyflue Selkirk # 3PV-HVST 3” InnoFlue Centrotherm # IASPP03

If necessary to achieve required clearance above grade, CPVC or CPVC/PVC vent systems may be terminated using fittings on snorkels as shown in Figure 7.12. When this is done, the equivalent length of all pipe on the exterior of the building, except for the terminal fittings themselves, must be counted when calculating the equivalent length. The maximum vertical run of the snorkel is 7 feet. Brace both the vent and inlet piping if required. PolyPro, InnoFlue and Polyflue may not be snorkeled.

Terminal Option B: Ipex Low Profile Terminal (Acceptable for Vent Option 1) – This terminal is shown in Figure

7.7. If the terminal is oriented vertically (alternate orientation shown in Fig 7.7) the exhaust opening must be on the top as shown. See Section VII - E of this manual and the Ipex instructions provided with the terminal, for installation details.

Terminal Option C: DiversiTech “Low Profile” Terminal (Acceptable for Vent Option 1) – This terminal is shown in Figure 7.7. If the terminal is oriented vertically (alternate orientation shown in Fig 7.7) the exhaust opening must be on the top as shown. See Section VII - E of this manual and the DiversiTech instructions provided with the terminal, for installation details.

Terminal Option D: Ipex FGV Concentric Terminal (Acceptable for Vent Option 1) - This terminal is shown in Figure 7.8 and may be used with CPVC/PVC vent systems. This terminal is available in various lengths and in both PVC and CPVC. Terminals acceptable for use with these vent options are as follows:

Ipex PN FGV Concentric Terminal Description 196006 3 x 20” PVC 196106 3 x 32” PVC 196116 3 x 44” PVC 197107 3 x 32” CPVC 197117 3 x 44” CPVC

See Section VII - E of this manual and the Ipex instructions provided with the terminal, for installation details.

Terminal Option E: DiversiTech Concentric Terminal (Acceptable for Vent Option 1) - This terminal is shown in Figure 7.8 and may be used with CPVC/PVC vent systems. See Section VII - E of this manual and the DiversiTech instructions provided with the terminal, for installation details.

Terminal Option F: DuraVent PolyPro Concentric Terminal (Acceptable for Vent Option 2) - This terminal is shown in Figure 7.10 and may be used with DuraVent 3” PolyPro vent systems. See Section VII - F of this manual and the DuraVent instructions provided with the terminal, for installation details.

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Page 23

VII. Venting B. Design Requirements Unique to Horizontal Twin Pipe Venting Systems (continued)

Table 7.5: Summary of Horizontal Twin Pipe Venting Options

Vent Option 1 2 3 4

Illustrated in Figure 7.6, 7.7, 7.8 7.9, 7.10 7. 9 7. 9 Pipe

Penetration through Structure

Material

Nominal Diameter

Min Equivalent Vent Length:

Models

Max Equivalent Vent Length (Note 1):

Models

Terminal Option A

(Fittings)

Terminal Option B

(Ipex Low Profile)

Terminal Option C

(DiversiTech HVENT)

Terminal Option D

(Ipex FGV Concentric)

Terminal Option E

(DiversiTech CVENT)

Terminal Option F

(DuraVent Horizontal Concentric)

Vent Wall Wall Wall Wall

Intake Wall Wall Wall Wall

CPVC/

Vent

Intake PVC PVC PVC PVC Vent 3” 3” 3” 3” Intake 3” 3” 3” 3”

135 12” 12” 12” 12” 150 52” 52” 52” 52”

180 52” 52” 52” 52”

135 135ft 135ft 135ft 135ft 150 135ft 135ft 135ft 135ft 180 135ft 135ft 135ft 135ft

Vent

Intake

PVC

(Note 2)

Coupling

w/screen

(Note 3)

Elbow

w/screen

(Note 3)

Ipex

#196985

HVENT-3 Not Permitted

Ipex

196006

CVENT-3 Not Permitted

Not

Permitted

DuraVent

PolyPro

(Rigid)

3PPS-12B

3PPS-36B

w/screen

Elbow

w/screen

3PPS-HK Not Permitted

Selkirk

Polyflue

3PF-10UV

3PF-39UV

w/screen

Elbow

w/screen

Not Permitted

Centro-

therm

InnoFlue

ISEP03 or ISEP0339

w/screen

Elbow

w/screen

Notes:

1. Max vent lengths shown also apply to the intake. For example, Vent Option #1 may have up to 135ft of vent pipe and also up to 135 ft of intake pipe.

2. First 30” of vent and vent Elbow connected to boiler must be CPVC. Downstream vent pipe can be PVC except as noted in text.

3. PVC Terminal coupling and inlet elbow may be offset on snorkels as shown in Figure 7.12.

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Page 24

VII. Venting B. Design Requirements Unique to Horizontal Twin Pipe Venting Systems (continued)

PITCH INTAKE AWAY FROM

BOILER IF POSSIBLE

BOILER ROOM

TRIM

COLLAR

BUILDING EXTERIOR

2. Horizontal Vent and Air Intake Terminal Location - Observe the following limitations on the vent terminal location (also see Figure 7.11). When locating a concentric terminal, observe the limitations outlined below for “vent terminals”.

• Vent terminal must be at least 1 foot from any door, window, or gravity inlet into the building.

• When Terminal Option A (fittings) are used, maintain the correct clearance and orientation between the intake and exhaust terminals. If possible, locate vent and combustion air terminals on the same wall to prevent nuisance shutdowns. If not, boiler may be installed with roof vent terminal and sidewall combustion air terminal (see Section D). When installed on the same wall, locate exhaust vent terminal at same height or higher than combustion air intake terminal. Horizontal separation: Recommended: 36”, Minimum: 12”, Maximum: none. Minimum horizontal separation of 12” is required regardless of vertical separation.

• The bottom of all terminals must be at least 12” above the normal snow line. In no case should they be less than 12” above grade level.

• The bottom of the vent terminal must be at least 7 feet above a public walkway.

• Do not install the vent terminal directly over windows or doors.

• The bottom of the vent terminal must be at least 3 feet above any forced air inlet located within 10 feet.

• USA Only: A clearance of at least 4 feet horizontally must be maintained between the vent terminal and gas meters, electric meters, regulators, and relief equipment. Do not install vent terminal over this equipment. In Canada, refer to B149.1 Installation Code for clearance to meters, regulators and relief equipment.

• Do not locate the vent terminal under decks or similar structures.

• Top of terminal must be at least 24” below ventilated eves, soffits and other overhangs. In no case may the overhang depth exceed 48”. Where permitted by the authority having jurisdiction and local experience, the terminal may be located closer to unventilated soffits. For the minimum vertical separation, which depends upon the depth of the soffit, see Figure 7.11.

• Vent terminal must be at least 6 feet from an inside corner.

• Under certain conditions, water in the flue gas may condense, and possibly freeze, on objects around the vent terminal including on the structure itself. If these objects are subject to damage by flue gas condensate, they should be moved or protected.

• Install the vent and air intake terminals on a wall away from the prevailing wind. Reliable operation of this boiler cannot be guaranteed if these terminals are subjected to winds in excess of 40 mph.

• Air intake terminal must not terminate in areas that might contain combustion air contaminates, such as near swimming pools. See WARNING on page 14.

Figure 7.6: Horizontal CPVC/PVC Venting, (Vent Option #1, Terminal Option A)

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Page 25

VII. Venting B. Design Requirements Unique to Horizontal Twin Pipe Venting Systems (continued)

CPVC VENT PIPE

(FIRST 30" + ELBOW)

PVC AIR

INTAKE PIPE

PITCH INTAKE AWAY FROM

BOILER IF POSSIBLE

BOILER ROOM

PVC VENT PIPE

PITCH VENT PIPE 1/4" PER FOOT TOWARDS BOILER

ALTERNATE ORIENTATION

BUILDING EXTERIOR

Figure 7.7: Horizontal CPVC/PVC Venting with Low Profile Terminal,

CPVC VENT PIPE

(FIRST 30" + ELBOW)

3" PVC AIR

INTAKE PIPE

PITCH INTAKE AWAY FROM

BOILER IF POSSIBLE

(Vent Option #1, Terminal Options B & C)

PVC VENT PIPE

PITCH VENT PIPE 1/4" PER FOOT TOWARDS BOILER

BUILDING EXTERIOR

BOILER ROOM

Figure 7.8: Horizontal CPVC/PVC Venting with Concentric Vent Terminal,

(Vent Option #1, Terminal Options D & E)

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Page 26

VII. Venting B. Design Requirements Unique to Horizontal Twin Pipe Venting Systems (continued)

SELKIRK POLYFLUE OR CENTROTHERM INNOFLUE VENT PIPE

BUILDING EXTERIOR

PITCH INTAKE AWAY FROM

BOILER IF POSSIBLE

BOILER ROOM

TRIM

COLLAR

Figure 7.9: Duravent PolyPro, Selkirk, Polyflue or Centrotherm InnoFlue Horizontal Venting

(Vent Options #2-4, Terminal Option A)

PITCH VENT PIPE 5/8" PER FOOT TOWARDS BOILER

3" DURAVENT POLYPRO VENT PIPE

PVC AIR

INTAKE PIPE

PITCH INTAKE AWAY FROM

BOILER IF POSSIBLE

BOILER ROOM

Figure 7.10: Duravent PolyPro Horizontal Venting with Concentric Terminal,

BUILDING EXTERIOR

(Vent Option #2, Terminal Option F)

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Page 27

VII. Venting B. Design Requirements Unique to Horizontal Twin Pipe Venting Systems (continued)

108095-02- 4/18

Terminal (Shown) Two-Pipe System Air Intake Terminal (Not Shown)

Note: Air intake termination not shown.

Figure 7.11: Location of Vent Terminal Relative to Windows, Doors, Grades, Overhangs, Meters and Forced Air Inlets - Two-Pipe System Vent

Page 28

VII. Venting C. Design Requirements Unique to Vertical Venting Systems (continued)

Figure 7.12: Snorkel Terminal Configuration (CPVC/PVC Vent Systems Only)

C. Design Requirements Unique to Vertical Venting Systems

Table 7.13a summarizes all vertical twin pipe vent options. Table 7.13.b summarizes vent options in which an abandoned B-vent chimney is used both as a chase for the vent pipe and as a conduit for combustion air. In addition to the requirements in Section VII - A, observe the following design requirements:

1. Permitted Terminals for Vertical Venting

Terminal Option H: Fittings (Acceptable for Vent Options 5-8) – Vent terminates in a plain end (coupling for PVC, bell end for PolyPro, Polyflue and plain end pipe for InnoFlue). Intake terminates in a PVC 180 elbow pointing down (two sweep 90’s may be substituted). Observe the clearances from the roof, and normal snow line on the roof, shown in Figures 7.15 and 7.17. The section of PolyPro, Polyflue or InnoFlue exposed to the outdoors must be UV resistant.

Use of rodent screens (not supplied) is generally recommended for both terminations. These can be fabricated from 2 x 2 (1/2” mesh) stainless steel screen. Rodent screens and are installed as shown in Figure 7.29. Rodent screens (“bird guards”) for PolyPro, InnoFlue and Polyflue are as follows:

Size/Vent System Rodent Screen (“Bird Guard”) 3” PolyPro DuraVent # 3PPS-BG

3” Polyflue Selkirk # 3PV-HVST 3” InnoFlue Centrotherm # IASPP03

Terminal Option I: Ipex FGV Concentric Terminal (Acceptable for Vent Option 5) - This terminal is shown in Figure 7.16 and may be used with CPVC/PVC vent systems. Use a compatible roof flashing and storm collar in accordance with the Ipex instructions for this terminal. This terminal is available in various lengths and in both PVC and CPVC. Terminals acceptable for use with these vent options are as follows:

Ipex PN FGV Concentric Terminal Description 196006 3 x 20” PVC

196106 3 x 32” PVC 196116 3 x 44” PVC 197107 3 x 32” CPVC 197117 3 x 44” CPVC

See Section VII - E of this manual and the Ipex instructions provided with the terminal, for installation details.

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Page 29

VII. Venting

C. Design Requirements Unique to Vertical Venting Systems (continued)

Table 7.13a: Summary of Vertical Twin Pipe Venting Options

Option 5 6 7 8

Illustrated in Figure 7.15, 7.17 7. 17, 7. 1 8 7. 1 7 7. 1 7

Pipe Penetration through Structure

Material

Nominal Diameter

Min Equivalent Vent Length:

Models

Max Equivalent Vent Length (Note 1):

Models

Vent Roof Roof Roof Roof

Intake Roof Roof Roof Roof

CPVC/

Vent

Intake PVC PVC PVC PVC Vent 3” 3” 3” 3” Intake 3” 3” 3” 3”

135 12” 12” 12” 12” 150 52” 52” 52” 52” 180 52” 52” 52” 52”

135 135ft 135ft 135ft 135ft 150 135ft 135ft 135ft 135ft 180 135ft 135ft 135ft 135ft

PVC

(Note 2)

DuraVent

PolyPro

(Rigid)

Selkirk

Polyflue

Centro-

therm

InnoFlue

Terminal Option H

(Fittings)

Terminal Option I

(Ipex FGV Concentric)

Vent

Intake

Coupling

w/Screen

180 Elbow

w/Screen

Ipex

196006

(Note 3)

3PPS-12B

3PPS-36B

w/Screen

180 Elbow

w/Screen

3PF-10UV

3PF-39UV

w/Screen

180 Elbow

w/Screen

Not Permitted

ISEP03 or ISEP0339

w/Screen

180 Elbow

w/Screen

Terminal Option J

(DiversiTech CVENT Concentric)

Terminal Option K

(DuraVent Vertical Concentric)

Notes:

1. Max vent lengths shown also apply to the intake. For example, Vent Option #1 may have up to 135ft of vent pipe and also up to 135 ft of intake pipe.

2. First 30” of vent and vent Elbow connected to boiler must be CPVC. Downstream vent pipe can be PVC except as noted in text.

3. Ipex FGV Concentric Terminal available in various lengths and also CPVC (see text).

CVENT-3 Not Permitted

Not

Permitted

3PPS-VK Not Permitted

All vertical terminals require compatible roof flashing and storm collars.

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Page 30

VII. Venting C. Design Requirements Unique to Vertical Venting Systems (continued)

Table 7.13b: Summary of Vertical “B-Vent Air Chase” Vent Options

(B-Vent Chase MUST Be Sealed)

Option 9 10

Illustrated in Figure 7. 1 9 7.20

Pipe Penetration Through Structure

Material

Nominal Diameter

Min Equivalent Vent Length:

Models

Max Equivalent Vent Length (Note 1):

Models

Vent Manufacturer’s PN for Flex Termination/Components Required

Vent Roof Roof

Intake Roof Roof

Vent

Intake B Vent/PVC B Vent/PVC

Vent 3” 3”

Intake 3” 3”

Min B Vent ID 6” 6”

135 36” 36”

150 52” 52”

180 52” 52”

135 135ft 135ft

150 135ft 135ft

180 135ft 135ft

DuraVent

PolyPro

(Rigid/Flex)

3PPS-VFT

3PPS-BV*

3PPS-FLEX**

Centrotherm

InnoFlue SW/Flex

IFBK03****

IAWP03B

* Specify size of B vent (e.g. 3PPS-BV6 is for use with 6” B vent) ** Specify length in feet. **** Specify Flex length and B-vent diameter (e.g. IFBK032506 includes 25ft of flex and used with 6” B vent)

Note 1: Max vent lengths shown also apply to the intake. Flex vent reduces the maximum allowable vent length. See equivalent lengths for flex vent shown in Table 7.14 and sizing example on next page.

NOTICE Vertical venting and combustion air roof penetrations (where applicable) require the use of roof flashing and storm collar, which are not supplied with the boiler, to prevent moisture from entering the structure.

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Page 31

VII. Venting C. Design Requirements Unique to Vertical Venting Systems (continued)

Terminal Option J: DiversiTech Concentric Terminal (Acceptable for Vent Option 5) - This terminal is shown in Figure 7.16 and may be used with CPVC/PVC vent systems. See Section VII - E of this manual and the DiversiTech instructions provided with the terminal, for installation details.

Terminal Option K: DuraVent PolyPro Concentric Terminal (Acceptable for Vent Option 6) - This terminal is shown in Figure 7.18 and may be used with DuraVent 3” PolyPro vent systems. Use a compatible DuraVent roof flashing and storm collar in accordance with the DuraVent instructions for this terminal See Section VII - F of this manual and the DuraVent instructions provided with the terminal, for installation details.

2. Vertical Vent and Air Intake Location – Observe the following clearances from roof mounted terminals:

• Bottom of air intake opening must be at least 12” above the normal snow line anticipated on the roof.

• Exhaust opening must be at least 2ft above any portion of the roof or structure located within horizontally within 10ft.

• For terminal option H, maintain at least 12” of vertical separation between the exhaust and intake opening as shown in Figure 7.15 and 7.17.

3. Requirements for B-Vent Air Chase Options – Observe the following additional requirements when using an abandoned B-vent chimney as an air chase as described in Options # 9 & 10. Also refer to Figures 7.19 & 7.20.

• B vent must be clean and in good condition.

• Use of flex Polypropylene outside of B-vent chimney is not permitted.

• All joints and seams in the B-vent must be sealed with RTV. If these seams are not accessible, vent options 9 - 10 cannot be used while complying with the National Fuel Gas Code (as an alternative, the B-vent chimney can be used as a chase for the vent pipe while combustion air is piped from an outside wall - see Section VII - D for additional details).

• All venting is Polypropylene supplied by the vent manufacturer shown in Table 7.13b. The portion of this venting within the B–vent is flexible.

• All flex pipe must be installed vertically. Up to two offsets (four bends) may be made in the vertical run of flex pipe. Bends used to make these offsets may not exceed 45 degrees.

• Because the flex pipe is corrugated, it has a higher pressure drop than the rigid pipe used elsewhere in the vent system. Equivalent lengths for flex venting are shown in Table 7.14. Reduce the maximum allowable vent length shown in Table 7.13b by this equivalent length for each foot of flex pipe used, as well as for each elbow in addition to the first. The termination is not counted. If offsets (described above) are present, the equivalent length of the bends in these offsets can also be ignored.

Example: A 135MBH model is to be installed as using Vent Option 9 as shown in Figure 7.19. The following components are used:

Vent: 3” DuraVent Poly-Pro (Rigid) – 4ft 3” DuraVent Poly-Pro Flex – 20ft Poly-Pro elbows – 2 DuraVent 3PPS-VFT Terminal (exhaust side)

Intake: 3” PVC – 6ft 3” PVC Sweep 90 – 3 Turn in B vent Tee Straight B-vent (6” or larger) containing flex vent – 20ft DuraVent 3PPS-VFT Terminal (intake side)

Vent Equivalent length – First elbow is ignored. The terminal is also ignored. From Table 7.14, the equivalent length of 3” DuraVent Poly-Pro Flex is 2.0ft. From Table 7.1 the equivalent length of the second 90 elbow is 8.7ft. The equivalent length of the vent system is therefore:

4 + 8.7 + (20 x 2.0) = 52.7ft. Since Vent Option 9 shows a max vent length of 135ft, the planned vent length of OK.

Intake Equivalent length - First elbow and the turn in the B vent tee are ignored, leaving two sweep 90 elbows that must be counted. From Table 7.1, the equivalent length of each of these elbows is 4.0ft. From Table 7.14 the equivalent length of the vent containing flex is 1.0ft. Equivalent length of the intake system is therefore:

(2 x 4.0) +6 +(20 x 1.0) = 34.0ft.

Since this is less than 135ft, the planned intake length is OK.

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VII. Venting C. Design Requirements Unique to Vertical Venting Systems (continued)

Table 7.14: Equivalent Length of Flex Pipe

Equivalent Length (ft)

Flex Vent (1 ft):

3” DuraVent PolyPro Flex 2.0 ft

3” Centrotherm InnoFlue Flex 2.3 ft

3” Selkirk Polyflue 2.3 ft

3” Duravent FasNSeal Flex 1.0 ft

B-Vent Air Chase (1ft):

3” Flex Vent in 6” (or larger) B-Vent 1.0 ft

Note: Up to four 45 degree bends may be made in flex pipe or air chase. These bends are not counted when figuring equivalent length.

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VII. Venting C. Design Requirements Unique to Vertical Venting Systems (continued)

Figure 7.15: Vertical CPVC/PVC Venting (Vent Option 5, Terminal Option H)

Figure 7.16: Vertical CPVC/PVC Venting with IPEX Concentric Vent Terminal

(Vent Option 5, Terminal Option I, J)

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VII. Venting C. Design Requirements Unique to Vertical Venting Systems (continued)

Figure 7.17: Duravent PolyPro, Selkirk Polyflue or Centrotherm InnoFlue Vertical Single Wall PP Venting

(Vent Options #6-8, Terminal Option H)

Figure 7.18: Duravent PolyPro Vertical Venting with Concentric Terminal

(Vent Option #6, Terminal Option K)

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VII. Venting C. Design Requirements Unique to Vertical Venting Systems (continued)

Figure 7.19: Duravent PolyPro B-Vent Air Chase System (Vent Option #9)

Figure 7.20: Centrotherm InnoFlue B-Vent Air Chase System (Vent Option #10)

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VII. Venting D. Design Requirements Unique to Split Vent Systems (continued)

D. Design Requirements Unique to Split Vent Systems

Table 7.21 summarizes all split vent options. Illustrations of split vent systems are shown in Figures 7.22, 7.23,

7.24a and 7.25a. In addition to the requirements in Section VII - A, observe the following design requirements:

1. Permitted Terminals for Split Venting:

Rigid Vent Systems (Vent Options 11-14) – Vent terminates in a plain end (coupling for PVC, bell end for PolyPro,

Polyflue, and plain end pipe for InnoFlue). Intake terminates in a PVC 90 sweep elbow pointing down. The section of PolyPro, Polyflue or InnoFlue exposed to the outdoors must be UV resistant.

Use of rodent screens (not supplied) is generally recommended for both terminations. These can be

fabricated from 2 x 2 (1/2” mesh) stainless steel screen. Rodent screens and are installed as shown in Figure

7.28. Rodent screens are installed as shown in Figure 7.28. Rodent screens (“bird guards”) for PolyPro, Polyflue and InnoFlue are as follows:

Size/Vent System Rodent Screen (“Bird Guard”) 3” PolyPro DuraVent # 3PPS-BG 3” Polyflue Selkirk #3PF-HVST 3” InnoFlue Centrotherm # IASPP03

Flex Vent Terminals (Options 15-18) – The flex vent kits shown for options 15-18 include vent terminals that must

be installed in accordance with the vent manufacturer’s instructions. In some cases, different terminals are used for Masonry and B-vent chimney chases.

Air Intake Terminals (Vent Options 11-18) - All split venting options shown in Tables 7.21 terminate in a

PVC 90 sweep elbow pointing down. Use of rodent screens (not supplied) is generally recommended for both terminations. These can be fabricated from 2 x 2 (1/2” mesh) stainless steel screen. Rodent screens and are installed as shown in Figure 7.28.

2. Vent Terminal Location – Observe the following clearances from roof mounted vent terminals (also see Figures

7.22, 7.23, 7.24a or 7.25a):

• Bottom of terminal must be at least 12” above the normal snow line anticipated on the roof.

• Exhaust opening must be at least 2ft above any portion of the roof or structure located within horizontally within 10ft.

3. Horizontal Air Intake Terminal Location - Observe the following limitations on the intake terminal location (also see Figures 7.22, 7.23,7.24a, and 7.25a):

• The bottom of all terminals must be at least 12” above the normal snow line. In no case should they be less than 12” above grade level.

• If possible, install the intake terminal on a wall away from the prevailing wind. Reliable operation of this boiler cannot be guaranteed if the intake terminal is subjected to winds in excess of 40 mph.

• Air intake terminal must not terminate in areas that might contain combustion air contaminates, such as near swimming pools. See WARNING on page 13.

4. Use of abandoned chimneys as a Vent Chase for flexible Polypropylene Venting (Options 15-17) – Vent options 15-17 permit flexible Polypropylene venting to be routed to the roof using an abandoned masonry or B- vent chimney. In these applications combustion air is drawn horizontally from a wall terminal. See Figure 7.23 or

7.24a. When using one of these vent options, observe the following requirements:

• When a masonry chimney containing multiple flues is used as a chase, ALL flues must be abandoned (Figure 7.24b).

• Masonry or B vent chimney used as a chase must be structurally sound and in good repair.

• Use of flex Polypropylene outside of a masonry or B-vent chimney is not permitted unless allowed by the vent manufacturer and permitted by local codes.

• All venting is Polypropylene supplied by the vent manufacturer shown in Table 7.21. The portion of this venting within the masonry or B–vent chimney is flexible.

• All flex pipe must be installed vertically. Up to two offsets (four bends) may be made in the vertical run of flex pipe. Bends used to make these offsets may not exceed 45 degrees (Figure 7.24b).

• Because the flex pipe is corrugated, it has a higher pressure drop than the rigid pipe used elsewhere in the vent system. Equivalent lengths for flex venting are shown in Table 7.14. Reduce the maximum allowable vent length shown in Table 7.21 by this equivalent length for each foot of flex pipe used, as well as for each elbow in addition to the first. The first elbow and termination are not counted. If offsets (described above) are present, the equivalent length of the bends in these offsets can also be ignored.

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VII. Venting D. Design Requirements Unique to Split Vent Systems (continued)

5. Use of abandoned chimney as vent chase for flexible Stainless Steel venting (option 18) - Vent option 18 permits flexible Stainless Steel venting to be routed to the roof using an abandoned masonry type chimney. In this application, combustion air is drawn horizontally from a wall terminal. See Figure 7.25a. When using one of these options, observe the following requirements:

• When a masonry chimney containing multiple flues is used as a chase, the flexible stainless vent installation is permitted through an adjacent UNUSED flue providing local authority having jurisdiction approves such installation. (Figure 25b)

• Masonry chimney used as a chase must be structurally sound and in good repair.

• All venting is stainless steel supplied by the vent manufacturer shown in Table 7.21. The portion of this venting within the masonry or B-vent chimney is flexible.

• When flexible stainless steel is used for combustion product venting, it must be installed at vertical or near vertical plane. This will insure proper condensate flow back to the boiler. (Figure 25a)

Example: A 135MBH model is to be installed as using Vent Option 15 in a masonry chimney as shown in Figure

7.24a. The following components are used:

Vent: 3” DuraVent Poly-Pro (Rigid) – 4ft 3” DuraVent Poly-Pro Flex – 30ft Poly-Pro elbows – 2 (one at base of chimney and one above boiler) DuraVent 3PPS-FK Terminal

Intake: 3” PVC – 6ft 3” PVC Sweep 90 – 2 (one above the boiler and one as an intake terminal)

Vent Equivalent length – First elbow is ignored. The terminal is also ignored. From Table 7.14, the equivalent

length of 3” DuraVent Poly-Pro Flex is 2.0ft. From Table 7.1 the equivalent length of the second 90 elbow is 8.7ft. The equivalent length of the vent system is therefore:

4 + 8.7 + (30 x 2.0) = 72.7ft.

Since Vent Option 15 shows a max vent length of 135ft, the planned vent length of OK.

Intake Equivalent length - First elbow and termination elbow are ignored, leaving just the straight pipe.

Equivalent length of the intake system is therefore 6ft. Since this is less than 135ft, the planned intake length is OK.

WARNING

Asphyxiation Hazard. Flexible polypropylene vent must be installed only in an UNUSED chimney. A chimney flue is considered UNUSED when it is not being used for any appliance venting. If chimney is a multiple flue type where one of the multiple flues is being used for an appliance venting, the flexible vent installation is not permitted through any of the adjacent flues.

Asphyxiation Hazard. Flexible stainless steel vent must be installed only in an UNUSED chimney flue. A chimney flue is considered UNUSED when it is not being used for any appliance venting. If chimney is a multiple flue type where one of the multiple flues is being used for an appliance venting, the flexible stainless vent installation is permitted through an adjacent, unused flue providing a local authority having jurisdiction approves such installation.

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VII. Venting D. Design Requirements Unique to Split Vent Systems (continued)

Table 7.21: Summary of Split Vent System Options

Option # 11 12 13 14 15 16

Illustrated in Figure 7.22 7.22 7.22 7.22 7.23, 7.24 7.23, 7.24

Pipe Penetration Through Structure

Material

Nominal Diameter

Min Equivalent Vent Length:

Models

Max Equivalent Vent Length (Note 1):

Models

Rigid Vent Terminals

Flex Termination & Components (Masonry Chimney Chase) (Note 3)

Flex Termination & Components (B-Vent Chimney Chase)

Vent Roof Roof Roof Roof Roof Roof

Intake Wall Wall Wall Wall Wall Wall

Vent

Intake PVC PVC PVC PVC PVC PVC

Vent 3” 3” 3” 3” 3” 3”

Intake 3” 3” 3” 3” 3” 3”

135 48” 48” 48” 48” 48” 48”

150 52” 52” 52” 52” 52” 52”

180 52” 52” 52” 52” 52” 52”

135 135ft 135ft 135ft 135ft 135ft 135ft

150 135ft 135ft 135ft 135ft 135ft 135ft

180 135ft 135ft 135ft 135ft 135ft 135ft

Vent

Intake

Vent

CPVC/PVC

(Note 2)

Coupling w/Screen

90 Elbow w/Screen

DuraVent

PolyPro

(Rigid)

3PPS-12B or

3PPS-36B

w/Screen

90 Elbow w/Screen

Selkirk

Polyflue

3PF-10UV

or 3PF-

39UV

w/Screen

90 Elbow

w/Screen

Centrotherm InnoFlue SW

ISEP03 or

ISEP0339 w/

Screen

90 Elbow w/

Screen

Not Permitted

Intake

Vent

Not Permitted

Intake

DuraVent

PolyPro

(Rigid/Flex)

Not Permitted

3PPS-FK

3PPS-FLEX**

90 Elbow w/Screen

3PPS-VFT

3PPS-BF*

3PPS-FLEX**

90 Elbow w/Screen

Selkirk Polyflue

(Rigid/Flex)

3PF-FLEX-KIT

3PF-FLEX

90 Elbow w/Screen

3PF-10UV or

3PF-39UV

w/Screen

3PF-BVSC

(Note 3)

90 Elbow w/Screen

* Specify size of B vent (e.g. 3PPS-BV6 is for use with 6” B vent). ** Specify length in feet.

Note 1: Max vent lengths shown also apply to the intake. Flex vent reduces the maximum allowable vent length in some applications. See equivalent lengths for flex vent shown in Table 7.14 and sizing example on page 32. Note 2: First 30” plus first exhaust elbow are CPVC. Note 3: See Polyflue installation manual for gaskets, spacers and other required vent components.

All vertical terminals require compatible roof flashing and storm collars.

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Page 39

VII. Venting D. Design Requirements Unique to Split Vent Systems (continued)

Table 7.21: Summary of Split Vent System Options (cont.)

Option # 17 18

Illustrated in Figure 7.23, 7.24 7.23, 7.24

Pipe Penetration Through Structure

Material

Nominal Diameter

Min Equivalent Vent Length:

Models

Max Equivalent Vent Length (Note 1):

Models

Rigid Vent Terminals

Vent Roof Roof

Intake Wall Wall

Centrotherm

Vent

Intake PVC PVC

Vent 3” 3”

Intake 3” 3”

135 48” 48”

150 52” 52”

180 52” 52”

135 135ft 135ft

150 135ft 135ft

180 135ft 135ft

Vent

Innoflue

(Ridgid/Flex)

DuraVent

FasNSeal

(Stainless,

Ridgid/Flex)

Not Permitted

Intake

Flex Termination & Components (Masonry Chimney Chase)

Flex Termination & Components (B-Vent Chimney Chase)

** Specify length in feet. **** Specify Flex length and B vent diameter (e.g. IFBK032506 includes 25ft of flex and used with 6” B vent).

Vent IFCK03**

Intake

Vent IFBK03**** 2SVFLXR03

Intake

90 Elbow

w/Screen

90 Elbow

w/Screen

2SVSCKIT03**

2SVFLXCN03**

90 Elbow

w/Screen

90 Elbow

w/Screen

All vertical terminals require compatible roof flashing and storm collars.

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VII. Venting D. Design Requirements Unique to Split Vent Systems (continued)

FIRE STOP LISTED FOR

USE WITH VENT SYSTEM

PITCH 1/4" PER FT TOWARDS TRAP

PVC AIR INTAKE PIPE

Figure 7.22: Split Rigid Vent System (Vent Options 11-14)

PVC AIR INTAKE PIPE

Figure 7.23: Split Vent System (Flex in B-Vent Chase) Vent Options 15-17)

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VII. Venting D. Design Requirements Unique to Split Vent Systems (continued)

EXHAUST

NOTE: DURAVENT POLYPRO FLEX

COMPONENTS SHOWN.

PPs FLEX

CLEAN, TIGHT

UNUSED CHIMNEY

BASE SUPPORT

AND ELBOW FOR

PPs FLEX PIPE

EXTERIOR

WALL PLATE

DURAVENT POLYPRO VENT PIPE

PVC AIR

INTAKE PIPE

BOILER

OUTSIDE WALL

PVC ELBOW WITH RODENT SCREEN

12" MIN

NORMAL SNOW LINE ABOVE GROUND LEVEL

10" OR LESS

Figure 7.24a: Split Vent System (PP Flex in Abandoned Masonry Chimney) (Vent Options 15-17)

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VII. Venting D. Design Requirements Unique to Split Vent Systems (continued)

BOILER

WITH CROWN

45° MAX

BOILER

CHIMNEY AND

FOUNDATION ARE

STRUCTURALLY SOUND

Venting of Other

Appliances

(Or Fireplace) into Chase

Adjacent Flues Prohibited!

Figure 7.24b: Flexible PP Masonry Chimney Chase Requirements

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VII. Venting D. Design Requirements Unique to Split Vent Systems (continued)

RIGID SINGLE WALL VENT

RIGID TEE FOR SS FLEX PIPE W/ CONDENSATE DRAIN CAP

CLEAN, UNUSED, MASONRY CHIMNEY FLUE

STAINLESS STEEL, DOUBLE LAYER, FLEXIBLE LINER

EXTERIOR WALL PLATE

BOILER

FEMALE FLEX ADAPTER

MALE FLEX ADAPTER

RIGID ELBOW FOR SS FLEX PIPE

ALTERNATE VENT PIPING

RIGID TEE WITH CONDENSATE DRAIN CAP

12" MIN.

10" OR LESS

NORMAL SNOW LINE ABOVE GROUND LEVEL

PVC ELBOW WITH RODENT SCREEN

PVC AIR INTAKE PIPE

OUTSIDE WALL

RAIN CAP

Figure 7.25a: Split Vent Systems (SS Flex in Abandoned Masonry Chimney) (Vent Option 18)

Figure 7.25b: Flexible SS Masonry Chimney Chase Requirements

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VII. Venting E. Assembly of CPVC/PVC Vent Systems (continued)

E. Assembly of CPVC/PVC Vent Systems

WARNING

Asphyxiation Hazard. Failure to follow these instructions could cause products of combustion to enter the building, resulting in severe property damage, personal injury or death.

•

Use all CPVC vent components for near-boiler vent piping before transitioning to Schedule 40 PVC pipe (ASTM 2665) components for remainder of vent system.

•

Use CPVC vent components within any interior space where air cannot circulate freely, including through vertical or horizontal chase ways, inside a stud wall, in closets and through wall penetrations.

•

The use of cellular core PVC (ASTM F891), cellular core CPVC or Radel (polyphenolsulfone is prohibited.

•

All condensate that forms in the vent must be able to drain back to the boiler.

•

Never leave the boiler in operation without the gas sample cap in place (Figure 7.27).

1. Assemble the vent system, starting at the boiler:

a. If 3” PVC is to be used for venting, a 3” CPVC elbow and the 30” straight section of CPVC must be used

before transitioning to PVC. If necessary the 30” straight section of CPVC may be cut at any location and a CPVC elbow can be inserted between the two resulting segments.

b. When cutting CPVC or PVC pipe, use a miter saw or a saw designed to cut PVC pipe. Use a miter box or

other method to cut pipe squarely. De-burr both the inside and outside of the cut end. c. Dry fit all vent components before assembly. d. The vent adaptor has three different inside diameters. The larger (upper) inside diameter accepts 3” CPVC

pipe and is used in this application (the middle inside diameter accepts 3” nominal PolyPro, Polyflue or

InnoFlue, and the smaller, lower inside diameter accepts 3” stainless steel). A locking band clamp in the

adaptor prevents the vent pipe from coming out of the adaptor once it is installed and tightened. Lubricate the

upper gasket in the vent adaptor with water and insert the first piece of 3” CPVC into the vent adaptor until it

bottoms out. Tighten locking band clamp to secure vent pipe.

e. Assemble a 3” CPVC elbow and remainder of 30” CPVC piping before transitioning to PVC. If 3” PVC is

used, the first piece of PVC will either be connected to the CPVC elbow or the end of a section of CPVC vent

pipe. In the latter case, a PVC coupling may be used to connect the first piece of PVC to the last piece of

CPVC. f. Clean all CPVC and PVC components with the appropriate primer before cementing. Cement the vent system

together, starting at the boiler and following the instructions provided on the cans of cement and primer. Use

a field supplied cement and primer that is listed for use with the materials being joined (CPVC and/or PVC).

The following, or its equivalent, may be used to join CPVC to PVC:

• IPS Corporation #P-70 Primer

• IPS Corporation #790 Multi-Purpose Solvent Cement

Always use primer on both the pipe and fitting before applying the cement. Assemble the pipe in accordance with the instructions on the cans of primer and cement. g. Assemble the rest of the vent system, being sure to pitch horizontal sections back towards the boiler 1/4”/ft.

Support the vent at intervals not exceeding 4ft. h. Maintain the clearances from the vent pipe outlined in Section VII - A of this manual. If exiting the exterior wall

using PVC pipe, use half of an appropriately sized wall thimble (or a sheet metal plate) on the exterior of the

building, to provide a weather tight seal while maintaining the proper clearance in the wall penetration. Seal

the joint between the pipe and the wall plate using RTV applied on the exterior side of the wall. This sealant

must not restrain the expansion of the vent pipe.

2. Installation of Air Intake System - Start assembly of the PVC air intake system at the boiler. Assembly of the air intake system is done in the same manner as the vent system except as follows:

a. Drill a 7/32” clearance hole into the front side of the air intake adapter. Insert the first piece of PVC air

intake pipe into the air intake connection and drill a 1/8” tap hole into the PVC which lines up with the 7/32” clearance hole and secure them together with a #10 x 1” sheet metal screw. Seal the joint

between the intake pipe and the adaptor with RTV. b. All intake piping may be PVC. c. There is a 0” minimum clearance between the air intake piping and all types of construction. d. To the extent possible, pitch horizontal air intake piping towards the outdoors.

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VII. Venting E. Assembly of CPVC/PVC Vent Systems (continued)

Figure 7.27: Vent Connections and Flue Gas Sample Cap Location

3. Installation of Horizontal Fitting Terminals (Terminal Option A):

a. See Figure 7.28 for proper orientation of twin pipe horizontal terminals. Outer edge of both terminals must be

within 10” from wall surface. (Figure 7.6)

b. If desired, the terminals can be attached to the end of the vent and/or intake pipes with field supplied

stainless steel screws so that they can be later removed for cleaning and inspection. If this is done, drill a clearance hole in the coupling or elbow and a tap hole in the end of the vent/intake pipes to accept these screws.

c. If these terminals are installed on snorkels, assemble the snorkels as shown in Figure 7.12. Brace the vertical

run of piping on the building exterior as required.

4. Installation of Vertical Fitting Terminals (Terminal Option H): a. See Figure 7.29 for the proper orientation of twin pipe vertical terminals. b. The coupling is used to secure the rodent screen to the end of the vent pipe. c. A 180° bend (or two 90° elbows) are installed on the top of the air intake pipe. If two 90° elbows are used, a

rodent screen can be installed between them (Figure 7.29). If a 180° bend is used, install a rodent screen in the open side of the bend, using a ring made of PVC pipe. If desired, the termination fittings can be attached to the end of the vent and/or intake pipes with field supplied stainless steel screws so that they can be later removed for cleaning and inspection. If this is done, drill a clearance hole in these fittings and a tap hole in the end of the vent/intake pipes to accept these screws.

d. Use roof flashings and storm collars to prevent moisture from entering the building. Seal the roof flashing to

the roof using generally accepted practice for the type of roof on the installation. Apply RTV to seal the storm collars to the vent and intake pipes.

5. Installation of IPEX low profile vent terminal (Terminal Option B) - See Figure 7.30: a. Cut two holes in wall to accommodate the size PVC pipe being used. The distance between hole centers is

5.6”.

b. Slide both vent and intake air pipes through the holes, and cement them to the base of the vent termination kit

using a primer and cement listed for use with PVC.

c. Fasten the vent base to the wall using the supplied screws and anchors. The anchors require the drilling of a

3/16” hole x 1-3/16” deep. Locate the holes using the vent base as a template.

d. Screw the vent cap to the vent base using the supplied screws.

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VII. Venting E. Assembly of CPVC/PVC Vent Systems (continued)

Figure 7.28: Installation of Standard Horizontal Terminals

Figure 7.29: Installation of Standard Vertical Terminals

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VII. Venting E. Assembly of CPVC/PVC Vent Systems (continued)

e. Once the vent termination and pipes are secure seal the wall penetrations from the interior using a weather

resistant RTV sealant.

6. Installation of DiversiTech Low Profile Terminal (Terminal Option C) – See Figure 7.31: a. Use vent plate as a guide to locate the openings for the vent and air intake pipes, as well as to locate the

holes for the mounting screws. b. Drill two 3-1/8 holes through the wall for the vent and intake pipes. c. Drill four 3/16 holes for the mounting screws. d. Install the vent and intake pipe sections passing through the wall. Cut the pipes so that they protrude the

following distances from the surface on which the vent plate will be mounted:

• Vent: Between 1-3/4 and 2-1/4”

• Intake: Between ¼ and 1” e. Seal pipe penetrations in wall with RTV (silicone sealant). f. Mount the vent plate using the #8 x 2” screws and anchors provided with this kit. g. Seal the vent plate to the wall with RTV. h. Apply a bead of RTV around the OD of the vent pipe near its end. i. Slide the vent cap over the vent pipe and secure to the wall plate with the #8 x 2” screws provided.

7. Installation of IPEX FGV or DiversiTech CVENT Concentric Vent Terminal (Terminal Options D,E,I & J) - This terminal may be used for either horizontal or vertical venting. See Figure 7.33 for horizontal installation or Figure

7.34 for vertical installation. When PVC is used for venting, a 30” CPVC straight section and CPVC elbow must be used prior to connection of the vent system to this terminal. If the vent system is too short to permit this, use the IPEX FGV CPVC terminal: a. For horizontal installations at the planned location cut a round hole in the exterior wall 1/2” larger than the “C’

dimension indicated on Figure 7.32 for the size terminal being used. (See Section VII - B of this manual for permitted terminal locations).

b. For vertical installations, cut a hole in the roof large enough to clear the concentric terminal at the location of

the terminal (see Section VII - C of this manual for permitted terminal locations).

c. If desired, the terminal can be shortened. See Figure 7.32 for specific information on making the terminal kit

shorter based on the kit size being used. Cut the pipe squarely and de-burr both the OD and ID of the cut edges.

d. Cement the inner pipe section of PVC pipe supplied with this kit to the Wye fitting using a primer and cement

listed for use with PVC. e. Cement the outer pipe to the Wye, being careful, to keep the inner and outer pipes concentric. f. Slip the partially assembled terminal through the wall or ceiling from the inside and for horizontal installations

orient so that the side outlet on the Wye is on or above the horizontal plane. g. For horizontal installations, seal the gap between the OD of the “outer pipe” and the exterior side of the wall

with RTV sealant. h. Cement the rain cap onto the inner pipe. If desired, the rain cap can be attached to the inner pipe with the

supplied stainless steel screw and nut so that it can be later removed for cleaning and inspection. If this is

done, drill a 3/16”clearance hole in the rain cap and inner pipe in the location shown on Figure 7.32 for the

size terminal kit being used and affix screw and nut. Do not overtighten. A field supplied rodent screen may

also be installed on the end of the rain cap.

WARNING

Asphyxiation Hazard. CPVC/PVC vent piping and fittings rely on glued joints for proper sealing. Follow all manufacturer instructions and warnings when preparing pipe ends for joining and using the primer and the cement.

•

When PVC is used with the concentric vent kit, a 30” CPVC straight section and elbow must be used prior to connection of the vent system to this terminal. If the vent system is too short to permit this, use an FGV CPVC terminal.

•

Do not operate boiler without the rain cap in place.

•

Method of securing and sealing terminals to the outside wall must not restrain the expansion of vent pipe.

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VII. Venting E. Assembly of CPVC/PVC Vent Systems (continued)

Figure 7.30: Installation of IPEX Low Profile Terminal Through Sidewall

Figure 7.31: Installation of DiversiTech Low Profile Terminal Through Sidewall

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Page 49

VII. Venting E. Assembly of CPVC/PVC Vent Systems (continued)

Figure 7.32: Cutting IPEX and DiversiTech Concentric Vent Terminals

Figure 7.33: Installation of IPEX and DiversiTech Concentric Terminal through Sidewall

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VII. Venting E. Assembly of CPVC/PVC Vent Systems (continued)

Figure 7.34: Installation of IPEX and DiversiTech Concentric Terminal Through Roof

i. For vertical installations, use a roof flashing and storm collar to prevent moisture from entering the building.

Seal the roof flashing to the roof using generally accepted practice for the type of roof on the installation. Install the storm collar after verifying that the bottom of the rain cap will be at least 12” above the normal snow line. Apply RTV to seal the storm collars to the terminal.

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VII. Venting F. Assembly of DuraVent PolyPro Vent Systems (continued)

F. Assembly of DuraVent PolyPro Vent Systems

1. This boiler has been approved for use with the DuraVent PolyPro single wall Polypropylene vent system to be provided by the installer.

WARNING

Asphyxiation Hazard. Follow these instructions and the installation instructions included by the original Polypropylene venting component manufacturers, M&G/DuraVent. Failure to do so could cause products of combustion to enter the building, resulting in severe property damage, personal injury or death. Where a conflict arises between M&G/DuraVent instructions and these instructions, the more restrictive instructions shall govern. If any controls are replaced, they must be replaced with identical models.

Do not mix vent components or joining methods for listed manufacturers.

Examine all components for possible shipping damage prior to installation.

All condensate that forms in the vent must be able to drain back to the boiler.

2. Assemble the vent system, starting at the boiler:

a. The vent adaptor has three different inside diameters. The middle inside diameter accepts 3” nominal PolyPro

(Figure 7.27). A locking band clamp in the adaptor prevents the vent pipe from coming out of the adaptor once it is installed and tightened. Lubricate the upper gasket in the vent adaptor with soapy water and insert the first piece of 3” PolyPro into the adaptor until it bottoms out. Tighten locking band clamp to secure vent pipe.

b. Assemble the next piece of 3” PolyPro. c. For each joint, verify that the gasket is evenly seated in the bell (female) end of the pipe. Lubricate this gasket

with water. Slide a locking band over the male end of the pipe to be joined as shown in Figure 7.35. Push the male end of the next section of pipe into the bell until it bottoms out, then back out 1/4-5/8” to provide room for thermal expansion. Push barb on locking band over the bell end of the first section of pipe as shown in Figure 7.35.

d. Assemble the rest of the vent system per the manufacturer’s installation instructions, being sure to pitch

horizontal sections back towards the boiler 5/8” per ft.

e. Support each horizontal pipe section with a minimum of one wall strap each and at intervals not exceeding

4ft.

Figure 7.35: PolyPro Locking Band Installation

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VII. Venting F. Assembly of DuraVent PolyPro Vent Systems (continued)

3. Installation of Air Intake System - Start assembly of the PVC air intake system at the boiler. Assembly of the air intake system is done in the same manner as the vent system except as follows:

a. Drill a 7/32” clearance hole into the front side of the air intake adapter. Insert the first piece of PVC air

pipe and the adaptor with RTV. b. All intake piping may be PVC. c. There is a 0” minimum clearance between the air intake piping and all types of construction. d. To the extent possible, pitch horizontal air intake piping towards the outside.

WARNING

Asphyxiation Hazard. Vent systems made by M&G/DuraVent rely on gaskets for proper sealing. When these vent systems are used, take the following precautions:

• Make sure that gasket is in position and undamaged in the female end of the pipe.

• Make sure that both the male and female pipes are free of damage prior to assembly.

• Only cut vent pipe as permitted by the vent manufacturer in accordance with their instructions. When pipe is cut, the cut end must be square and carefully de-burred prior to assembly.

• Use locking band clamps at all vent pipe joints.

• Do not use anything other than soapy water to lubricate gaskets.

NOTICE The venting system must be free to expand and contract and supported in accordance with the installation instructions included by the original Polypropylene venting component manufacturer, M&G/ DuraVent. Polypropylene pipe sections must be disengaged 1/4 to 5/8 in. (6 mm to 16 mm) per joint to allow for thermal expansion.

4. Installation of Horizontal Fitting Terminals (Terminal Option A):

a. See Figure 7.36 for proper orientation of twin pipe horizontal terminals. Outer edge of exhaust coupling must

be 10” or less from the wall surface. (Figure 7.9) b. Remove the gasket from the end of the integral exhaust coupling and insert DuraVent Bird Guard #3PPS-BG

in it’s place. c. Add PVC intake per instructions from Section VII - F.

5. Installation of Vertical Fitting Terminals (Terminal Option H):

a. See Figure 7.37 for the proper orientation of twin pipe vertical terminals. b. Remove the gasket from the end of the integral exhaust coupling and insert the installer supplied rodent

screen in it’s place. c. A 180° bend (or two 90° elbows) are installed on the top of the air intake pipe. If two 90° elbows are used,

a rodent screen can be installed between them (Figure 7.37). If a 180° bend is used, a the rodent screen in

the open side of the bend, using a ring made of PVC pipe. If desired, the termination fittings can be attached

to the end of the intake pipes with field supplied stainless steel screws so that they can be later removed for

cleaning and inspection. If this is done, drill a clearance hole in these fittings and a tap hole in the end of the

intake pipes to accept these screws. d. Use roof flashings and storm collars to prevent moisture from entering the building. Seal the roof flashing to

the roof using generally accepted practice for the type of roof on the installation. Apply RTV to seal the storm

collars to the vent and intake pipes.

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VII. Venting F. Assembly of DuraVent PolyPro Vent Systems (continued)

Figure 7.36: Installation of Duravent PolyPro UV Resistant Single Wall Horizontal Terminal

Figure 7.37: Installation of Duravent PolyPro UV Resistant Single Wall Vertical Terminal

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VII. Venting F. Assembly of DuraVent PolyPro Vent Systems (continued)

6. Installation of DuraVent PolyPro Horizontal Concentric Vent Terminal (Terminal Option D) -

Install PolyPro Horizontal Concentric Termination Kit #3PPS-HK (Figure 7.39) as follows:

a. At the planned location cut a 5-1/8” round hole for the 3” terminal in the exterior wall. (See Section VII - A of

this manual for permitted terminal locations). b. If desired, the terminal can be shortened. Mark the desired location of the cut on the outer pipe no closer than

2” from the edge of the tab on the interior wall plate. Prior to cutting outer pipe measure dimension ‘A’ of the

inner pipe as shown in Figure 7.38 and maintain this dimension after cutting the outer pipe. All cuts must be

square and de-burred. c. Attach the exterior wall plate and seal all around with weather resistant RTV. d. Slide the cap through the exterior wall plate and hole from the outside of the building and orient the

termination so the air intake slots face down. The cap must be installed level or sloped 1/8” per foot away

from the appliance. e. Seal the termination to the exterior wall plate with weather resistant RTV. f. Slide the interior wall plate over the termination and attach to the wall from inside the room. g. Attach the interior wall plate to the termination with the provided hardware. h. Install gaskets into co-linear adapter. i. Attach co-linear adapter to horizontal termination and orient so that the side outlet on the adapter is on or

above the horizontal plane.

7. Vertical Installations using PolyPro Vertical Concentric Termination Kit #3PPS-VK (Figure 7.40):

a. Cut a hole in the roof large enough to clear the concentric terminal at the location of the terminal (see Section

VII - A of this manual for permitted terminal locations). b. Use a roof flashing and storm collar to prevent moisture from entering the building. See Figure 7.40 for the

model number of the flashing to be used depending on the type of roof. Seal the roof flashing to the roof

using generally accepted practice for the type of roof on the installation. c. Slide the vertical termination into the flashing from above until seated on the flashing. d. Plumb the termination and mount the support bracket to the structure. e. Install gaskets into co-linear adapter. f. Attach co-linear adapter to vertical termination.

Figure 7.38: Cutting Duravent PolyPro Horizontal Concentric Vent Terminal

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VII. Venting F. Assembly of DuraVent PolyPro Vent Systems (continued)

Figure 7.39: Installation of Duravent PolyPro Concentric Vent Terminal Through Sidewall

Figure 7.40: Installation of Duravent PolyPro Concentric Terminal Through Roof

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VII. Venting F. Assy of DuraVent PolyPro & G. Selkirk Polyflue Vent Systems (continued)

8. Installations using PolyPro-flex (Vent Options 9 & 15):

WARNING

Asphyxiation Hazard. When using PolyPro flex, observe the following precautions:

• PolyPro flex may be damaged by handling at low temperatures. Do not bend, uncoil, or attempt to install if it has been stored at a temperature below 42°F without allowing it to warm to a higher temperature first.

• Do not bend PolyPro flex more than 45°.

• Instructions below reference the DuraVent PolyPro Flex instruction manual. Not all vent configurations shown in the DuraVent manual are approved for use with this boiler.

Refer to DuraVent PolyPro flex Instructions for assembly of all flex components including the chimney cap and the adaptor to rigid PolyPro at the base of the masonry or B vent chimney. In addition, observe the following requirements:

a. Refer to the appropriate Vent option in Tables 7.13b or 7.21 for a list of the principle flex components

required. Rigid vent pipe by the same manufacturer will also be required for the run from the boiler to the

base of chimney. b. Masonry chimneys cannot be used for an air chase c. B vent chimneys can only be used for an air chase (Vent option 9) if the B vent has the minimum size shown

in Table 7.13b and is fully accessible for sealing of all joints and seams. d. When Vent Option 9 is used, install a Tee on the base of the B-vent that is the same size as the B- Vent

chimney. Install the PolyPro Lower B–Vent adaptor in the base of this Tee as described in the DuraVent

PolyPro Flex instructions. Connection of the PVC air intake pipe to the side outlet of the tee is made using a cap and a PVC socket x

male thread adaptor. Cut a clearance hole in the cap for the male threads. Secure the adaptor to the cap

using a 3” electrical conduit lock nut. Seal all joints with RTV.

G. Assembly of Selkirk Polyflue Vent Systems

1. This boiler has been approved for use with the Selkirk Polyflue single wall Polypropylene vent system to be provided by the installer.

2. Assemble the vent system, starting at the boiler: a. The vent adaptor has three different inside diameters. The middle inside diameter accepts 3” nominal Polyflue

(Figure 7.27). A locking band clamp in the adaptor prevents the vent pipe from coming out of the adaptor once it is installed and tightened. Lubricate the gaskets in the vent adaptor with mild soapy water and insert the first piece of 3” Polyflue into the adaptor until it bottoms out. Tighten locking band clamp to secure vent

pipe. b. Assemble the next piece of 3” Polyflue. c. For each joint, verify that the gasket is evenly seated in the bell (female) end of the pipe. Lubricate this gasket

with mild soapy water. Slide a Pipe Locking Band over the male end of the pipe to be joined as shown in

Figure 7.41. Push the male end of the next section of pipe into the bell until it bottoms out, then back out 1/8—

1/4” to provide room for thermal expansion. Slide pipe locking band over the female end of the connections

and tighten both hose clamps. d. Assemble the rest of the vent system per the manufacturer’s installation instructions, being sure to pitch

horizontal sections back towards the boiler 5/8” per ft.

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VII. Venting G. Assembly of Selkirk Polyflue Vent Systems (continued)

3. Installation of Air Intake System - Start assembly of the PVC air intake system at the boiler. Assembly of the air

intake system is done in the same manner as the vent system except as follows: a. Drill a 7/32” clearance hole into the front side of the air intake adapter. Insert the first piece of PVC air

b. All intake piping may be PVC. There is a 0” minimum clearance between the air intake piping and all types of

construction.

c. To the extent possible, pitch horizontal air intake piping towards the outside.

4. Installation of Horizontal Fitting Terminals (Terminal Option A):

a. See Figure 7.42 for proper orientation of twin pipe horizontal terminals. Outer edge of exhaust coupling must

be 10” or less from the wall surface. (Figure 7.9) b. Remove the gasket from the end of the integral exhaust coupling and insert Selkirk #3PFHVST in its place. c. Add PVC intake per instructions from Section VII - F.

5. Installation of Vertical Fitting Terminals (Terminal Option H): a. See Figure 7.43 for the proper orientation of twin pipe vertical terminals. b. Remove the gasket from the end of the integral exhaust coupling and insert Selkirk #3PFHVST in its place. c. A 180° bend (or two 90° elbows) are installed on the top of the air intake pipe. If two 90° elbows are used, a

rodent screen can be installed between them (Figure 7.43). If a 180° bend is used, install a rodent screen in the open side of the bend, using a ring made of PVC pipe. If desired, the termination fittings can be attached to the end of the intake pipes with field supplied stainless steel screws so that they can be later removed for cleaning and inspection. If this is done, drill a clearance hole in these fittings and a tap hole in the end of the intake pipes to accept these screws.

d. Use roof flashings and storm collars to prevent moisture from entering the building. Seal the roof flashing to

the roof using generally accepted practice for the type of roof on the installation. Apply RTV to seal the storm collars to the vent and intake pipes.

WARNING

Asphyxiation Hazard. Selkirk Polyflue vent systems rely on gaskets for proper sealing. When this vent system is used, take the following precautions:

• Make sure that gasket is in position and undamaged in the female end of the pipe.

• Make sure that both the male and female pipes are free of damage prior to assembly.

• Only cut vent pipe as permitted by the vent manufacturer in accordance with their Instructions. When pipe is cut, the cut end must be square and carefully de-burred prior to assembly.

• Use pipe locking bands at all vent pipe joints.

NOTICE The venting system must be free to expand and contract and supported in accordance with the installation instructions included by the original Polypropylene venting component manufacturer, Selkirk. Polypropylene pipe sections must be disengaged 1/8 to 1/4 in. (3mm to 6mm) per joint to allow for thermal expansion.

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VII. Venting G. Assembly of Selkirk Polyflue Vent Systems (continued)

6. Installations using flexible Polyflue (Vent Option 16):

WARNING

Asphyxiation Hazard. When using Polyflue flex, observe the following precautions:

• Polyflue flex may be damaged by handling at low temperatures. Do not bend, uncoil or attempt to install if it has been stored at a temperature below 42°F without allowing it to warm to a higher temperature first.

• Do not bend Polyflue flex more than 45°.

• Instructions below reference the Selkirk Polyflue instruction manual. Not all vent configurations shown in the Selkirk vent manual are approved for use with this boiler.

Refer to Selkirk Polyflue Instructions for assembly of all flex components including the chimney cap and the adaptor to rigid Polyflue at the base of the masonry or B vent chimney. In addition, observe the following requirements:

a. Refer to the appropriate Vent option in Table 7.21 for a list of the principle flex components required. Rigid

vent pipe by the same manufacturer will also be required for the run from the boiler to the base of the chimney.

b. Polyflue may not be used in air chase applications.

Figure 7.41: Polyflue Pipe Locking Band Installation

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VII. Venting G. Assembly of Selkirk Polyflue Vent Systems (continued)

Figure 7.42: Installation of Selkirk Polyflue UV Resistant Single Wall Horizontal Terminal

Figure 7.43: Installation of Selkirk Polyflue UV Resistant Single Wall Vertical Terminal

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VII. Venting H. Assembly of Centrotherm InnoFlue Vent Systems

H. Assembly of Centrotherm InnoFlue Vent Systems

1. This boiler has been approved for use with the Centrotherm InnoFlue single wall Polypropylene vent system to

be provided by the installer.

WARNING

Asphyxiation Hazard. Follow these instructions and the installation instructions included by the original Polypropylene venting component manufacturers, Centrotherm. Failure to do so could cause products of combustion to enter the building, resulting in severe property damage, personal injury or death. Where a conflict arises between Centrotherm instructions and these instructions, the more restrictive instructions shall govern.

Do not mix vent components or joining methods for listed manufacturers.

Read, understand and follow all the instructions and warnings contained in all the sections of this manual.

If any electrical wires are disconnected during service, clearly label the wires and assure that the wires are reconnected properly.

Never jump out or bypass any safety or operating control or component of this boiler.

Assure that all safety and operating controls and components are operating properly before placing the boiler back in service.

Annually inspect all vent gaskets and replace any exhibiting damage or deterioration.

2. Assemble the vent system, starting at the boiler: a. The vent adaptor has three different inside diameters. The middle inside diameter accepts 3” nominal

InnoFlue (Figure 7.27). A locking band clamp in the adaptor prevents the vent pipe from coming out of the adaptor once it is installed and tightened. Lubricate the upper gasket in the vent adaptor with water and insert the first piece of 3” InnoFlue into the adaptor until it bottoms out. Tighten locking band clamp to secure

vent pipe. b. Assemble the next piece of 3” InnoFlue. c. For each joint, verify that the gasket is evenly seated in the bell (female) end of the pipe. Lubricate this gasket

with Centrocerin # IACE50. Slide a connector ring over the male end of the pipe to be joined as shown in

Figure 7.44. Push the male end of the next section of pipe into the bell until it bottoms out, then back out 1/4”

to provide room for thermal expansion. Push hook on connecting ring over the bell end of the first section of

pipe as shown in Figure 7.44. d. Assemble the rest of the vent system per the manufacturer’s installation instructions, being sure to pitch

horizontal sections back towards the boiler 5/8”/ft. e. Support each horizontal pipe section with a minimum of one wall strap each and at intervals not exceeding

39in.

Figure 7.44: InnoFlue Connector Ring Installation

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VII. Venting H. Assembly of Centrotherm InnoFlue Vent Systems

3. Installation of Air Intake System - Start assembly of the PVC air intake system at the boiler. Assembly of the air

intake system is done in the same manner as the vent system except as follows:

a. Drill a 7/32” clearance hole into the front side of the air intake adapter. Insert the first piece of PVC air

WARNING

Asphyxiation Hazard. Vent systems made by Centrotherm rely on gaskets for proper

sealing. When this vent system is used, take the following precautions:

• Make sure that gasket is in position and undamaged in the female end of the pipe.

• Make sure that both the male and female pipes are free of damage prior to assembly.

• Only cut vent pipe as permitted by the vent manufacturer in accordance with their instructions. When pipe is cut, the cut end must be square and carefully de-burred prior to assembly.

• Use connector rings at all vent pipe joints.

NOTICE The venting system must be free to expand and contract and supported in accordance with the installation instructions included by the original Polypropylene venting component manufacturer, Centrotherm. Polypropylene pipe sections must be disengaged 1/4 in. (6mm) per joint to allow for thermal expansion.

4. Installation of Horizontal Fitting Terminals (Terminal Option A): a. See Figure 7.45 for proper orientation of twin pipe horizontal terminals. Outer edge of end pipe must be 10”

or less from the wall surface. (Figure 7.5)

b. Use plain end UV stabilized Centrotherm 3” pipe # ISEP03 or ISEP0339 and insert Centrotherm Bird Screen

#IASPP03 in the end of the pipe.

c. Add PVC intake per instructions from Section VII - F.

5. Installation of Vertical Fitting Terminals (Terminal Option H): a. See Figure 7.46 for the proper orientation of twin pipe vertical terminals. b. Use plain end UV stabilized Centrotherm 3” pipe # ISEP03 or ISEP0339 and insert Centrotherm Bird Screen

#IASPP03 in the end of the pipe.

c. A 180° bend (or two 90° elbows) are installed on the top of the air intake pipe. If two 90° elbows are used, a

rodent screen can be installed between them (Figure 7.46). If a 180° bend is used, install a rodent screen in the open side of the bend, using a ring made of PVC pipe. If desired, the termination fittings can be attached to the end of the intake pipes with field supplied stainless steel screws so that they can be later removed for cleaning and inspection. If this is done, drill a clearance hole in these fittings and a tap hole in the end of the intake pipes to accept these screws.

d. Use roof flashings and storm collars to prevent moisture from entering the building. Seal the roof flashing to

the roof using generally accepted practice for the type of roof on the installation. Apply RTV to seal the storm collars to the vent and intake pipes.

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VII. Venting H. Assembly of Centrotherm InnoFlue Vent Systems

Figure 7.45: Installation of Centrotherm InnoFlue UV Stabilized Single Wall Horizontal Terminal

Figure 7.46: Installation of Centrotherm InnoFlue UV Stabilized Single Wall Vertical Terminal

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VII. Venting H. Assembly of Centrotherm InnoFlue Vent Systems

6. Installations using InnoFlue Flex (Vent Options 10 & 17):

WARNING

Asphyxiation Hazard. When using InnoFlue Flex, observe the following precautions:

• InnoFlue Flex may be damaged by handling at low temperatures. Do not bend, uncoil or attempt to install if it has been stored at a temperature below 42°F without allowing it to warm to a higher temperature first.

• Do not bend InnoFlue Flex more than 45°.

• Instructions below reference the Centrotherm InnoFlue instruction manual. Not all vent configurations shown in the Centrotherm manual are approved for use with this boiler.

Refer to Centrotherm InnoFlue Instructions for assembly of all flex components including the chimney cap and the adaptor to rigid InnoFlue at the base of the masonry or B vent chimney. In addition, observe the following requirements:

a. Refer to the appropriate Vent option in Tables 7.13b or 7.21 for a list of the principle flex components required.

Rigid vent pipe by the same manufacturer will also be required for the run from the boiler to the base of

chimney. b. Masonry chimneys cannot be used for an air chase c. B vent chimneys can only be used for an air chase (Vent option 10) if the B vent has the minimum size shown

in Table 7.13b and is fully accessible for sealing of all joints and seams. d. When Vent Option 10 is used, install a Tee of the same size at the base of the vent. Route the smooth section

of InnoFlue Flex (3”) through a cap in the base of this Tee. Use a Centrotherm IAWP03B wall plate and RTV to

seal this penetration. Install the Base Support using the Base support bracket as described in the InnoFlue

installation manual. Connection of the PVC air intake pipe to the side outlet of the tee is made using a cap and a PVC socket x

male thread adaptor. Cut a clearance hole in the cap for the male threads. Secure the adaptor to the cap

using a 3” electrical conduit lock nut. Seal all joints with RTV.

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VII. Venting I. Assembly of Stainless Steel Vent Systems

I. Assembly of Stainless Steel Vent Systems

1. This boiler has been approved for use with Duravent FasNSeal Flex Stainless Steel vent systems to be provided by the installer.

WARNING

Asphyxiation Hazard. Follow these instructions and the installation instructions

included by the original stainless steel venting component manufacturer, DuraVent. Failure to do so could cause products of combustion to enter the building, resulting in severe property damage, personal injury or death. Where a conflict arises between DuraVent instructions and these instructions, the more restrictive instructions shall govern.

Do not mix vent components from listed manufacturers.

Examine all components from listed manufacturers.

All condensate that forms in the vent must be able to drain back to the boiler.

2. The vent adaptor has three different inside diameters. The smaller, lower diameter accepts 3” Stainless steel (Figure 7.27). A locking band clamp in the adaptor prevents the vent pipe from coming out of the adaptor once it is installed and tightened. Lubricate the upper gaskets in the vent adaptor with water and insert the first piece of 3” stainless into the adaptor until it bottoms out. Tighten locking band clamp to secure vent pipe.

3. Installation of Air Intake System - Start assembly of the PVC air intake system at the boiler. Assembly of the air intake system is done in the same manner as the vent system except as follows:

a. Drill a 7/32” clearance hole into the front side of the air intake adaptor. Insert the first piece of PVC air

b. All intake piping may be PVC.

c. There is a 0” minimum clearance between the air intake piping and all types of construction.

d. To the extent possible, pitch horizontal air intake piping towards the outside.

WARNING

sealing. When these vents systems are used, take the following precautions:

• Make sure that gasket is in position and undamaged in the female end of the pipe

• Make sure that both male and female pipes are free of damage prior to assembly.

• Only cut vent pipe as permitted by the vent manufacturer in accordance with their instructions. When pipe is cut, the cut end must be square and carefully de-burred prior to assembly.

4. Installation using DuraVent FasNSeal Flex (Vent Option 18) Refer to manufacturer’s instructions for assembly of all flex components including the chimney cap and

adaptor to rigid pipe at base of masonry or B Vent Chimney (DuraVent FasNSeal Flex only permitted in

a. Refer to the appropriate Vent option in table 7.21 for a list of the principle flex components required. Rigid

b. Masonry chimneys cannot be used for an air chase. c. Flexible stainless steel vent shall be installed in an UNUSED masonry chimney/chase and supplying

masonry type chimneys). In addition, observe the following requirements:

vent pipe by the same manufacturer will also be required for the run from the boiler to the base of chimney.

combustion air through a separate wall or roof combustion air terminal. The unused chimney flue must be structurally sound and in good repair. A chimney is considered UNUSED when it is not being used for any appliance venting. If chimney is a multiple flue type where one of the multiple flues is being used for an appliance venting, the flexible stainless vent installation is permitted through an adjacent, unused flue providing a local authority having jurisdiction approves such installation. (Figure 7.25b)

Asphyxiation Hazard. Vent systems made by Duravent rely on gaskets for proper

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VII. Venting I. Assembly of Stainless Steel Vent Systems (continued)

d. When flexible stainless steel pipe is used for combustion product venting, it must be installed at vertical or

near vertical orientation. This will insure proper condensate flow back towards the boiler.

e. Follow flexible stainless steel pipe manufacturer specific instructions regarding application/listing, permits,

minimum clearances to combustibles, installation details (proper joint assembly, pipe support and routing, gasket and fitting installation, optional tooling availability/usage, routing through masonry combination of combustion product venting and combustion air supply).

f. When there is a conflict between flexible stainless steel pipe manufacturer installation instructions and boiler

installation, Operating and Service Instructions, the more restrictive instructions shall govern.

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VII. Venting J. Condensate Trap and Drain Line (continued)

J. Condensate Trap and Drain Line

All condensate which forms in the boiler or vent system passes through the heat exchanger and out of a bottom drain port which is connected to the condensate trap with a hose. This trap allows condensate to drain from the heat exchanger while retaining flue gases in the boiler. This trap is an integral part of the boiler but must be connected to a drain pipe as shown in Figure 7.47. A length of corrugated tubing is supplied with the boiler and is connected to the trap as shown in Figure 7.47. Note the following when disposing of the condensate:

1. If the corrugated condensate drain line must be extended, construct the extension from PVC or CPVC pipe.

Insert the hose provided with the boiler into the end of the extension as shown in Figure 7.47.

2. Condensate is slightly acidic. Do not use metallic pipe or fittings in the condensate drain line. Do not route the

drain line through areas that could be damaged by leaking condensate.

3. Some jurisdictions may require that the condensate be neutralized before being disposed of. Dispose of

condensate in accordance with local codes.

4. Do not route, or terminate, the condensate drain line in areas subjected to freezing temperatures.

5. If the point of condensate disposal is above the trap, it will be necessary to use a condensate pump to move

the condensate to the drain. In such cases, select a condensate pump that is approved for use with condensing boilers. If overflow from this pump would result in property damage, select a pump with an overflow switch and use this switch to shut down the boiler. Alternatively, if heat is a necessity, use the overflow switch to trigger an alarm.

6. Do not attempt to move the trap from the location shown in Figure 7.47. Do not attempt to substitute another trap

for the one provided with the boiler.

7. The trap vent is connected to a barbed fitting attached to the right side panel with rubber tubing and must be left

open for the trap to work properly.

WARNING

Asphyxiation Hazard. Failure to install the condensate drain in accordance with the

above instructions could cause flue gas to enter the building, resulting in personal injury or death.

NOTICE Indicates special instructions on installation, operation, or maintenance which are important but not related to personal injury hazards.

Figure 7.47: Condensate Piping Arrangement

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VII. Venting K. Removing an Existing Boiler From a Common Chimney (continued)

K. Removing an Existing Boiler From a Common Chimney

This section only applies if this boiler is replacing an existing boiler that is being removed from a common chimney.

In some cases, when an existing boiler is removed from a common chimney, the common venting system may be too large for the remaining appliances. At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.

(a) Seal any unused openings in the common venting system. (b) 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.

appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.

(d) Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so the

appliance will operate continuously.

(e) Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a

match or candle, or smoke from a cigarette, cigar, or pipe.

(f) After it has been determined that each appliance remaining connected to the common venting system properly

vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gasburning appliances to their previous condition of use.

(g) Any improper operation of the common venting system should be corrected so the installation conforms with the

National Fuel Gas Code, ANSI Z223.1. When re-sizing any portion of the common venting system, the common venting system should be re sized to approach the minimum size as determined using the appropriate tables in Part 11 of the National Fuel Gas Code, ANSI Z223.1.

WARNING

Never common vent this boiler with other appliances.

Au moment du retrait d’une chaudière existante, les mesures suivantes doivent être prises pour chaque appareil toujours raccordé au système d’evacuation commun et qui fonctionne alors que d’autres appareils toujours raccordés au système d’évacuation ne fonctionnent pas:

(a) Sceller toutes les ouvertures non utilisées du système d’évacuation. (b) Inspecter de façon visuelle le système d’évcuation pour déterminer la grosseur et l’inclinaison horizontale qui

conviennent et s’assurer que le système est exempt d’obstruction, d’étranglement, de fuite, de corrosion et autres défaillances qui pourraient présenter des risques.

(c) Dans la mesure du possible, fermer toutes les portes et les fenêtres du bâtiment et toutes les portes entre l’espace où les appareils toujours raccordés au système d’évacuation sont installés et les autres espaces du bâtiment. Mettre en marche les sécheuses, tous les appareils non raccordés au système d’évacuation commun et tous les ventilateurs d’extraction comme les hottes de cuisinière et les ventilateurs des salles de bain. S’assurer que ces ventilateurs fonctionnent à la vitesse maximale. Ne pas faire fonctionner les ventilateurs d’été. Fermer les registres des cheminées.

(d) Mettre l’appareil inspecté en marche. Suivre les instructions d’allumage. Régler le thermostat de façon que l’appareil fonctionne de façon continue.

(e) Faire fonctionner le brùleur principal pendant 5 min ensuite, déterminer si le coupe-tirage déborde à l’ouverture de décharge. Utiliser la flamme d’une allumette ou d’une chandelle ou la fumée d’une cigarette, d’un cigare ou d’une pipe.

(f) Une fois qu’il a été déterminé, selon la méthode indiquée ci-dessus, que chaque appareil raccordé au système d’évacuation est mis à l’air libre de façon adéquate. Remettre les portes et les fenêtres, les ventilateurs, les registres de cheminées et les appareils au gaz à leur position originale.

(g) Tout mauvais fonctionnement du système d’évacuation commun devrat être corrigé de façon que l’installation soit conforme au National Fuel Gas Code, ANSI Z223.1/NFPA 54 et (ou) aux codes d’installation CAN/ CSA-B149.1. Si la grosseur d’une section du système d’évacuation doit être modifiée, le système devrait être modifié pour respecter les valeurs minimales des tableaux pertinents de l’appendice F du National Fuel Gas Code, ANSI Z223.1/NFPA 54 et (ou) des codes d’installation CAN/CSA-B149.1.

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VIII. Gas Piping

WARNING

Explosion Hazard. Failure to properly pipe gas supply to boiler may result in improper operation or leaks of flammable gas.

•

Gas supply to boiler and system must be absolutely shut off prior to installing or servicing boiler gas piping.

•

Always assure gas piping is absolutely leak free and of the proper size and type for the connected load.

•

Use a thread compound compatible with liquefied petroleum gas. Failure to use proper thread compounds on all gas connectors may result in leaks of flammable gas.

If inlet pressure is above 1/2 psig (3.4 kPa) an additional gas pressure regulator is required. Consult gas

•

supplier.

•

Size corrugated stainless steel tubing (CSST) to ensure proper capacity and minimize flow restrictions.

Gas piping to the boiler must be sized to deliver adequate gas for the boiler to fire at the nameplate input at an inlet pressure between the minimum and maximum values shown in Table 8.2. When sizing, also consider other existing and expected future gas utilization equipment (i.e. water heater, cooking equipment). For more information on gas line sizing, consult the utility or the National Fuel Gas Code, NFPA54/ANSI Z223.1, and/or CAN/CSA B149.1 Natural Gas and Propane Installation Code.

Figure 8.1 shows typical gas piping connection to the boiler. A sediment trap must be installed upstream of all gas controls. Install a manual shut-off valve (provided by installer) outside the jacket with a ground joint union as shown. All above ground gas piping upstream from manual shut-off valve must be electrically continuous and bonded to a grounding electrode. Refer to National Electrical Code, NFPA 70.

The boiler and its gas connection must be leak tested before placing the boiler in operation. When doing this, the boiler and its individual shut-off must be disconnected from the rest of the system during any pressure testing of that system at pressures in excess of 1/2 psi (3.5kPa). When pressure testing the gas system at pressures of 1/2 psi (3.5kPa) or less, isolate the boiler from the gas supply system by closing its individual manual shut-off valve. Locate leaks using approved combustible gas non-corrosive leak detector solution.

DANGER

Explosion Hazard. Do not use matches, candles, open flames or other ignition source to

check for leaks.

WARNING

If gas pressure in the building is above ½ psig (3.4 kPa), an additional gas pressure regulator is required. Using one additional regulator for multiple gas appliances may result in unsafe boiler operation. The additional regulator must be able to properly regulate gas pressure at the input of the smallest appliance. If the regulator can not do this, two or more additional regulators are required. Consult regulator manufacturer and/or local gas supplier for instructions and equipment ratings.

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VIII. Gas Piping (continued)

CAUTION

Support the weight of the gas line piping independently from the boiler gas connection fitting located on the bottom of the boiler.

If an additional regulator is used to reduce boiler inlet pressure below 1/2 psig (3.4 kPa) it must be at least 6 to 10 ft. upstream of the boiler.

It is very important that the gas line is properly purged by the gas supplier or utility company.

NOTICE Install 1/2” ground joint union (nut side down) as shown in Figure 8.1. Failure to do so will make it difficult or impossible to remove burner for servicing.

Table 8.2: Minimum and Maximum Inlet Pressures

Model Max. (Natural & LP) Min. (Natural) Min. (LP)

135-180 14.0” 2.5” 11.0”

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Figure 8.1: Gas Connection to Boiler

Page 70

IX. System Piping

A. General System Piping Precautions

WARNING

Failure to properly pipe boiler may result in improper operation and damage to boiler or structure.

•

Install boiler so that the gas ignition system components are protected from water (dripping, spraying, rain, etc.) during boiler operation and service (circulator replacement, etc.).

•

Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components and can lead to boiler failure. Warranty does not cover problems caused by oxygen contamination of boiler water or scale (lime) build-up caused by frequent addition of water.

CAUTION

1. The heat transfer-medium must be water or other nontoxic fluid having a toxicity rating or Class of 1, as listed in Clinical Toxicology of Commercial Products, 5th edition.

2. The pressure of the heat transfer medium must be limited to a maximum of 30 PSIG by an approved safety or relief valve.

WATER QUALITY AND BOILER WATER ADDITIVES

IMPORTANT NOTE

The heat exchanger used in this boiler is made from stainless steel coils having relatively narrow waterways. Once filled with system water, it will be subjected to the effects of corrosion, as well as fouling from any debris introduced from the system. Take the following precautions to minimize the chance of severe heat exchanger damage caused by corrosion and/or overheating:

1. Flush the system before connecting the boiler - In a replacement installation, flushing the system will remove impurities, such as sediment, solder flux, metal shavings, and traces of old boiler additives. Even if the system is new, do not omit this step – new systems will contain flux and may even contain some of the other impurities listed above. Flush the system completely and repeat if necessary to completely remove these contaminants. If necessary, a cleaning agent may be used to assist in system cleaning. See Section XII (“Start-up and Check-out”) for recommended cleaners.

2. Make sure that the system is tight - This is the single most important guideline. Tap water contains dissolved

oxygen which causes corrosion. In a tight system, this oxygen comes out of solution and is quickly removed from the system through the automatic air vent. The system then remains essentially free of oxygen. If the system is not tight, however, frequent additions of make-up water can expose the heat exchanger to oxygen on a continuous basis. In addition, frequent additions of hard make-up water can cause calcium deposits to collect in the heat exchanger, causing severe damage. To minimize additions of make-up water:

• Inspect the system thoroughly for leaks before placing it in service.

• If the system includes underground piping, or other piping in which a leak might go undetected, consider isolating the boiler from the system with a heat exchanger.

• Make sure that the expansion tank is properly sized and in good condition. If it is not, the relief valve may open frequently, resulting in regular additions of make-up water.

• If an automatic fill valve is installed, installation of a water meter in the fill line is strongly recommended so that routine additions of make-up water can be detected and their cause corrected.

3. Non-Metallic Tubing - Even if the system is tight, oxygen can be introduced into the system through some types of non-metallic tubing used in radiant or snow melt systems. Other nonmetallic tubing is equipped with an oxygen barrier to prevent migration of oxygen into the water. If the boiler is to be installed in a system containing non-metallic tubing without an oxygen barrier, it must be isolated from the boiler with a heat exchanger as shown in Figure 9.8.

4. Water Chemistry, Antifreeze, and Boiler Water Additives – Improper boiler water chemistry can cause the heat exchanger damage described above, as well as deterioration of seals. Observe the water chemistry requirements shown in Section XII (“Start-up and Check-out”).

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IX. System Piping (continued)

B. Standard Piping Installation Requirements

Observe the following requirements when installing the boiler piping:

1. Relief Valve (Required) – The relief valve is shipped loose and must be installed in the location shown in Figure 9.0. Pipe the outlet of the relief valve to a location where water or stream will not create a hazard or cause property damage if the valve opens. The end of the discharge pipe must terminate in unthreaded pipe. If the relief valve discharge is not piped to a drain, it must terminate at least 6” above the floor. Do not run the discharge piping through an area that is prone to freezing. The termination of the relief valve must be in an area where it is not likely to become plugged by debris.

The relief valve supplied with the boiler is set to open at 30 psi. If it is replaced, the replacement must have a setting less than or equal to the maximum allowable working pressure (MAWP) shown on the ASME data plate located on the left side of the heat exchanger.

DANGER

Explosion Scald Hazard. Pipe relief discharge to a location where the potential of severe burns is eliminated.

•

Do not install a relief valve having a setting greater than the MAWP shown on the rating plate.

•

Do not install a valve in the relief valve discharge line.

•

Do not install a relief valve in a location other than that specified by the factory.

•

Do not plug the relief valve discharge.

2. Circulator (required) – The boiler loop circulator is factory installed inside the boiler cabinet. Usually at least one addition circulator (not supplied) will be required for the system to work properly. See the following section for more information.

3. Expansion Tank (required) – If this boiler is replacing an existing boiler with no other changes in the system, the old expansion tank can generally be reused. If the expansion tank must be replaced, consult the expansion tank manufacturer’s literature for proper sizing. If using antifreeze, account for additional expansion of glycol solution when sizing an expansion tank. In a typical residential heating system, a glycol mixture has an expansion rate about 1.2 times that of water alone, therefore a tank for an anti-freeze system should be at least 1.2 times greater in size.

4. Fill Valve (required) – Either a manual or automatic fill valve may be used, but a manual valve is preferred because it eliminates unmonitored additions of make-up water to the system. The ideal location for the fill valve is at the expansion tank. If using antifreeze with automatic fill valve, it is recommended to install a water meter to monitor makeup water. Antifreeze concentration will decrease as makeup water is added. If using antifreeze, local codes often require a backflow preventer or disconnect from city water.

5. Automatic Air Vent (required) – At least one automatic air vent is required. Manual air vents will usually be required in other parts of the system to remove air during initial fill.

6. Manual Reset High Limit (required by some codes) - This control is required by ASME CSD-1 and some other codes. Install the high limit in the boiler supply piping just above the boiler with no intervening valves. Set the manual reset high limit to 200°F. Wire the limit per Figure 11.3 in the Wiring section.

7. Isolation Valves (recommended) - Isolation valves are useful when the boiler must be drained, as they will eliminate having to drain and refill the entire system.

8. Strainer (recommended) – Install a Y Strainer, or other suitable strainer, to prevent any system debris from entering the boiler and fouling the water passages. Note that some strainers have a significant pressure drop, which may impact the ability of the boiler pump to obtain the required flow. See Part C of this section for additional information.

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IX. System Piping (continued)

9. Drain Valve (required) – Install the drain valve (provided by the installer) as shown in Figure 9.2.

10. Low Water Cut-off (may be required by local jurisdiction) – Protection of this boiler against low water and/or inadequate flow is provided by the UL353 certified flow switch built into the boiler. This is a water tube boiler and this flow switch is therefore the only effective way to provide such protection. Section HG614(c ) of the 2015 ASME boiler and Pressure Vessel Code recognizes the use of a listed flow switch in lieu of a low water cut-off on water tube boilers.

In the event that a local jurisdiction insists upon the installation of a low water cut-off with this boiler, refer to Part XI and the low-water cut-off manufacturer’s instructions for proper wiring. Install the low water cut-off in the supply piping at the point prescribed the local jurisdiction (generally at a point above the boiler).

If a probe type low water cut-off is used, be certain that it is located at a point in the piping from which

air can escape to an automatic air vent. Generally, this means that there should be no down-turns in the piping between the low water cut-off and the point where the automatic air vent is installed. Failure to do this may result in nuisance boiler shut-downs due to small amounts of air trapped around the probe.

Figure 9.0: Factory Supplied Piping and Trim Installation

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IX. System Piping (continued)

C. Near Boiler Piping Design

Proper operation of this boiler requires that the water flow rate through it remain within the limits shown in Table 9.1 any time the boiler is firing. At flow rates below the minimum shown, the boiler’s flow switch and/or temperature rise limit function may prevent the boiler from firing. Flow rates through the boiler in excess of the maximum shown in Table 9.1 can result in excessive noise or erosion damage to piping

There are two basic methods that can be used to pipe this boiler into the system. Method #1 (primary-secondary piping) is always preferred. Additional information on hydronic system design can be found in the I=B=R Guide RHH published by the Air-Conditioning, Heating and Refrigeration Institute (AHRI).

Table 9.1 Water Flow Rate Limits

Model

135 6.2 13.3

150 7. 7 13.3

180 9.3 13.3

Method 1: Primary/Secondary Piping (Strongly Recommended)

This method is shown in Figure 9.2. In this system, the flow rate through the boiler (“secondary loop”) is completely independent of the flow rate through the system (“primary loop”). Use the following guidelines to ensure that the boiler will have the required flow shown in Table 9.1 regardless of the flow in the heating system.

Minimum Maximum

Flow (GPM)

1. System Loop Piping - Size the system circulator and piping to obtain the design flow rate through the heating system as you would on any other heating system. All piping between the expansion tank and secondary connection tees must be at least 1”. In order to keep the flow rates in the system and boiler loops independent of each other, provide at least 8 diameters of straight pipe upstream of the first tee and 4 diameters downstream of the second tee. Keep the distance between the expansion tank and the first secondary tee as short as practical.

2. Boiler Loop Piping – All boilers are supplied with a built in circulator which will deliver the flow required by Table 9.1 provided both of the following conditions are met:

• All piping in the boiler loop has a nominal size of at least 1”

• The equivalent length of all piping in the boiler loop is 60 ft or less.

To verify that the 60 ft, equivalent length is not exceeded, do the following:

a. Count all fittings in the planned boiler loop (the shaded piping in Figure 9.5).

b. Using Table 9.3, find the equivalent lengths of all fittings in the secondary loop. Total these equivalent lengths and add them to the total length of planned straight pipe in the secondary loop. c. The result is the total equivalent length of the planned boiler loop. If the equivalent length calculated in (b) is under the limit shown in Table 9.4, the boiler pump will achieve a flow rate and temperature rise approximately equal to that shown in this table. Otherwise, the equivalent length must be reduced.

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IX. System Piping (continued)

Figure 9.2: Piping Method #1 - Near Boiler Piping - Heating Only

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IX. System Piping (continued)

Example – A 135MBH model is to be connected to a heating system as shown in Figure 9.5. A total of 20 ft of straight pipe will be installed between the boiler and the system loop.

Count all fittings in the boiler loop (shaded in Figure 9.5):

4 90° Elbows

2 Turn in Tee

2 Isolation Valves

Note: Unions, Secondary Connection Tees, and factory supplied fittings are ignored.

Calculate total equivalent length from Table 9.3:

20 ft Straight Pipe + 4 Elbows x 2.8 + 2 Turn in Tee x 5.5 + 2 Valves x 0.7 = 43.6 Equivalent Feet

Since the total equivalent length is less than 60 ft, flow through boiler loop meets requirements in Table 9.1.

3. Hydraulic Separators – Hydraulic separators serve the same purpose as the closely spaced tees connecting the boiler and system loops in Figure 9.2. They also generally provide effective connection points for automatic air elimination devices and an expansion tank. These separators are available from several sources and may be used in place of the closely spaced tees shown in Figure 9.2. When a hydraulic separator is used in place of the tees, the 60 ft equivalent length limitation still applies. Select a hydraulic separator having 1” or larger boiler connections that is designed for the boiler flow rates shown in Table 9.1.

Table 9.3: Equivalent Lengths for Selected Valves and Fittings

(May Be Used for Copper or Threaded Fittings)

Fitting Pipe Size Equivalent Length (ft)

90° Elbow 1” 2.8

45° Elbow 1” 1. 4

90° Turn in Tee 1” 5.5

Run of Tee 1” 1. 8

Gate Valve (Open) 1” 0.7

Full Port Ball Valve 1” 0.7

Y-Strainer* 1” 7. 0

* Based on Cv of 20. Pressure drop through strainers varies widely. 7 ft equivalent length may be assumed for strainers having a published Cv greater than 20.

Table 9.4a: Flow Available with Boiler Loop Equivalent Length of 30 ft or Less

Table 9.4b: Flow Available with Boiler Loop

Equivalent Length of 60 ft or Less

Boiler Model

135 8.6 25 135 8.3 26

150 11. 8 23 150 11. 1 24

180 11. 8 28 180 11. 1 29

Approx. Flow

(GPM)

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Approx. Rise (°F)

Boiler Model

Approx. Flow

(GPM)

Approx. Rise

(°F)

Page 76

IX. System Piping (continued)

Figure 9.5: Piping Method #1 - Near Boiler Piping - Shaded Boiler Loop

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IX. System Piping (continued)

Method 2: Direct Connection to Heating System (Generally NOT Recommended)

In some relatively rare cases it may be possible to connect this boiler directly to the heating system as is done with conventional boilers (Figure 9.6). If this is done, the flow rate through the boiler will equal the flow rate through the system. The flow rate through the system must therefore always remain within the limits shown in Table 9.1. For this reason, the pressure drop through the entire system must be known.

This method is generally not recommended because it is often very difficult to accurately calculate the pressure drop through the system. In replacement installations, it may be impossible to get an accurate measurement of the amount of piping and number of fittings in the system. In addition, if the system is zoned, the system flow may drop well below the minimum required when only one zone is calling for heat.

The one advantage to this method is its installation simplicity. It may make sense to use this method when the boiler is to be installed with a new single zone system having a low-pressure drop.

Figure 9.7 shows the performance curve for the pump in each boiler model, taking into account the pressure drop through the boiler’s heat exchanger and internal piping. These curves therefore show the flow that can be achieved through the boiler as a function of the pressure drop through the connected piping. Calculation of the system pressure drop must be performed by someone having familiarity with pressure drop calculations, such as an HVAC engineer.

NOTICE Where it is not possible to install a separate boiler loop, the system circulator must be sized to ensure that the flow through the boiler stays within the defined parameters to prevent overheating when the boiler is fired at it’s full rated input. Install a flow meter to measure the flow, or fire the boiler at full rate and ensure the boiler delta T does not exceed 35°F (19°C).

Figure 9.6: Piping Method #2 - Direct Connection of Boiler to Heating System

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Page 78

0246810

AvailableHead(ft

IX. System Piping (continued)

Note: These curves show the flow that can be achieved through the boiler as a function of the

pressure drop through the connected piping.

Flow(GPM)

Figure 9.7a: 135 Net Circulator Performance Curve (Taco 0011)

AvailableHead(ft

0 2 4 6 8 10 12 14

Figure 9.7b: 150/180 Net Circulator Curve (Taco 0013)

Flow(GPM)

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IX. System Piping (continued)

D. Piping for Special Situations

1. System containing oxygen - Many hydronic systems contain enough dissolved oxygen to cause severe corrosion damage to a boiler. Some examples include:

• Radiant systems that employ tubing without an oxygen barrier.

• Systems with routine additions of fresh water.

• Systems which are open to the atmosphere.

If the boiler is to be used in such a system, it must be separated from the oxygenated water being heated

with a heat exchanger as shown in Figure 9.8. Consult the heat exchanger manufacturer for proper heat exchanger sizing as well as flow and temperature requirements. All components on the oxygenated side of the heat exchanger, such as the pump and expansion tank, must be designed for use in oxygenated water.

2. Piping with a Chiller - If the boiler is used in conjunction with a chiller, pipe the boiler and chiller in parallel. Use isolation valves to prevent chilled water from entering the boiler.

3. Air Handlers - Where the boiler is connected to air handlers through which refrigerated air passes, use flow control valves in the boiler piping or other automatic means to prevent gravity circulation during the cooling cycle.

Figure 9.8: Isolation of the Boiler from Oxygenated Water with a Plate Heat Exchanger

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X. Domestic Hot Water Piping

DANGER

Scald Hazard. Under certain conditions this boiler can deliver domestic hot water

(DHW) at temperatures in excess of the DHW set point on the boiler control. An installer-supplied, ASSE 1017 or ASSE 1070 certified tempering valve is therefore REQUIRED as part of this boiler’s installation.

• Select and install tempering valve in accordance with the valve manufacturer’s instructions and applicable local codes. In the absence of such codes follow the Uniform Plumbing Code (IAPMO/UPC-1). Also note that additional tempering valves may be required at the fixtures themselves.

NOTICE

•

DHW feature on this boiler is designed to only to heat potable water (i.e. water from a well or water utility that is suitable for drinking) having the following characteristics:

a. Hardness less than 200PPM b. PH between 6 and 8 c. Chloride level less than 80PPM.

Use of water not having these characteristics could result in premature failure of the DHW handling components in this boiler.

• Internal components near the Hot and Cold connections can be damaged by excessive heat during soldering. If copper adaptors are mounted directly on the combi, solder adjacent piping to these adaptors before installing them on the boiler. Failure to do so may cause internal leaks and/or other damage to the boiler.

Install the domestic hot water piping as shown in Figure 10.1. Combi connections are ¾” NPT male thread. The components in this system, and their functions are as follows:

1. ASSE 1070 or ASSE 1017 Listed Tempering Valve (Required) – This boiler is equipped with a control system that attempts to regulate the DHW outlet temperature to a DHW set point (default set point is 120F – see Section XIII for more information). As with all water heaters there are inherent limitations on the ability of the control system to accurately regulate water temperature to this set point under all conditions. Extremely low draw rates and transitions from heating to DHW are two examples of conditions that can cause the temperature of water leaving the boiler to significantly exceed the DHW set point. To minimize “spikes” in DHW temperature, a tempering valve is therefore required. Select and install in accordance with the valve manufacturer’s instructions and applicable codes. Note that some codes require additional tempering devices at some of the fixtures as well.

2. Flow Restrictor (Optional) - If domestic hot water is drawn from at a rate in excess of the rating in Table 2.2, the temperature of the hot water may be too low to be of use. The use of a flow restrictor will help prevent this problem by limiting the rate at which water can pass through the DHW heat exchanger. If a restrictor is used, select one having a rating in GPM approximately equal to that shown in Table 2.2 at the desired temperature rise.

3. Pressure Relief Valve (Required) - Limits the pressure in the domestic hot water piping. Use a valve designed for DHW service, such as the Watts #3L or #53L. Note that this is a pressure relief valve, not a T&P valve. Select a valve with a pressure setting less than or equal to 145 psi. Pipe the discharge to a safe location using piping the same size as the discharge connection on the valve.

4. Hose Bib Valves (Recommended) - These valves permit the DHW plate heat exchanger be periodically “back flushed” to remove sediment.

5. Globe or Ball Valve (Recommended) - Used to aid in back flushing the heat exchanger and to isolate the DHW piping if it must be serviced. In addition, the upstream valve may be used to limit the DHW flow if necessary.

6. Thermal Expansion Tank (Required if a backflow preventer is installed) – If a back flow preventer or check valve is installed upstream of the cold connection, a thermal expansion tank will prevent the build-up of pressure in the DHW piping. Use a thermal expansion tank designed for use in potable water service.

7. Unions – Improve serviceability of DHW piping.

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X. Domestic Hot Water Piping (continued)

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Figure 10.1: Domestic Hot Water Piping

Page 82

XI. Wiring

DANGER

Electrical Shock Hazard. Positively assure all electrical connections are unpowered

before attempting installation or service of electrical components or connections of the boiler or building. Lock out all electrical boxes with padlock once power is turned off.

WARNING

All wiring and grounding must be done in accordance with the authority having jurisdiction or, in the absence of such requirements, with the National Electrical Code /NFPA 70). In Canada, all wiring and grounding must be done in accordance with the Canadian Electrical Code, Part 1 (CSA C22.1 - latest edition).

Failure to properly wire electrical connections to the boiler may result in serious physical harm.

Electrical power may be suppled from more than one circuit. Make sure all power is off before attempting any electrical work.

Each boiler must be protected with a properly sized over-current device.

Never jump out or make inoperative any safety or operating controls.

The wiring diagrams contained in this manual are for reference purposes only. Each boiler is shipped with a wiring diagram attached to the front door. Refer to this diagram and the wiring diagram of any controls used with the boiler. Read, understand and follow all wiring instructions supplied with the controls.

NOTICE This boiler is equipped with a listed high water temperature limit function. This limit provides boiler shutdown in the event the boiler water temperature exceeds the set point of the limit control. Certain Local Codes require an additional water temperature limit. If necessary, install an additional water temperature limit such as a Honeywell L4006 Aquastat. Wire as indicated in Figure 11.3.

Figure 11.1 shows the locations for making both high voltage and low voltage field connections.

1. Line Voltage (120 VAC) Field Connections – Leads for the line voltage connections are located in the junction box as shown in Figure 11.1. Provide a dedicated circuit for the boiler of 15A or greater. A service switch is recommended and is required by many local codes. Locate this switch in accordance with local codes or, in the absence of any, in a location where it can be safely accessed in an emergency involving the boiler. All 120VAC connections to the boiler itself are wire nut connections, except for the ground, which is a screw. The leads are color coded as follows:

• 120VAC Hot - Black

• 120VAC Neutral - White

• System Pump Hot - Yellow

See Figure 11.2 for line voltage field connection wiring.

Note that the system circulator is field supplied and is the pump that, in most cases, actually circulates water

through the radiation. The system pump is always on when the boiler is responding to a call for space heat. Maximum recommended current draw for the system pump is 2.0A.

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XI. Wiring (continued)

2. Low Voltage Connections – Commonly used low voltage field connections are located on the low voltage PCB and are shown in Figure 11.3 and listed from left to right:

1 Heat T’Stat - 24VAC heating thermostat 2 Heat T’Stat - 24VAC heating thermostat 3 DHW Stat - No field connection 4 DHW Stat - No field connection 5 External Limit - Field supplied low voltage safety limit contacts (1) 6 External Limit - Field supplied low voltage safety limit contacts (2) 7 Outdoor Sensor - Tasseron TSA00AA Outdoor Temperature Sensor (1) 8 Outdoor Sensor - Tasseron TSA00AA Outdoor Temperature Sensor (2)

External power must not be applied to any of the low voltage terminals - doing so may damage the boiler control. Also note the following: a. External Limit - The external limit terminals are intended for use with a field supplied safety device, such as a manual reset high limit or low-water cut-off. When an external limit is used, the jumper between these two terminals must be removed. Failure to remove this jumper will render the external safety devices ineffective. b. Outdoor Sensor - Use only the Tasseron TSA00AA outdoor sensor supplied with the boiler. When this sensor is connected and enabled, the boiler will adjust the target supply water temperature downwards as the outdoor air temperature increases. This sensor should be located on the outside of the structure in an area where it will sense the average air temperature around the house. Avoid placing this sensor in areas where it may be covered with ice or snow. In general, locations where the sensor will pick up direct radiation from the sun should also be avoided. Avoid placing the sensor near potential sources of electrical noise such as transformers, power lines, and fluorescent lighting. Wire the sensor to the boiler using 22 gauge or larger wire. As with the sensor itself, the sensor wiring should be routed away from sources of electrical noise. Where it is impossible to avoid such noise sources, wire the sensor using a 2 conductor, UL Type CM, AWM Style 2092 shielded cable. Connect one end of the shielding on this cable to ground. See Section XIII of this manual for information on enabling the outdoor reset sensor.

Figure 11.1: Location of High and Low Voltage Field Electrical Connections

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Page 84

XI. Wiring (continued)

Figure 11.2: Line Voltage Field Connections

Figure 11.3: Low Voltage PCB Terminal Connections

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Page 85

XI. Wiring (continued)

c. Low water cut-off wiring – Although not necessary to protect this boiler (see Part IX), some jurisdictions may insist that a low water cut-off (LWCO) be installed with this boiler. There are two ways to wire a LWCO into this boiler:

• A 120V LWCO may be wired to break 120V power to the boiler (Figure 11.4a)

• A 24V LWCO may be wired so that its contacts are wired to the external limit connections on the boiler. When this is done either:

• A separate transformer must be supplied by the installer to power the LWCO’s sensing circuit. This transformer must be completely isolated from the boiler wiring (Figure 11.4b). OR

• Power may be taken from EnviraCOM connections, if not otherwise in use (Figure 11.4c)

d. 4-20 mA Energy Management System (EMS) - A 4-20 mA EMS may be wired to the Sage controller (Figure

11.5). Manufacturer part numbers for contacts (field supplied) required to install wire leads in JST housing are:

• SRSF-61T-250A (Recommended for size 16 AWG wire)

• ASRSFSRSF16K51B (2" lead between contacts)

• ASRSFSRSF16K152B (6" lead between contacts)

• ASRSFSRSF16K305B (12" lead between contacts)

• SRSF-21T-250A (Recommended for size 20 AWG wire)

• ASRSFSRSF20K51B (2" lead between contacts)

• ASRSFSRSF20K152B (6" lead between contacts)

• ASRSFSRSF20K305B (12" lead between contacts)

3. Data Connections – Modbus and EnviraCOM connections are located in the green control connector shared with the display connections (Figure 11.6). These connections have the following uses:

a. EnviraCOM - Used to connect EnviraCOM thermostat or other EnviraCOM device listed by the boiler manufacturer for use with this boiler.

b. MODBUS - Boiler-To-Boiler communication network is used for multiple boiler (“Lead-Lag”) installations. Note that combi boilers may only be used as slaves in such a system.

CAUTION

When making low voltage connections, make sure that no external power source is present in the thermostat or limit circuits. If such a power source is present, it could destroy the boiler’s control. One example of an external power source that could be inadvertently connected to the low voltage connections is a transformer in the old thermostat wiring.

Do not attempt to use EnviraCOM connections for any purpose not explicitly permitted by the boiler manufacturer. Attempting to do so may result in unreliable operation and/or damage to controls.

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XI. Wiring (continued)

Figure 11.4a: 120 Volt LWCO Field Wiring

Figure 11.4b: 24 Volt LWCO Field Wiring Using 24

VAC Transformer

Figure 11.4c: 24 Volt LWCO Field Wiring Using

Control ECOM

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Page 87

XI. Wiring (continued)

Figure 11.5: 4-20 mA EMS Field Wiring

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Figure 11.6: J3 Field Wiring

Page 88

XI. Wiring (continued)

P3‐6

R7910BBoilerControl

J3‐A

‐V

J3‐B

MB1

MB2

ReturnSensor

SupplySensor

Spark

J1‐2

J9‐1

J9‐2

J9‐3

J9‐4

J9‐5

J9‐6

WiringLegend

R7910BBoilerControl

AT140B

BoilerPump

SystemPump

Gnd

J8‐3

J8‐2

J6‐3

J4‐10

J7‐7

J4‐12

J8‐1

J5‐1

J6‐2

J5‐2



GasValve

Sump

Press.Sw.

Ext.

Limit

T1‐5

P2‐4

CHT’stat

T1‐6

T1‐1 T1‐2

Boiler

FlowSw.

J3‐ECOM1(D)

J3‐ECOM2(R)

J3‐ECOM3(C)

Ignitor

Flame

Rod

FactoryWireHarness

Fieldwiring

Connector

Screw

Terminal

120VAC/60Hz/1Ph

L3‐1

J4‐4

J4‐6

J4‐2

J4‐7

J4‐5

J4‐3

CombustionFan

(120VConn.)

1 3

J8‐6

J8‐10

J8‐4

J8‐9

J8‐8

J8‐11

J8‐5

J10‐7

J10‐8

Outdoor

Temp

J6‐7

J6‐8

FlueGasSensor

1(DC+)

2(Tach.)

4(PWM)

5(DC‐)

J2‐3(FanPWM)

J2‐4(DC‐)

J2‐1(Tach.)

J2‐2(DC+)

CombustionFan

(DCConn.)

T1‐8

T1‐7

Internal,non

replaceable2amp

J6‐1

L3‐2

L2‐1 L2‐3

Thermal

Fuse

Groundscrewin

boilerJ‐box

“AirProving

Switch”

WireNut

P1‐1P1‐2

P1‐5

P5‐1

P5‐7

P3‐5

P3‐4

P2‐3

P2‐2

P2‐6

P3‐9

P3‐1

P3‐12

P3‐10

P3‐3

P3‐11

P4‐5

P4‐4

P4‐1

P4‐11

P4‐10

P4‐2

P4‐7

P4‐8

P4‐12

P4‐9

P4‐3

P4‐6

Condensate

Trap

¼”Q.C.

PCBTrace/Components

Groundscrew

onboilerframe



3‐WayZoneValve

DHW

FlowSw.

DHWSensor

P5‐9

P5‐6

6.3ASlo BlowIn‐

LineFuse

BP‐1 BP‐2

ZV‐1 ZV‐2

P5‐4

P3‐8

P3‐7

P3‐2

P2‐1

P5‐2 P5‐5

Panasonic

GT02

Display

SD+

RD+

SD‐

‐5V

+5V

RD‐

DFS‐3 DFS‐2

Note:DHWThermostat

Terminals(#3&#4)arenot

shownandarenotused.



ModBusConnections (ifused)

EnviraCOM

Connections(ifused)

Figure 11.7: Internal Ladder Diagram

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Page 89

XI. Wiring (continued)

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Page 90

XI. Wiring (continued)

Figure 11.8: Internal Wiring Connections Diagram

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Page 91

XI. Wiring (continued)

Table 11.8: Internal Wire Connection Markings Cross Reference Table

WIRE NO. IN

FIG. 11.8

1 RD J8-8/P4-1, P4-1/SUP-1 20 BK SPL BK-1/P1-2, P1-2/120V

2 VI J9-4/P4-2, P4-2/FLUE-1 20a BK SPL BK-1/L2-1

3 RD J2-2/P4-3, P4-3/FAN-1 20b BK J4-2/SPL BK-1

4 R/G J8-9/P4-4, P4-4/SUP-2 20c BK J4-4/SPL BK-1

5 V/G J9-5/P4-5, P4-5/FLUE-2 20d BK J4-6/SPL BK-1

6 WH J2-1/P4-6, P4-6/FAN-2 20e BK SPL BK-1/P3-8, P3-8/B1-1

7 GY J8-10/P4-7, P4-7/SUP-3 21 GY P2-6/P3-9, P3-9/THERM-1

8 GY J9-6/P4-8, P4-8/FLUE-3 22 GR J4-10/P3-10, P3-10/SPL GR-1

9 BK J2-3/P4-9, P4-9/FAN-4 22a GR SPL GR-1/B1-3

10 BL J8-4/P4-10, P4-10/RET-1 22b GR SPL GR-1/GND

11 BL/G J8-5/P4-11, P4-11/RET-2 23 OR J1-2/P3-11, P3-11/SPL OR-1

12 BL J2-4/P4-12, P4-12/FAN-5 23a OR SPL OR-1/TRAP

13 BL/G J6-2/P3-1, P3-1/APS 23b OR SPL OR-1/FLAME

14 YE L3-2/SPL Y-1 24 GY J6-3/P3-12, P3-12/SPL GY-1

14a YE J8-2/SPL Y-1 24a GY SPL GY-1/FLOW-1

14b YE SPL Y-1/P3-2, P3-2/GAS-2 24b GY SPL GY-1/SPS

15 GR J4-12/P3-3, P3-3/IGN GND 25 GY SPS/THERM-2

16 RD J5-2/P3-4, P3-4/GAS-1 26 BL J4-3/P5-7, P5-7/ZV-1

17 BL L3-1/SPL BL-1 27 RD J4-5/P5-1, P5-1/BP-1

17a BL SPL BL-1/J8-1 28 YE J8-3/P2-4

17b BL SPL BL-1/P2-1 29 YE J10-7/P2-2

17c BL SPL BL-1/P3-5, P3-5/APS 30 RD J10-8/P2-3

17d BL SPL BL-1/P5-2, P5-2/DFS-3 31 BR J7-7/P5-5, P5-5/DFS-2

18 GY J5-1/P3-6, P3-6/FLOW-3 32 YE SYS PUMP/P1-5, P1-5/J4-7

19 WH NEUT/ P1-1, P1-1/SPL W-1 33 Y/G J9-1/P5-9, P5-9/DS

19a WH SPL W-1/L2-3 34 Y/G J9-2/P5-6, P5-6/DS

19b WH SPL W-1/P3-7, P3-7/B1-2 35 OR J3-1/SPL OR-1

19c WH SPL W-1/P5-4, P5-4/SPL W-1 35a OR SPL OR-1/ +RD

19d WH P5-4/SPL W-1, SPL W-1/BP-2 35b OR SPL OR-1/ +SD

19e WH SPL W-1/ZV-2 36 VI J3-2/SPL VI-1

USE WIRE CODE ON CONNECTIONS DIAGRAM TO DETERMINE COLOR.

WIRE MARKING

WIRE NO. IN

FIG 11.8

36a VI SPL VI-1/ -RD

36b VI SPL VI-1/ -SD

37 BL J3-3/ 5V+

38 PI J3-6/ 5V-

WIRE MARKING

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Page 92

XI. Wiring (continued)

Figure 11.9: TACO SR504 or Equivalent Zone Panel Wiring Connection Diagram

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Page 93

XI. Wiring (continued)

Figure 11.10: Sage Zone Control Circulator Panel Wiring Connection Diagram

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Page 94

XII. Start-Up and Checkout

WARNING

Completely read, understand and follow all instructions in this manual before attempting start-up.

NOTICE Safe lighting and other performance criteria were met with the gas train assembly provided on the boiler when the boiler underwent the tests specified in Z21.13.

Use the following procedure for initial start-up of the boiler:

1. Verify that the venting, water piping, gas piping and electrical system are installed properly.

2. Confirm all electrical, water and gas supplies are turned off at the source and that vent is clear of obstructions.

3. Confirm that all manual shut-off gas valves between the boiler and gas source are closed.

4. If not already done, flush the system to remove sediment, flux, and traces of boiler additives.

5. Fill the boiler and hydronic system with water meeting the following requirements below (also see the note on the next page):

• pH between 6.5 and 9.5

• Hardness less than 7 grains/gallon

• Chlorides less than 200 ppm

• Pressurize the system to at least 12 psi at the boiler

WARNING

Burn Hazard. The maximum operating pressure of this boiler is 30 psig (210 kPa) or 50 psig (340 kPa), depending on the model and safety relief valve option selected. Never exceed the maximum allowable working pressure on the heat exchanger ASME plate.

6. Bleed air from the heat exchanger using the manual air vent in the top left side of the heat exchanger (Figure 12.1). To do this install a piece of ¼” ID clear tubing over the hose barb and route the tubing to a location where water will not damage controls or nearby construction. Turn vent counter clockwise and allow heat exchanger to vent until a steady stream of water is observed. Close vent and remove hose.

7. Check all gas piping for leaks and purge piping sections that are filled with air. Refer to the National Fuel Gas Code for additional information on testing and purging gas lines.

DANGER

Explosion Hazard. Do not use matches, candles, open flames or other ignition source to check for leaks.

Make sure that the area around the boiler is clear and free from combustible materials, gasoline and other flammable vapors and liquids.

8. Confirm vent system is complete and free of obstructions before attempting to fire boiler.

9. Inspect all wiring for loose, uninsulated or miswired connections.

10. If the boiler is to be converted to propane, convert as described in conversion kit instructions. If boiler is operating at elevations above 2000ft, see Appendix A of this manual for setup instructions.

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XII. Start-Up and Checkout (continued)

DANGER

Asphyxiation Hazard. Failure to properly convert this boiler for use on LP gas can cause

unreliable operation at elevated carbon monoxide (CO) levels, resulting in personal injury or death.

NOTICE To minimize the risk of premature heat exchanger failure, observe the following water chemistry requirements:

1. Minimize the introduction of make-up water, dissolved oxygen, and contaminants into the boiler by following the installation guidelines shown in the “Water Quality and Boiler Water Additives Note” on Page 70.

2. Make sure the system is filled with water meeting the following criteria:

• pH between 6.5 and 9.5 (for systems containing aluminum components, between 6.5 and 8.5)

• Chloride level less than 200 PPM. If fill water is drawn from a system containing a water softener, test a sample of the fill water to confirm that this criteria is met.

• Hardness less than 7 grains/gallon.

3. Avoid the use of petroleum based boiler additives and ester-based oils/lubricants. These can attack seals in both the boiler and system.

4. If freeze protection is required, use the following or its equivalent:

• Fernox Alphi -11 (inhibited Propylene Glycol)

• Sentinel® X500 Inhibited Propylene Glycol antifreeze (combined antifreeze and inhibitor)

Refer to the antifreeze manufacturer’s instructions for required dosage. In general these products are a blend of glycol (for freeze protection) and inhibitors (to protect the glycol from attacking metallic system components). Do not add any more antifreeze than is necessary to protect the system from freeze damage. Many of these products require annual testing of the system water to ensure that the inhibitors are still active; consult the manufacturer’s instructions for maintenance requirements. Allowance must be made for the additional expansion of the glycol solution.

5. Test antifreeze and inhibitor concentration annually.

• Inhibitor concentration test kit for Fernox Protector F1, 25 tests per kit. Part Number: 101148-01

• Inhibitor, Fernox Protector F1, 1 pint (500 mL). Part Number: 101147-01

6. For system cleaning, use the following or its equivalent:

• Fernox Cleaner F3

• Sentinel® X300 System cleaner (for New Heating systems)

• Sentinel® X 400 System Restorer (For old Closed Loop Hydronic Heating Systems)

Refer to the instructions supplied with the cleaner for proper dosage and use.

Fernox products are available from Alent PLC Consumer Products Division, 4100 6th Avenue, Altoona PA, (972) 547-6002 (fernox_usa@alent.com) Sentinel® Products are available from Douglas Products and Packaging, 1550 E. Old 210 Highway, Liberty, MO 64068, Tel: (877) 567-2560 (Toll Free) and /or selected HVAC distributors.

WARNING

Poison Hazard. Use only inhibited propylene glycol solutions specifically formulated for

hydronic systems. Do not use ethylene glycol, which is toxic and can attack gaskets and seals used in hydronic systems. Use of ethylene glycol could result in property damage, personal injury or death.

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Page 96

XII. Start-Up and Checkout (continued)

ATTACH 1/4" ID CLEAR

TUBING TO HOSE BARB

AND ROUTE TO SAFE PLACE

AWAY FROM CONTROLS

BEFORE OPENING VENT.

MANUAL AIR VENT

FLAME ROD

Figure 12.1: Location of Manual Air Vent

11. Start the boiler using the lighting instructions on page 100. With the boiler powered up, and with no call for heat, the display should look like Figure 12.2a. Once a call for heat is present, it will look like Figure 12.2b.

12. The boiler should attempt to fire approximately 30 seconds after a call for heat appears. With the front door open, this try for ignition will appear as an audible spark (lasting approximately 4 seconds) and an audible click from the gas valve. Upon initial start-up, the gas train will be filled with air. Even if the gas line has been completely purged of air, it may take several tries for ignition before a flame is established. If the boiler does not light after six tries for ignition, it will enter a “soft lockout” and will wait for one hour before attempting another ignition sequence. This soft lockout can be reset by interrupting power to the boiler for a few seconds. Once a flame has been established for the first time, subsequent calls for burner operation should result in a flame on the first try.

13. If there is a problem that appears before the first try for ignition, or if the boiler fails to light after six tries for ignition, the blinking “HELP” button is highlighted on the Home screen (Figure 12.2c). Touching this “HELP” button will take the user to the Diagnostics menu where the cause of the problem can usually be found by pressing the flashing button on each successive screen.

14. Inspect the flame visible through the window. On high fire the flame should be stable and mostly blue (Figure 12.3). No yellow tipping should be present; however, intermittent flecks of yellow and orange in the flame are normal.

15. Check the inlet gas pressure. Verify that the inlet gas pressure is between the upper and lower limits shown on the rating plate with all gas appliances on and off.

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Page 97

XII. Start-Up and Checkout (continued)

Boiler /Combi

Status

Detail

Help

Adjust

Figure 12.2a: Home Screen at Power-Up (No Call for Heat)

Status

Detail

Help

Adjust

Figure 12.2b: Home Screen on Heat Demand

Status

Detail

Help

Adjust

180 F

Standby

Energy Save On

High Efficiency On

180 F

Central Heat

Energy Save On

High Efficiency On

180 F

Standby

Energy Save On

High Efficiency On

kbtu

Figure 12.2c: Home Screen with Active Fault

Figure 12.3: Burner Flame

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XII. Start-Up and Checkout (continued)

Figure 12.4: Gas Valve Detail

WARNING

Do not attempt to operate this boiler on LP gas without converting it using the proper conversion kit.

Do not attempt to convert this boiler to LP gas without the use of a combustion analyzer.

Before attempting to operate this boiler at altitudes above 2000 ft., follow instructions shown in Appendix A of this manual.

16. Perform a combustion test. Boilers are equipped with a screw cap in the vent adapter. Be sure to replace this cap when combustion testing is complete. Check CO2 (or O2) and CO at both high and low fire. Ensure the door panel is sealed before combustion readings are taken. The boiler may be temporarily locked into high or low fire as follows:

a. Fire the boiler through any call for heat.

b. From the Home Screen, press “ADJUST” to enter the adjust menu.

c. Press “ADJUST”.

d. Press “LOGIN”.

e. Press “000”.

f. Enter the password “086”

g. Press return arrow to close the keypad.

h. Press “SAVE”.

i. Press “ADJUST”

j. Press “MANUAL CONTROL”.

k. Press “HIGH” or “LOW” as appropriate.

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XII. Start-Up and Checkout (continued)

To return the boiler to automatic modulation, press AUTO FIRE. Note: If the Auto Fire button is not pressed, boiler will remain in manual fire for around 10 minutes. After 10 minutes boiler automatically returns to automatic modulation.

At both high and low fire, CO readings should be less than 200 PPM air free. Typical CO are shown in Table 12.5A. Final readings should be taken with all doors and covers in place. If adjustments are needed, make them as follows:

a. With burner at high fire, adjust gas valve throttle (Fig 12.4) as needed to obtain CO2 (or O2) setting shown in Table 12.5A.

• To reduce the CO

• To increase the CO

(increase the O2), turn throttle clockwise.

(reduce the O2), turn throttle counter-clockwise.

Make adjustments in increments of 1/8 to 1/4 turns and allow the boiler at least a minute to respond before making another adjustment.

b. With the burner at low fire, adjust gas valve offset regulator (Fig 12.4) as needed to obtain CO

(or O2) setting shown in Table 12.5A.

• To reduce the CO2 (increase the O2), turn offset regulator counter-clockwise.

• To increase the CO2 (reduce the O2), turn offset regulator clockwise. Make adjustments in increments of no more than 1/8 turns and allow the boiler at least a minute to

respond before making another adjustment.

WARNING

Improper gas valve adjustments can result in unreliable operation, substantial property damage, personal injury or loss of life due to carbon monoxide (CO) poisoning. Observe the following precautions:

•

Do not attempt to adjust gas valve without a combustion analyzer.

•

Each boiler is tested at the factory and adjustments to the gas valve are normally not necessary when operating on natural gas at sea level. Before making any adjustments, make sure that the analyzer is calibrated and that combustion readings have stabilized.

•

Regulator (“offset”) screw used for low fire adjustment is very sensitive. Adjust no more than 1/8 turn before checking combustion with analyzer. Maximum total regulator adjustment is ± 1 turn from factory setting.

and O2 readings

17. Perform a check of the ignition safety shut-off device. With the burner firing, carefully unplug the orange flame rod wire at the flame rod using a pair of insulated pliers (Figure 12.1). The burner

should shut off immediately.

18. Test any external limits or other controls in accordance with the manufacturer’s instructions.

19. Refer to the Operation Manual to set-up the control for the system in which the boiler is installed. Some common set-up tasks include:

• Setting the CH temperature set-point.

• Defining the system pump operation.

20. Adjust the heating thermostat to its final set point.

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Page 100

XII. Start-Up and Checkout (continued)

NOTICE In some cases, such as when the gas valve is replaced, the throttle may be far enough out of adjustment that it is not possible to fire the boiler while “dialing in” the CO analyzer. In such a case, do the following:

1. Turn the throttle screw clockwise until it stops turning.

2. For natural gas applications, turn the throttle screw counter-clockwise by the number of turns shown in Figure 12.5B.

3. For LP gas applications set the preliminary throttle setting per conversion kit instructions.

4. Start the boiler using the lighting instructions on Page 100.

5. Once the boiler is firing, use a combustion analyzer to adjust the CO2 (or O2) to its final value as described above.

Table 12.5A: Typical Natural Gas Combustion Readings (Sea Level Only)

(or O2) using a combustion

Boiler Size

Measured High Fire %CO

Range Target

Maximum CO Air-Free

135

8.7-9.2 9.1 200ppm150

180

* Low Fire Range and Target values are the same as High Fire above. Ensure low fire CO than or equal to high fire CO2 reading.

Boiler Size

Measured High Fire %O

Range Target

Maximum CO Air-Free

135

4.7-5.6 4.9 200ppm150

180

** Low Fire Range and Target values are the same as High Fire above. Ensure low fire O than or equal to high fire O2 reading.

Table 12.5B: Starting Number of Throttle Turns for Natural Gas

Model

# Counter-clockwise Turns (From Fully

Closed)

135 12-1/4

150 10

180 15

reading is less

reading is greater

NOTICE This boiler has a limited warranty, a copy of which is included with this boiler. It is the responsibility of the installing contractor to see that all controls are correctly installed and are operating

properly when the installation is complete.

100

108095-02 - 4/18

Velocity Phantom PHNTM135CB, Phantom PHNTM150CB, Phantom PHNTM180CB Installation, Operating And Service Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual