Intelli-Fin 0 Manuale

INSTALLATION AND SERVICE MANUAL

Intelli-Fin®

Hot Water Heating Boilers

Domestic Hot Water Supply Boilers

1,500,000 — 1,700,000 — 2,000,000 Btu/hr Models

IFB/IFW-i&s-05

FIG. 1 Front View FIG. 2 Rear View

Installation and service must be performed by a qualified service

installer, service agency or the gas supplier.

Factory warranty (shipped with unit) does not apply to units

improperly installed or improperly operated.

Experience has shown that improper installation or system design,

rather than faulty equipment, is the cause of most operating

problems.

1. Excessive water hardness causing a lime/scale

build-up in the copper tube is not the fault of the

equipment and is not covered under the

manufacturer’s warranty. (See Water Treatment and

Water Chemistry)

2. Excessive pitting and erosion on the inside of the

copper tube may be caused by too much water

velocity through the tubes and is not covered by

the manufacturer’s warranty (See Boiler Flow Rates

and Temperature Rise for flow requirements).

This manual supplies information for the installation, operation

and servicing of the appliance. It is strongly recommended that

this manual be reviewed completely before proceeding with an

installation.

WARRANTY

SPECIAL INSTRUCTIONS

TO OWNER

NOTE: Retain this manual for future reference.

WARNING

IMPROPER INSTALLATION, ADJUSTMENT,

ALTERATION, SERVICE OR MAINTENANCE can

cause injury or property damage. Refer to this manual. For

assistance or additional information, consult a qualified

installer, service agency or the gas supplier.

TABLE OF CONTENTS

Warranty .......................................................................... 1

Safety Warnings .............................................................. 3

Codes .......................................................................... 3

Installation Requirements ............................................ 4

Location .................................................................... 4

Clearances ................................................................ 4

Combustion/Ventilation Air Requirements .............. 5

Construction Air Filter .............................................. 7

Venting Systems ............................................................ 8

Category IV Venting ........................................................ 9

Flue Pipe Materials............................................ 9

Installation Guidelines ...................................... 9

Vent Length Requirements ................................10

Drain Tee Installation ........................................10

Vertical Terminations ........................................11

Sidewall Terminations ......................................12

Direct Vent Systems ........................................................13

Air Inlet Pipe Materials ....................................14

Air Inlet Pipe Length Requirements..................14

Vertical Direct Vent ..................................................15

Location Requirements......................................15

Multiple Direct Vent Installations......................16

Horizontal Direct Vent ..............................................16

Location Requirements......................................16

Multiple Direct Vent Installations......................18

Intelli-Vent Systems..................................................18

Materials ............................................................18

Length Requirements ........................................18

Vertical Flue - Sidewall Air ..............................19

Sidewall Flue - Rooftop Air ..............................20

Sidewall Flue - Sidewall Air..............................21

Gas Supply ....................................................................23

Gas Pressures and Piping ..................................23

Manifold Pressure..............................................23

Supply Pressure Measurement ..........................25

Manifold Pressure Measurement ......................26

Water Connections ..........................................................27

Heat Exchangers ..............................................................28

Integral Bypass ................................................................29

Valve and Pump ................................................29

Synchronization ................................................29

Set-up Maximum Flow......................................30

Bypass Operation ..............................................31

Minimum Water Temperatures ..................................31

Flow Switch ....................................................................32

Low Water Cut-Off ..........................................................32

Gas Train..........................................................................32

Relief Valve......................................................................33

Ratio Gas Valve ........................................................33

Diaphragm Gas Valve ..............................................33

Electrical Requirements ..................................................34

Jacket ..........................................................................34

Components and Controls ............................................35

Variable Frequency Drive..................................36

Low Air Pressure Switch ..................................37

Gas Pressure Switches ......................................37

Excel 10 Boiler Interface Controller ................37

Manual Override Control ..................................39

Temperature Adjustment....................................39

Command Display ............................................39

Password ....................................................40

Changeable Points ......................................40

Data Points in Display................................41

Status Points — Operation ........................43

Status Points — Alarm ..............................44

Outdoor Reset Function ............................44

Multiple Appliance Installations........................45

Sequencing Options....................................45

E-Bus Connection ......................................46

Temperature Limit Control................................48

Hot Surface Ignition Control ............................48

Hot Surface Igniter..............................49

Diagnostic Status LED........................49

Operation/Diagnostic Lights and Switches ......50

Burner Assembly ..............................................51

Combustion Air Blower ....................................52

Condensate Management System......................53

Installation and Operation ..................53

Condensate Trap Installation ..............54

Lighting Instructions ....................................................55

Sequence of Operation ..................................................57

Maintenance ............................................................58

Vent System ............................................................58

Flame Patterns ..........................................................58

Burner Cleaning........................................................59

Heat Exchanger Inspection ......................................61

Lubrication ............................................................62

Combustion Air Measurements ................................62

Freeze Protection ......................................................63

Heating Boiler ............................................................64

Piping ............................................................64

Piping Length and Diameter ....................................65

Integral Pump Limitations ................................65

Boiler Pump Operation......................................65

Primary/Secondary Piping ................................66

Minimum Water Temperatures ..........................66

Three Way Valves ..............................................67

Boiler Flow Rates ..............................................67

Placing the Boiler in Operation ........................68

Boiler Temperature Control ..............................69

Water Heater/Domestic Hot Water Supply Boiler ....70

Typical Piping....................................................70

Set-up Maximum Flow......................................70

Temperature Rise ..............................................71

Water Chemistry ................................................72

Piping Requirements ........................................73

Pump Operation ................................................74

Temperature Adjustment....................................75

Minimum Inlet Temperatures ............................75

Risk of Scald Warnings ....................................76

Relief Valve ......................................................76

Ladder Diagram ............................................................77

Wiring Diagram ............................................................78

Revision Notes ..............................................Back Cover

Upon receiving equipment, check for signs of shipping damage.

Pay particular attention to parts accompanying the boiler, which

may show signs of being hit or otherwise being mishandled. Verify

total number of pieces shown on packing slip with those actually

received. In case there is damage or a shortage, immediately notify

carrier.

CHECKING EQUIPMENT

DO NOT

WARNING

Do not use this appliance if any part has been under water.

The possible damage to a flooded appliance can be extensive

and present numerous safety hazards. Any appliance that

has been under water must be replaced.

If the information in this manual is not followed exactly, a

fire or explosion may result causing property damage,

personal injury or loss of life.

This appliance MUST NOT be installed in any location

where gasoline or flammable vapors are likely to be present,

unless the installation is such to eliminate the probable

ignition of gasoline or flammable vapors.

WHAT TO DO IF YOU SMELL GAS

•Do not try to light any appliance.

•Do not touch any electric switch: do not use any phone in

your building.

•Immediately call your gas supplier from a neighbor’s

phone. Follow the gas supplier’s instructions.

•If you cannot reach your gas supplier, call the fire

department.

Installation and service must be performed by a

qualified installer, service agency or the gas

supplier.

OWNER WARNING

The information contained in this manual is intended

for use by qualified professional installers, service

technicians or gas suppliers. Consult your local expert

for proper installation or service procedures.

IMPORTANT

Consult and follow local Building and Fire Regulations and

other Safety Codes that apply to this installation. Contact

the local gas utility company to authorize and inspect all gas

and flue connections.

A gas appliance that draws combustion air from the equipment

room where it is installed must have a supply of fresh air circulating

around it during burner operation for proper gas combustion and

proper venting.

1. Boilers and water heaters are heat producing appliances.

To avoid damage or injury, do not store materials against

the appliance or the vent-air intake system. Use proper care

to avoid unnecessary contact (especially children) with the

appliance and vent-air intake components.

2. Never cover your appliance, lean anything against it, store

trash or debris near it, stand on it or in any way block the

flow of fresh air to your appliance.

3. UNDER NO CIRCUMSTANCES must flammable

materials such as gasoline or paint thinner be used or stored

in the vicinity of this appliance, vent-air intake system or

any location from which fumes could reach the appliance

or vent-air intake system.

The equipment shall be installed in accordance with those

installation regulations in force in the local area where the

installation is to be made. These shall be carefully followed in all

cases. Authorities having jurisdiction shall be consulted before

installations are made. In the absence of such requirements, the

installation shall conform to the latest edition of the National Fuel

Gas Code, ANSI Z223.1 and/or CAN/CGA-B149 Installation Code.

Where required by the authority having jurisdiction, the installation

must conform to American Society of Mechanical Engineers Safety

Code for Controls and Safety Devices for Automatically Fired

Boilers, ASME CSD-1. All boilers conform to the latest edition of

the ASME Boiler and Pressure Vessel Code, Section IV. Where

required by the authority having jurisdiction, the installation must

comply with the CSA International, CAN/CGA-B149 and/or local

codes. This appliance meets the safe lighting performance criteria

with the gas manifold and control assembly provided, as specified

in the ANSI standards for gas-fired units, ANSI Z21.13.

CODES

WARNING

Should overheating occur or the gas supply fail to shut off,

DO NOT turn off or disconnect the electrical supply to

the pump. Instead, shut off the gas supply at a location

external to the appliance.

WARNING

To minimize the possibility of serious personal injury, fire or

damage to your appliance, never violate the following safety

rules.

1. Locate the appliance so that if water connections should

leak, water damage will not occur. When such locations

cannot be avoided, it is recommended that a suitable drain

pan, adequately drained, be installed under the unit. The pan

must not restrict combustion airflow. Under no

circumstances is the manufacturer to be held responsible for

water damage in connection with this unit, or any of its

components.

2. The appliance must be installed so that the ignition

system components are protected from water

(dripping, spraying, etc.) during appliance operation and

service (circulator replacement, control replacement, etc.).

3. Appliances located in a residential garage and in adjacent

spaces that open to the garage and are not part of the living

space of a dwelling unit must be installed so that all burners

and burner ignition devices have a minimum clearance of

not less than 18" (46cm) above the floor. The appliance

must be located or protected so that it is not subject to

physical damage by a moving vehicle.

4. DO NOT install this appliance in any location where

gasoline or flammable vapors are likely to be present.

5. The appliance must be installed on a level floor.

Combustible floor locations may be used. Maintain required

clearances from combustible surfaces.

6. The appliance must not be installed on carpet.

7. The appliance must be installed indoors where it

is protected from exposure to wind, rain and

weather.

8. This appliance may condense the products of

combustion when operating at water temperatures

below 130°F (54.4°C). Ensure that the appliance is

located near an acceptable drain where the

condensate from the heat exchanger and venting

system may be properly collected, neutralized and

disposed.

INSTALLATION PROCEDURE

LOCATION OF UNIT

TABLE - A

Clearances from

Combustible Construction:

Right Side - 0"

Rear - 9" (23 cm) (Minimum 24" (0.61 m) suggested for

service to pump and components)

Left Side - 0"

Front - ALCOVE* (Minimum 24" (0.61 m) suggested for

service)

Flue - 1" (25.4 mm)

Hot Water Pipes - 1" (25.4 mm)

*An ALCOVE is a closet without a door.

RECOMMENDED SERVICE CLEARANCES

FIG. 3 Recommended Service Clearances - Front FIG. 4 Recommended Service Clearances - Rear

NOTE

Clearances from combustible construction are noted on the

appliance rating plate.

Maintain minimum specified clearances for adequate operation.

All installations must allow sufficient space for servicing the vent

connections, water pipe connections, integral circulating pump,

bypass piping and other auxiliary equipment, as well as the

appliance. The clearance labels on each appliance note the same

service and combustible clearance requirements as shown in the

clearances from combustion construction table.

Multiple appliances may be installed in a modular boiler or water

heater installation. Multiple appliances may be installed side by

side with no clearance between adjacent appliances because this

appliance is approved for zero clearance from combustible surfac-

es and no service access is required from the sides.

Consult the venting section of the manual for specific installation

instructions for the appropriate type of venting system that you will

be using. Direct Vent and Intelli-Vent venting systems require

installation with Category IV flue pipe, sealed air inlet pipe and air

inlet caps, which must meet the manufacturer’s specifications.

COMBUSTION AND VENTILATION

AIR REQUIREMENTS FOR

APPLIANCES DRAWING AIR FROM

THE EQUIPMENT ROOM

Provisions for combustion and ventilation air must be in accordance

with Section 5.3, Air for Combustion and Ventilation, of the latest

edition of the National Fuel Gas Code, ANSI Z223.1, in Canada,

the latest edition of CAN/CGA Standard B149 Installation Code

for Gas Burning Appliances and Equipment, or applicable

provisions of the local building codes.

The equipment room MUST be provided with properly sized

openings to assure adequate combustion air and proper ventilation

when the unit is installed with a basic Category IV venting system.

FIG. 5 Combustion Air Direct from Outside

1. If air is taken directly from outside the building

with no duct, provide two permanent openings:

a. Combustion air opening, with a minimum free

area of one square inch per 4000 Btu input

(5.5 cm2per kW). This opening must be located

within 12" (30cm) of the bottom of the

enclosure.

b. Ventilation air opening, with a minimum free

area of one square inch per 4000 Btu input

(5.5 cm2per kW). This opening must be located

within 12" (30 cm) of the top of the enclosure.

FIG. 6 Combustion Air Through Ducts

2. If combustion and ventilation air is taken from the outdoors

using a duct to deliver the air to the mechanical room, each of

the two openings should be sized based on a minimum free

area of one square inch per 2000 Btu (11 cm2 per kW) of input.

TABLE - B

Minimum Recommended Combustion

AIR SUPPLY TO MECHANICAL ROOM

Btu/hr

Input

1,500,000 375 in2(2419 cm2)

425 in2(2742 cm2)

500 in2(3226 cm2)

567 in2(3658 cm2)

667 in2(4303 cm2)

1,500 in2(9,677 cm2)

1,700 in2(10,968 cm2)

2,000 in2(12,903 cm2)

1,700,000

2,000,000

Outside Air*

2 - Openings

Outside Air*

1 - Opening

Inside Air

2 - Openings

*Outside air openings shall directly communicate with the outdoors. When combustion air is drawn from the outside through a duct,

the net free area of each of the two openings must have twice (2 times) the free area required for Outside Air/2 Openings. The above

requirements are for the boiler only, additional gas fired appliances in the equipment room will require an increase in the net free area

to supply adequate combustion air for all appliances. Combustion air requirements are based on the latest edition of the National Fuel

Gas Code, ANSI Z223.1, in Canada refer to the latest edition of CAN/CGA B149. Check all local code requirements for combustion

air.

Combustion Air Source

FIG. 7 Combustion Air from Interior Space FIG 8 Combustion Air from Outside - Single Opening

3. If air is taken from another interior space, each of the two

openings specified above should have a net free area of one

square inch for each 1000 Btu (22 cm2per kW) of input,

but not less than 100 square inches (645 cm2).

4. If a single combustion air opening is provided to

bring combustion air in directly from the outdoors,

the opening must be sized based on a minimum

free area of one square inch per 3000 Btu (7 cm2

per kW). This opening must be located within 12"

(30 cm) of the top of the enclosure.

CAUTION

Under no circumstances should the mechanical room ever

be under a negative pressure. Particular care should be taken

where exhaust fans, attic fans, clothes dryers, compressors,

air handling units, etc., may take away air from the unit.

All dimensions based on net free area in square inches. Metal

louvers or screens reduce the free area of a combustion air opening

a minimum of approximately 25%. Check with louver

manufacturers for exact net free area of louvers. Where two

openings are provided, one must be within 12" (30 cm) of the

ceiling and one must be within 12" (30 cm) of the floor of the

mechanical room. Each opening must have net free area as

specified in Table - B. Single openings shall commence within 12"

(30 cm) of the ceiling.

The combustion air supply must be completely free of any

flammable vapors that may ignite or chemical fumes which may

be corrosive to the appliance. Common corrosive chemical fumes

which must be avoided are fluorocarbons and other halogenated

compounds, most commonly present as refrigerants or solvents,

such as Freon, trichlorethylene, perchlorethylene, chlorine, etc.

These chemicals, when burned, form acids which quickly attack

the heat exchanger finned tubes, headers, flue collectors, and the

vent system. The result is improper combustion and a non-

warrantable, premature appliance failure.

These chemicals, when burned form acids which quickly attack the

boiler tubes, tube sheets, flue collectors, and the appliance stack.

The result is improper combustion and a non-warrantable, prema-

ture failure of the appliance.

EXHAUST FANS: Any fan or equipment which exhausts air from

the equipment room may deplete the combustion air supply and/or

cause a downdraft in the venting system. Spillage of flue products

from the venting system into an occupied living space can cause a

very hazardous condition that must be immediately corrected. If a

fan is used to supply combustion air to the equipment room, the

installer must make sure that it does not cause drafts that could lead

to nuisance operational problems with the appliance.

A construction air filter is installed on the appliance as shipped.

The filter assembly is installed on the combustion air inlet located

at the rear of the appliance. The filter assembly slips over the air

inlet collar and is secured in place with the clamp provided with

the filter. If limited space is available at the rear of the appliance,

field supplied elbows may be used to mount the filter in the

alternate positions shown in the illustration. This filter is For

Temporary Use Only on an appliance that must be operated for

temporary heat or hot water when a building is under construction.

The filter will provide a temporary means to remove airborne dust,

dirt and particulate matter generated by construction. The filter

prevents airborne particulate contaminants from being drawn into

the burner with the combustion air. The filter can be cleaned

routinely during construction if necessary. Remove the filter to

clean. Wash the filter with water. A flow of water from the inside

to the outside should remove most particle matter. Allow the filter

to dry before reinstalling. Unfiltered combustion air from a

construction site can contain contaminants that will collect in the

burner reducing the firing rate. A burner that becomes clogged with

airborne particulate contaminants must be removed and cleaned to

restore proper operation to the burner. Sustained operation of an

appliance with a clogged burner may result in nuisance operational

problems, bad combustion and non-warrantable component failures.

CONSTRUCTION AIR FILTER

9.000

ELBOW(S)

NOT

PROVIDED

CABINET AIR

INLET OPENING

EDGE OF SCREEN 2"

MEDIA OVERLAP

FOLD OVERLAP AROUND

EDGE OF SCREEN AS

SHOWN.

PUSH FILTER ONTO AIR

INLET AND FASTEN WITH

CLAMP AS SHOWN.

BAND CLAMP

MODEL ABCD E REAR

2.0 19.750 12.250 4.875 15.000 24.000

1.7

1.5

19.250

18.750

10.750

9.250

4.375

3.875 6.000

7.500

14.000 24.000

14.500 24.000

FRONT

REAR

FIG. 9 Construction Air Filter

The construction air filter MUST be removed from the

appliance’s air inlet before the appliance is placed in normal

operation. Once the construction air filter is removed, ensure that

either the equipment room is supplied with combustion air from

properly sized combustion and ventilation air openings or a

combustion air duct from a Direct Vent or Intelli-Vent system is

connected to the appliance. The optional Direct Vent and

Intelli-Vent venting systems have specific requirements for a

special combustion air duct from the outside that is directly

connected to the appliance. See the requirements for this

combustion air duct in the venting section for each specialized

vent system.

CONSTRUCTION AIR FILTER KITS

TABLE - C

Input Construction

Btu/hr Air Filter Kit

1,500,000

________________________

1,700,000

________________________

2,000,000

KIT4000

________________________

KIT4001

________________________

KIT4002

VENTING

Vent System Options

This appliance has three venting system options. They are: (A)

Category IV Venting system with vertical roof top termination or

sidewall termination of the flue and combustion air supplied from

the mechanical room. (B) Direct Vent with a Category IV flue

and a separate combustion air pipe to the outdoors. The Direct

Vent system terminates both the flue and air inlet in the same

pressure zone. The flue outlet and combustion air intake may

terminate on either the sidewall or with a rooftop termination.

combustion air pipe to the outdoors.The Intelli-Vent system

terminates the flue and the combustion air inlet pipe in different

pressure zones. The Intelli-Vent system may terminate the flue on

the roof top and combustion air intake on the sidewall, the flue

on the sidewall and combustion air from the rooftop or the flue

on the sidewall and combustion air from a different sidewall. All

appliances are shipped from the factory equipped for Category

IV venting. The optional Direct Vent and Intelli-Vent venting

systems will require the installation of specific vent kits and

venting materials. The following is a detailed explanation of the

installation requirements for each venting system, components

used and part numbers of vent kits for each model.

General

Vent installations for connection to gas vents or chimneys must be

in accordance with Part 7, “Venting of Equipment,” of the latest

edition of the National Fuel Gas Code, ANSI Z223.1, in Canada,

the latest edition of CAN/CGA Standard B149 Installation Codes

for Gas Burning Appliances and Equipment or applicable

provisions of the local building codes.

Adequate combustion and ventilation air must be supplied to the

equipment room in accordance with the latest edition of the

National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition

of CAN/CGA Standard B149 Installation Codes for Gas Burning

Appliances and Equipment, or applicable provisions of the local

building codes.

The distance of the vent terminal from adjacent buildings, windows

that open and building openings MUST comply with the latest

edition of the National Fuel Gas Code, ANSI Z223.1, in Canada,

the latest edition of CAN/CGA Standard B149 Installation Code

for Gas Burning Appliances and Equipment.

Vent connection is made directly to the flue outlet opening on the

back of the unit. The connection from the appliance vent to the

stack must be made as direct as possible.

IMPORTANT

Examine the venting system at least once a year. Check all

joints and vent pipe connections for tightness. Also, check

for corrosion or deterioration. Immediately correct any prob-

lems observed in the venting system.

TABLE - D

The Category IV Flue Pipe Sizes

Input Btu/hr Flue Size

1,500,000

________________________

1,700,000

________________________

2,000,000

________________________

_______________________

Category IV Venting

A CATEGORY IV POSITIVE

PRESSURE VENTING SYSTEM

FIG. 10 Basic Category IV Venting - Vertical

FIG. 11 Basic Category IV Venting - Horizontal

A Category IV venting system for the flue products is required on

all models of this appliance. A Category IV venting system

operates with a positive pressure in the vent. This positive pressure

is generated by the internal combustion air blower which operates

the combustion process and also exhausts the flue products from

the building. The Category IV flue from this appliance can NOT

be combined with the vent from any other appliance. The Category

IV flues from multiple appliances can NOT be combined into a

common vent. The Category IV flue from this appliance must be

a dedicated stack. The flue from this Category IV appliance must

have all vent joints and seams sealed gas-tight. A Category IV

vent system has specific vent material and installation requirements.

The flue products in the vent system may be cooled below their

dew point and form condensate in the flue. The

materials used for a Category IV vent must be resistant to any

corrosive damage from flue gas condensate. The flue from a

Category IV vent system must have a condensate drain with

provisions to properly collect and dispose of any condensate that

may occur in the venting system.

Category IV Flue Pipe Materials

Select venting material from the following specified vent

distributors:

Heat-Fab Inc. Saf-T CI Vent with AL29-4C stainless steel

(Call 1-800-772-0739 for nearest distributor)

Protech Systems Inc. Fas N Seal Vent with AL29-4C stainless

steel (Call 1-800-766-3473 for nearest distributor)

Z-Flex Z-Vent with AL29-4C stainless steel

(Call 1-800-654-5600 for nearest distributor)

Or other listed Category IV vent systems suitable for a condensing,

positive pressure gas fired appliance.

Venting Guidelines for a Category IV Vent

The connection from the appliance vent to the stack or vent

termination outside the building MUST be made with listed

Category IV vent system and must be direct as possible with no

reduction in diameter. The Category IV vent and accessories, such

as firestop spacers, thimbles, caps, etc., MUST be installed in

accordance with the vent manufacturers instructions. The vent

connector and firestop must provide correct spacing to combustible

surfaces and seal to the vent connector on the upper and lower sides

of each floor or ceiling through which the vent connector passes.

In a typical installation, each appliance must have a dedicated

Category IV flue with no other appliance interconnected to any

part of the dedicated flue. Each appliance MUST connect to the

dedicated flue stack using a properly sealed vent adapter provided

by the vent manufacturer. The flues from multiple Intelli-Fin

appliances may only be combined when using an engineered vent

system incorporating an induced draft fan to ensure that flue

products will be properly exhausted from the building at all times.

Failure to use a properly sized induced draft fan on a combined vent

installation may result in a hazardous condition where flue gases

spill into an occupied living space. Consult the induced draft fan

manufacturer to size the induced draft fan and to determine the

diameter of the common vent pipe required for a combined vent

installation.

Any vent materials specified must be listed by a nationally

recognized test agency for use as a Category IV vent material.

The venting system must be planned so as to avoid possible

contact with concealed plumbing or electrical wiring inside walls,

floors or ceilings. Locate the appliance as close as possible to a

chimney or gas vent.

There shall be no reductions in vent diameter.

Horizontal portions of the venting system shall be supported to

prevent sagging. Horizontal runs should slope upwards not less

than 1/4 inch per foot (21 mm/m) from the drain tee installed in

the flue to the vertical portion of the flue or to the vent terminal

on sidewall venting installations. This ensures proper removal of

any condensate that may form in the flue. Follow the installation

instructions from the vent material manufacturer.

Do not use an existing chimney as a raceway if another appliance

or fireplace is vented through the chimney. The weight of the

venting system must not rest on the unit. Adequate support of the

venting system must be provided in compliance with local codes

and other applicable codes. All connections should be secured

and sealed per the vent manufacturers specifications.

Vent connectors serving appliances vented by natural draft shall

not be connected to any portion of the Category IV positive

pressure vent system used by this appliance. Connection of a

negative draft flue into the positive pressure stack from this

appliance may cause flue products to be discharged into an

occupied living space causing serious health injury.

When a Category IV vent system is disconnected for any reason,

the flue must be reassembled and resealed according to the vent

manufacturer’s instructions.

The installed length of the Category IV flue from the appliance

to the point of termination, outside of the building, must not

exceed a maximum of 100 equivalent feet (30.5 m) in length.

Subtract 5 feet (1.5 m) of equivalent length for each 90° elbow

installed in the vent. Subtract 2 1/2 feet (0.7 m) of equivalent

length for each 45° elbow installed in the vent.

The flue may terminate either vertically at the roof top or

horizontally on a sidewall. See the information about the specific

vent termination location for recommended location and

clearances.

General Category IV Vent Termination Clearances

The vent cap should have a minimum clearance of 4 feet (1.2 m)

horizontally from and in no case above or below, unless a 4 foot

(1.2 m) horizontal distance is maintained from electric meters,

gas meters, regulators and relief equipment.

The venting system shall terminate at least 3 feet (0.9 m) above

any forced air inlet within 10 feet (3.05 m).

The venting system shall terminate at least 4 feet (1.2 m) below,

4 feet (1.2 m) horizontally from, or 1 foot (30 cm) above any

door, window or gravity air inlet into any building.

Do not terminate the vent in a window well, stairwell, alcove,

courtyard or other recessed area. The vent cannot terminate

below grade. The bottom of the vent terminal shall be located at

least 12 inches (30 cm) above grade and above normal snow levels.

To avoid a blocked flue condition, keep the vent cap clear of snow,

ice, leaves, debris, etc.

Flue gases from this appliance may contain large amounts of water

vapor that will form a white plume in winter. Plume could obstruct

a window view.

Flue gas condensate can freeze on exterior surfaces or on the vent

cap. Frozen condensate on the vent cap can result in a blocked flue

condition. Flue gas condensate can cause discoloration of exterior

building surfaces. Adjacent brick or masonry surfaces should be

protected with a rust resistant sheet metal plate.

The manufacturer shall NOT be held liable for any personal injury

or property damage due to ice formation or the dislodging of ice

from the vent system or the vent termination.

Drain Tee Installation

WIRE TIE 4" Ø

CIRCULAR TRAP

TO SUITABLE DRAIN

FIG. 12 Drain Tee

A drain tee MUST be installed in the Category IV vent pipe to

collect and dispose of any condensate that may occur in the vent

system. The drain tee should be installed at the point where the

flue turns vertical for a roof top termination or as one of the first

fittings in a horizontal flue that will terminate on a sidewall. Ensure

that horizontal portions of the vent are properly sloped to allow

condensate to be evacuated at the drain tee. See the typical vent

installation drawings. Plastic drain tubing, sized per the vent

manufacturer’s instructions, shall be provided as a drain line from

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