AER Esteem 399 User manual

Instruction
No.
AERCO INTERNATIONAL, Inc. Northvale, New Jersey, 07647 USA
Concentric Vent System
Installation Supplement
Esteem 399
Low NOx
Gas Fired
Boiler
Visit www.aerco.com to View the Latest
Product Manuals and Information.
Printed in U.S.A. REVISED MAY 2010
GF-125V

Telephone Support
[phone]
Direct to AERCO Technical Support
(8 to 5 pm EST, Monday through Friday)
Please have the unit’s model number
and the serial number from the rating la-
bel on the backside of the control panel
when calling about service or trouble-
shooting.
Model #_________________________
Serial #__________________________
AERCO International, Inc.
159 Paris Avenue
Northvale, NJ 07647-0128
www.aerco.com
© AERCO International, Inc., 2010
The information contained in this document
is subject to change without notice from
AERCO International, Inc.
AERCO makes no warranty of any kind
with respect to this material, including but
not limited to implied warranties of mer-
chantability and fitness for a particular
application. AERCO International is not lia-
ble for errors appearing in this manual. Nor
for incidental or consequential damages
occurring in connection with the furnishing,
performance, or use of this material.

Contents
WARNINGS & CAUTIONS 1
Pre-Installation Items 2
General Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Vent/Air System Kit Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Vent/Air System Installation 4
Vent/Air System Clearance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Determine Termination Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Boiler Vent /Air System Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Vent/Air System Joint Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Termination Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cutting Termination Fitting to Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Adjustable Length Vent/Air System Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fire Stop Support Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Multiple Vent/Air System Terminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Maintenance Procedures 8
Inspect Vent/Air System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
i
Esteem 399 Low NOx Concentric Vent System Supplement
GF-125V

ii

1
WARNING!
INDICATES APOTENTIALLY HAZARDOUS SITU-
ATION WHICH, IF IGNORED, CAN RESULT IN
DEATH, SERIOUS INJURY OR SUBSTANTIAL
PROPERTY DAMAGE.
NOTICE
Indicates special instructions on in-
stallation, operation or maintenance,
which are important to equipment but
not related to personal injury hazards.
WARNING!
BEFORE ATTEMPTING TO PERFORM ANY MAINTENANCE ON THE UNIT, SHUT OFF ALL GAS AND ELECTRICAL
INPUTS TO THE UNIT.
WARNING!
THE EXHAUST VENT PIPE OF THE UNIT OPERATES UNDER APOSITIVE PRESSURE AND THEREFORE MUST BE
COMPLETELY SEALED TO PREVENT LEAKAGE OF COMBUSTION PRODUCTS INTO LIVING SPACES.
WARNING!
DONOT USE MATCHES, CANDLES, FLAMES, OR OTHER SOURCES OF IGNITION TO CHECK FOR GAS LEAKS.
NOTICE
This supplement is intended for the installation of a Concentric Vent/Air System Kit (P/N
P/N 39103) with an Esteem 399 Boiler. This Concentric Vent/Air System is not intended for
installation with any other boiler.
NOTICE
This Vent/Air System is listed to ULCS636 as Type BH Class IIC Vent System with a 110ºC
(230ºF) maximum flue temperature rating under Intertek/ETL Report number: 3122286
NOTICE
AERCO International reserves the right to modify the technical specifications and compo-
nents of its products without prior notice.
GF-125V
WARNINGS & CAUTIONS
Installers and operating personnel MUST, at all times, observe all safety regulations.
The following general warnings and cautions must be given the same attention as specific pre-
cautions included in these instructions. In addition to all the requirements included in this In-
struction Manual, the installation of units MUST conform with local building codes, or, in the ab-
sence of local codes, ANSI Z223.1 (National Fuel Gas Code Publication No. NFPA-54). Where
ASME CSD-1 is required by local jurisdiction, the installation must conform to CSD-1.
Where applicable, the equipment shall be installed in accordance with the current Installation
Code for Gas Burning Appliances and Equipment, CGA B149, and applicable Provincial regula-
tions for the class; which should be carefully followed in all cases. Authorities having jurisdiction
should be consulted before installations are made.
The following terms are used throughout this manual to bring attention to the presence of poten-
tial hazards or to important information concerning the product.

2
General Requirements
Pre-Installation Items
General Requirements
Installation of the vent/air system must com-
ply with local codes and requirements and
with the National Fuel Gas Code NFPA 54,
ANSI Z223.1 for installations in the U.S. For
Installations in Canada, the installation must
comply with CSA B149.1 or B149.2.
Use ONLY Esteem Concentric Vent/Air System
Kit (P/N 39103) and components (see figure 3)
from AERCO International. Do not mix compo-
nents or joining methods from other sources.
WARNING!
DONOT MIX VENT COMPONENTS OR JOINING
METHODS FROM ANY OTHER VENT MANUFAC-
TURER WITH AERCO INTERNATIONAL’SES-
TEEM CONCENTRIC VENT/AIR SYSTEM. FAILURE
TO COMPLY WITH THIS REQUIREMENT COULD
CAUSE VENT FAILURE RESULTING IN LEAKAGE OF
FLUE PRODUCTS INTO THE LIVING SPACE OF THE
BUILDING.
WARNING!
DONOT CONNECT MORE THAN ASINGLE BOILER
INTO THE VENT/AIR SYSTEM.
All penetrations of the vent/air system through
ceilings, floors or walls must be properly fire
stopped. Check with local codes and require-
ments regarding fire stops and vent penetra-
tions.
The vent/air system must not penetrate or be
routed through any active vent system or chim-
ney.
Vent/Air System Kit Components
Prior to installation of the vent/air system check
to ensure all parts required for the comple-
tion of the system are present. See Figure 1
for complete breakdown of concentric vent/
air system kit parts and Figure 3, for optional
components.
Termination Assembly
Elbow
Locking Band
Vent/Air Adapter Support Plate
Figure 1: Concentric Vent/Air System Kit Components (P/N 39103)
Note: Mounting Hardware Not Shown
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3
General Requirements
35”
Face of Wall 9 1/2”
10”
Clamp Hanging
P/N 39108
Clamp Seal
P/N 39109
Adjustable Length
(12.4” to 17”)
P/N 39105
Elbow - 90º
P/N 39106
Elbow - 45º
P/N 39107
Pipe - 40” Fixed
P/N 39105
Fire Stop Support
P/N 39111
Inner Pipe Gasket
Not Shown
P/N 39110
Figure 2: Assembled Vent/Air System Kit Dimensions
Figure 3: Optional Vent/Air System Components
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4
Vent/Air System Clearance Requirements
Vent/Air System Installation
Vent/Air System Clearance
Requirements
The vent/air system may maintain zero clear-
ance to combustible & non-combustible materi-
als.
Determine Termination Location
1. The maximum equivalent length of the
concentric vent/air system should not
exceed 100Ft (excluding the termination).
For each 90º elbow in the system, the
equivalent length is reduced by 10 feet.
For each 45º elbow in the system, the
equivalent length is reduced by 5 feet.
2. The installer must consider the following
when determining the location of the vent/
air system termination:
• Avoid areas where flue vapors may dam-
age surrounding shrubs, plants or air
conditioning equipment or be objection-
able to the end user.
• Avoid areas where the condensate
plume of the flue products could
obstruct window views.
• Avoid areas where prevailing winds
could cause a buildup of water/ice in the
combustion air inlet due to freezing of
flue condensate.
• Avoid locations with possibility of expo-
sure of persons or pets to flue vapors.
• Avoid locations where prevailing winds
cause recirculation of the flue gases,
such as inside corners of buildings or
near adjacent buildings or vertical sur-
faces, window wells, stairwells, alcoves,
courtyards, or other recessed areas.
• Do not terminate above any doors or
windows; flue condensate could freeze
causing ice formations.
• Locate or guard the termination to pre-
vent possible condensate damage to
exterior finishes.
3. Maintain the following clearances to the
termination:
• At least 3 feet from adjacent walls
• No closer than 3 feet below roof over-
hangs
• At least 7 feet above any public walk-
ways
• At least 3 feet above any forced air
intake (does not include the combustion
air inlet) within 10 feet.
• At least 4 feet from any electric meters,
gas meters, gas meter-regulators, relief
valves or other equipment. Never termi-
nate above or below any of these items
within 4 feet horizontally.
• Must maintain 12-inch clearances below
and horizontally from doors and win-
dows.
• Air intake must terminate at least 12
inches above grade or anticipated snow
line as shown in Figure 5.
Figure 4: Termination Clearances of Direct Vent
Systems
GF-125V

5
Boiler Vent /Air System Adapter
• Termination must not extend more than
9-1/2 inches beyond the exterior wall as
shown in Figure 5.
4. Horizontal or vertical runs of the vent/air
system must be supported at every joint.
Use the Hanging Clamp (P/N 39108) or
perforated metal strap hangers or equiva-
lent to support the piping.
5. The vent/air system must terminate using
the horizontal termination supplied in the
kit.
6. The vent/air system must be pitched back
to the boiler at minimum 5/8 inch per foot
on any horizontal runs.
Boiler Vent /Air System Adapter
Install boiler vent/air system adapter over the
boiler vent and air outlets. Secure the vent/air
system adapter using the band clamps found
on the vent and air adapters of the boiler.
NOTICE
Ensure Vent/Air System Adapter is
properly oriented over the boiler adapt-
ers. The concentric outlet of the adapter
should be installed toward the top left
side of the boiler.
Vent/Air System Joint Assembly
1. When installing the vent system, the
female end of the pipe or fitting should
face up or away from the boiler.
2. Prior to assembly of any piping or fittings
ensure the inner pipe gasket seal is pres-
ent, undamaged and properly seated in
the groove of the pipe.
3. Moisten the gasket seal with clean water.
Insert and rotate the male end of the inner
pipe into the female end of the previous
pipe section.
NOTICE
To aid in the assembly of the pipes and
fittings use only clean water to moisten
the gasket and the mating end of the
pipe. Use a twisting motion as the pipe
ends are pressed together.
4. Push the sections together firmly until the
outer jacket bead of the new section has
made contact with the edge of the female
end of the previous section. When fully
assembled, the outer female end of the
previous section will overlap the male end
by approximately 1”.
5. Use 2 self-drilling screws provided to
secure the outer sections together where
they overlap. Install screws 90º apart from
one another. No pre-drilling is required.
9 1/2”
Face of Wall
12”
Min.
Grade/Anticipated
Snow Line
Air Intake
Figure 5: Installation Requirements
Vent/Air Adapter
Boiler Vent
Outlet Adapter
Adapter Band Clamps
Boiler Air
Inlet Adapter
Figure 6: Assembly of Vent/Air Adapter
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6
Vent/Air System Joint Assembly
WARNING!
DONOT OVER TIGHTEN THE SELF-DRILLING
SCREWS. USE ALOW TORQUE SCREW DRIVE
TO PREVENT STRIPPING OUT THE HOLES. IFA
HOLE BECOMES STRIPPED, ALARGER DIAMETER
SCREW NO LONGER THAN 1/2” OR ASHORT POP
RIVET MAY BE USED.
6. Seal the two components together by
placing a clamp over the connection and
pressing down on the clamp lever. The
clamp should be centered over the con-
nection and the edge of the clamp should
cover the beads on the end of each com-
ponent. If the clamp does not cover and
lock onto the component jacket beads,
ensure the components are fully pressed
together and interlocked
WARNING!
ITIS VERY IMPORTANT THAT THE CLAMP BE
PROPERLY INSTALLED. FAILURE TO PROPERLY
CONNECT THE VENT COMPONENTS COULD LEAD
TO VENT FAILURE AND CAN RESULT IN DEATH,
SERIOUS INJURY OR SUBSTANTIAL PROPERTY
DAMAGE.
Clamp
Female
End
Male End
Outer Jacket
Bead
Inner Pipe
Gasket
Lever
Figure 7: Vent Joint Assembly
Note: Secure outer sections together where they
overlap with 2 self-drilling screws provided, 90º
apart using low torque setting of driver.
GF-125V

7
Termination Installation
Termination Installation
1. Determine the termination location using
the guidelines listed on page 4 and 5 and
drill or cut a 6 inch hole.
2. Install the interior support plate on the
inside wall using the screws provide in the
kit.
3. Mount the termination fitting through the
interior support plate from the exterior side
of the wall. Ensure the air inlet holes of
the termination fitting are facing down and
that the fitting is mounted level.
NOTICE
To determine the appropriate length of
the termination fitting, mount the exte-
rior support plate temporarily prior to the
installation of the interior support plate.
Insert the termination fitting from the in-
terior side of the wall through the exterior
support plate. The termination fitting has
a formed bead that limits the distance
of penetration through the exterior sup-
port plate. The termination fitting should
be measured and cut to length prior to
mounting the support plates. For infor-
mation on measuring and cutting the
termination fitting, see page 7.
4. Mount the exterior support plate around
the termination on the outside wall.
Ensure the support plate is flush to the
formed end of the termination fitting and
the fitting is mounted level.
NOTICE
The termination fitting must be installed
level without pitch to either the boiler or
away from boiler.
5. The gaps between the outer pipe of the
termination fitting and the support plates
must be sealed with a high quality silicone
caulk. Also apply the silicone caulk along
the outer edge of the support plates seal-
ing the plates to the wall.
Cutting Termination Fitting to Length
1. Only the termination fitting can be cut to
length if required.
2. Add 3/4” to the required length and mark
the end of the outer pipe.
NOTICE
Measure twice, cut once! Make sure to
add 3/4” to the overall required length
when cutting both pipes.
3. Cut the pipes using an abrasive cutoff saw
or hacksaw (minimum 32 teeth per inch).
Make sure that the inner pipe remains
centered in the outer pipe while cutting.
It may be helpful to temporarily connect
the vent section to be cut into another
vent pipe to keep the center pipe centered
while cutting.
4. Mark the end of the outer pipe at the
required length. The length of the outer
pipe should be 3/4” less than the inner
pipe.
5. Cut through the outer pipe ONLY using a
hacksaw (minimum 32 teeth per inch), or
snips.
6. File off any burrs or rough edges on both
pipes. Clean off any dust or dirt.
7. If the cutting process distorted the round-
ness of the pipes, carefully use your
thumbs to correct the distortion.
WARNING!
WHEN CUTTING OR CORRECTING THE SHAPE OF
THE OUTER PIPE, WEAR GLOVES. THE ENDS
OF THE VENT PIPES CAN BECOME VERY SHARP
WHEN CUT.
GF-125V

8
Adjustable Length Vent/Air System Pipe
Adjustable Length Vent/Air System
Pipe
WARNING!
THE COMPONENT PIPING AND FITTINGS (EX-
CLUDING THE TERMINATION FITTING) ARE NOT
DESIGNED TO BE CUT FOR CUSTOM LENGTHS.
CUTTING THE PIPING OR FITTINGS TO LENGTH
MAY COMPROMISE THE VENT SEAL CAUSE, PO-
TENTIAL VENT FAILURE OR LEAKAGE OF FLUE
GAS RESULTING IN DEATH, SERIOUS INJURY OR
INJURY.
1. An adjustable straight vent/air system pipe
length is available for applications that
require custom lengths.
2. The adjustable length vent/air system pipe
is adjustable from a minimum of 12” up to
a maximum of 16.5”.
3. To adjust the length, firmly grab each end
of the pipe and twist together to shorten or
twist apart to lengthen.
Fire Stop Support Plate
The Fire Stop Support Plate must be used when
the vent/air system piping passing through any
floors, ceilings, enclosed chase or exterior
walls. This plate can be used for vertical or
horizontal penetrations.
1. Prepare a 6-inch round or square opening.
Remove any insulation from the opening.
2. Secure the plate at corners using the
screws provided. For exterior wall penetra-
tions, 2 plates are required. For interior
wall/floor penetrations, 1 plate is required.
3. Install the concentric pipe through the
plate. Secure the pipe to the Fire Stop
Support Plate using only the self-drilling
screws provided, through the plate tabs
and into the concentric pipes outer jacket.
NOTICE
The Support Plate provided in the Con-
centric Vent/Air System Kit does not
have tabs for securing the pipe to the
plate. The Fire Stop Support Plate does.
4. Seal around the support plate where
attached to exterior of building and around
pipe penetration of the support plates with
silicone sealant.
Multiple Vent/Air System
Terminations
For multiple boiler vent/air system installations
maintain a minimum of 12 inches from center-
lines as shown in Figure 8.
Maintenance Procedures
Inspect Vent/Air System
WARNING!
FAILURE TO INSPECT THE VENT/AIR SYSTEM AND
HAVE ANY CONDITIONS REPAIRED CAN RESULT IN
SEVERE PERSONAL INJURY OR DEATH.
Visually inspect the vent/air system annu-
ally for blockage, deterioration or leakage.
Immediately repair deterioration or leakage
with the boiler turned off.
Figure 8: Multiple Vent/
Air System Terminations
GF-125V

Notes