DuraVent DirectVent Pro User manual

DirectVent ® Pro
Converting a Class-A
Metal Chimney or Masonry
Chimney to a
Direct Vent System
Installation Instructions

A MAJOR CAUSE OF VENT RELATED FIRES IS FAILURE
TO MAINTAIN REQUIRED CLEARANCES (AIR SPACES)
TO COMBUSTIBLE MATERIALS. IT IS OF THE UTMOST
IMPORTANCE THAT DIRECTVENT PRO BE INSTALLED ONLY
IN ACCORDANCE WITH THESE INSTRUCTIONS.
NOTE:
Read through all of these instructions
before beginning your installation.
Failure to install as described in this
instruction will void the manufacturer’s
warranty, and may have an eect on
your homeowner’s insurance and UL
listing status. Keep these instructions for
future reference.
.
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CONTENTS
Precautions | General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Typical Factory-Built Metal Chimney Conversion illustration . . . . . . . . . . . 5
Converting a Factory-Built Metal Chimney . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 6
Converting a Masonry Chimney . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Typical Masonry Chimney Conversion illustration . . . . . . . . .. . . . . . . . . . . . . . . 8
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DirectVent ® Pro
CONVERTING CLASS A METAL OR MASONRY CHIMNEY TO A DIRECT VENT
For the most up-to-date installation instructions, see www.duravent.com

4
INSTALLATION INSTRUCTIONS
FOR CONVERTING A CLASSA
METAL CHIMNEY OR MASONRY
CHIMNEY TO A DIRECT VENT
SYSTEM
These instructions apply to the DuraVent
Direct Vent Conversion Kits for factory-
built Class A metal chimneys and masonry
chimneys. These venting systems, in
combination with the gas appliance, have
been tested and listed by a major testing
agency such as UL, AGA, Omni or Warnock
Hersey. Check the manufacturer’s rating
plate and instruction manual to conrm that
a DuraVent Direct Vent Chimney Conversion
system is approved for use on the brand
name appliance you have selected.
IMPORTANT
Read all instructions carefully before starting
the installation. Failure to follow these
instructions may create a re or other safety
hazard, and will void the warranty. Be sure
to check the appliance manufacturer’s
installation instructions for specic venting
and clearance to combustible requirements,
which may vary from one appliance to
another.
INSTALLATION PRECAUTIONS
The DuraVent Direct Vent System is an
engineered product that has been designed
and tested for use with an approved list of
direct vent gas appliances. The DuraVent
warranty will be voided, and serious re,
health, or other safety hazards may result
from any of the following actions:
• Installation of any damaged Direct Vent
component.
• Unauthorized modication of the Direct
Vent System
• Installation of any component part not
manufactured or approved by DuraVent.
• Installation other than as instructed by
DuraVent and the appliance manufacturer.
Consult your local building codes before
beginning the installation.
Have the existing installation inspected by
a qualied chimney sweep or professional
installer, prior to converting to direct vent.
The existing chimney system must be in
serviceable condition, and functionally
sound. The direct vent conversion described
herein applies only to factory-built metal
ceiling-supported type systems and masonry
through-the-wall type systems. Note: You
cannot install a Conversion Kit in a through-
the-wall type factory-built metal chimney.
GENERAL
Two dierent types of direct vent conversion
systems are described here. One is through
an existing factory built metal chimney going
through the ceiling. The other is through the
wall of an existing masonry chimney. Follow
the appropriate directions for your situation.
A typical direct vent conversion of a factory
built metal chimney is shown in Figure 1.
The concept of direct vent conversion is
to connect an adapter to an Underwriters
Laboratories listed 4-inch diameter aluminum
ex pipe (DuraVent’s DuraFlex is an example
of an UL listed ex pipe). This is then passed
this down through the center of the existing
metal chimney system. Three sizes of Top
Adapters are available which should t
most sizes and makes of metal chimney
systems. The Retro Connector (909B) is then
attached to the bottom of the ex pipe. Both
the Top Adapter, and the Retro Connector
are attached to the existing chimney with
sheet metal screws. The appliance is then
connected to the chimney with appropriate
black direct vent pipe, and an adjustable
length section.
A typical conversion of an existing masonry
chimney is shown in Figure 6. For installation
through the wall of an existing masonry

5
Figure 1
TYPICAL FACTORYBUILT METALCHIMNEY CONVERSION
Termination Cap
0909B
4-inch ex pipe
0985K Top Adapter
0986K Top Adapter
0987K Top Adapter
Use Conversion Kit A (0931)
for the following chimneys:
6” ID Metalbestos
6” ID Security Chimney
6” ID Jackes-Evans
6” ID Hart & Cooley
6” ID Pro-Jet
Use Conversion Kit B (0932)
for the following chimneys:
6” ID Dura-Vent
7” & 8” ID Metalbestos
6” ID Security Chimney
7” & 8” ID Jackes-Evans
7” & 8” ID Hart & Cooley
7” & 8” ID Pro-Jet
6” ID Air-Jet
6” & 7” ID Metal-Fab
6” & 7” ID American Metals
Use Conversion Kit C (0933)
for the following chimneys:
7” & 8” ID Dura-Vent
8” ID Air-Jet
8” ID Metal-Fab
8” ID American Metals
Existing Metal
Chimney
System
4-inch
aluminum ex
pipe
Any black
direct vent
pipe plus an
adjustable
length
to make
a proper
connection
0909B Retro
Connector

6
Figure 3
chimney, a Top Adapter (985K) and Flashing
are used at the top of the masonry chimney.
The 4-inch aluminum liner is connected to
the adapter and is passed down the chimney
and out through the masonry wall. This
is attached to the Retro Connector (909B)
which is in turn, attached to the masonry wall
and is then connected to the direct vent pipe
leading to the appliance.
INSTALLATION INSTRUCTIONS
FOR CONVERTING A FACTORY
BUILT METAL CHIMNEY
Step 1. Remove the existing chimney cap.
Step 2. Measure the distance from the top
end of the chimney to the bottom of the
ceiling support box, add 3 inches to this
measurement, and cut a section of 4-inch ex
pipe to that length (the ex should already be
extended to its nominal length).
Step 3. Connect the end of the ex pipe
section to the underside of the Top Adapter
you have selected, using (3) sheet metal
screws. (Figure 2.)
Step 4. Pass the ex pipe down through the
center of the chimney system, and center
the adapter on the top of the chimney pipe.
Drill (4) 1/8-inch diameter holes through the
adapter, and into the chimney top. Insure
that you are in fact, drilling into the metal on
the chimney. Twist-lock the Termination Cap
(980 or 991) onto the Adapter. (Figures 3 and
4.)
Step 5. Pull the ex pipe down through
the ceiling support box, until it protrudes
approximately 3 inches. Connect the ex
pipe to the Retro Connector by slipping it
into the 4-3/4-inch diameter sleeve on the
top side of the Connector. Use (3) Sheet
Metal Screws, to assemble these two parts.
Figure 2
Top Adapter
Flex Pipe
Sheet Metal
Screws

7
Figure 4
Figure 5
Step 6. Push the ex pipe back up into the
ceiling support box, center the Retro
Connector, and attach it to the support box,
or decorative sleeve for double wall solid
packed pipe, with the Sheet Metal Screws
furnished. The holes in the Retro Connector
are pre-punched. (Figure 5.)
Termination
Cap
Sheet Metal
Screws
(3) Sheet Metal
Screws
(3) Sheet Metal
Screws
Drill (4)
1/8-inch
diameter holes
Existing Ceiling
Support Box

8
Figure 7
INSTALLATION INSTRUCTIONS
FOR CONVERTING A MASONRY
CHIMNEY
Important: The existing masonry ue
opening needs to have an area of at least a
35-sqr-in. to insure proper intake / exhaust
ow.
Step 1. Before cutting any holes, assemble
the desired sections of black direct vent
pipe to determine the center of the masonry
penetration.
Step 2. Once the center point of the
penetration has been determined, cut a 6”
diameter hole in the masonry. Be careful,
if the hole is too large, the Retro Connector
might not mount properly, and if the hole is
too small, then the appliance might starve
for intake air. If there is a frame wall in front
of the masonry wall, cut and frame a 10” clear
square opening in wall (centered around the
6” masonry opening). If there is sheet rock
only (no studs) in front of the masonry, the
10” clear opening is still needed, but does
not need to be framed. This allows the Retro
Figure 6
TYPICAL MASONRY CHIMNEY
CONVERSION
Termination Cap
Top Adapter
Flashing
4” Flex Liner
Retro
Connector
Black Direct
Vent Pipe
Cut & bend ashing as
needed to t chimney
Sealant adhesive

9
Figure 8
Figure 9
Connector to mount directly on the masonry
and provide clearance to the combustibles.
Refer to Figure 11.
Step 3. Secure the Flashing (705C) to the top
of the masonry chimney using a bead of non-
hardening sealant-adhesive. If the Flashing is
larger than the top of the chimney, then cut
and fold ashing as needed to t chimney.
See Figure 7.
Step 4. To determine the length of ex
required, measure from 3”above the top
of the Flashing down to the level of the
opening. Add to this measurement the
distance from the center of the chimney to
out through the wall. Cut a piece of 4-inch
ex to this length (the ex should already be
extended to its nominal length).
Step 5. Connect the 4-inch ex liner to the
Top Adapter (985K) using (3) sheet metal
screws. Refer to Figure 2.
Step 6. Feed the 4-inch ex liner through
the Flashing into the chimney. Continue to
feed the liner out through the opening in the
masonry wall.
Step 7. Secure the Top Adapter to the
Flashing. Use (3) sheet metal screws through
the side of the adapter into the ange on the
Flashing, as shown in Figure 8. Twist lock the
Termination Cap (980 or 991) on to the Top
Adapter.
Step 8. Attach the ex to the Retro
Connector. Use (3) sheet metal screws to
attach the ex liner to the Connector. See
Figure 9. Mount the Retro Connector to the
masonry wall using masonry bolts. Re-
drill larger holes on connector as needed.
Be careful to insure that the connector is
centered in the opening and the mounting
holes line up with the masonry wall.
6” diameter
opening in
masonry wall
(3)
Sheet
Metal
Screws
Highwind Termination
Cap
Flashing
Standard
Termination
Cap
Top Adapter
Retro Connector
(3) masonry bolts (not
included)

10
Figure 10
Figure 11
Step 9. Slide the Wall Thimble Cover (940)
over the Retro Connector and secure with
masonry bolts. (Figure 10) If you have a
framed wall in front of the masonry, use
wood screws to mount the Wall Thimble
Cover to the framed wall, over the Retro
Connector and the 10” square framed
opening. (Figure 11) If needed, add a section
of direct vent pipe to the Retro Connector in
order to extend through the opening in the
Wall Thimble Cover.
Step 10. The connection between the
appliance and the Retro Connector may be
completed with section of black direct vent
pipe, together with adjustable length pipe
section.
Retro
Connector
Masonry Chimney
Stud Wall
10” x 10” framed
opening in wall
Retro Connector
Wall Thimble Cover
Wall Thimble Cover
(4) Masonry Bolts
(Not Included)
(4) Masonry Bolts
(Not Included)