DuraVent PolyPro Flex Series User manual

PolyPro® Flex
Installation Instructions
PolyPro Double-Wall Flex
Gas Vent System for Category II &
IV Gas-Burning Appliances

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 POLYPRO®BE INSTALLED ONLY IN
ACCORDANCE WITH THESE INSTRUCTIONS.
Dear Customer, Installer, or End User:
We welcome any comments regarding
matters pertaining to our DuraVent products.
We welcome any ideas, input or complaints
to help improve our product oering.
If you are searching for tech support or
product information, please call us at
800-835-4429.
Or email us at:
[email protected]
• Examine all components for possible
shipping damage prior to installation;
• Read all instructions before beginning
the installation and follow these
instructions exactly as written.
• Proper joint assembly is essential for a
safe installation. Check the integrity of
ALL joints upon completion of assembly
• This venting system must be free to
expand and contract under normal
operation.
WARNING
Risk of carbon monoxide poisoning
or re due to joint separation or pipe
breakage.
Keep these instructions for future
reference.
PolyPro® is one of DuraVent's line of products.
Indicates a condition or hazard which
will or can cause minor personal injury
or property damage.
CAUTION
IMPORTANT
Throughout this manual you will see
special attention boxes intended to
supplement the instructions and make
special notice of potential hazards.
In the judgement of DuraVent, these
categories mean:
WARNING
Indicates a condition or hazard which
may cause severe personal injury, death
or major property damage.
• Assure unrestricted vent movement
where required through walls, ceilings
and roof penetrations.
• This venting system must be supported
in accordance with these instructions.
• Do not mix pipe, ttings, or joining
methods from dierent vent system
manufacturers. Do not use adhesives of
any kind with this venting system.
2

3
PolyPro Flex Gas Vent System
For the most up-to-date installation instructions, see www.duravent.com
PolyPro® Flex
CONTENTS
APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
MINIMUM CLEARANCE TO COMBUSTIBLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
GENERAL INSTRUCTION NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 4
INSTALLATION OF FLEX GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
MASONRY / SHEET ROCK ENCLOSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
B VENT / RELINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

4
APPLICATION / LISTING
For specic information on application,
equivalent length of ttings, listings, etc.,
please reference Duravent's installation
instructions for rigid pipe (Document L273).
Duravent's PolyPro vent pipe should not be
installed in areas where the temperature
could exceed 230 F / 110 C.
PERMITS
Check with your local Building Ocial, Fire
Ocial, or other authority having jurisdiction
regarding permits, restrictions, and
installation inspections in your area.
MINIMUM CLEARANCE TO
COMBUSTIBLES
Refer to Table A for minimum clearances
to combustible materials. Use the values
shown in this table unless the appliance
manufacturer species otherwise. If there
is a conict between the two, the greater
clearance shall apply. It is prohibited to place
any type of insulation around the venting
system within these clearances.
Installation applications and
terminations shown in these
instructions must be approved by the
manufacturer of the appliance to which
it is applied. Use only listed DuraVent
terminations with PolyPro Venting.
CAUTION
IMPORTANT
The vent system must terminate in
accordance with local code requirements
and appropriate National Codes:
In the US: NFPA 54 / ANSI Z223.1
National Fuel Gas Code or the
International Fuel Gas Code.
In Canada: CAN/CGA-B149.1 Natural
Gas Installation Code or CAN/CGA-149.2
Propane Installation Code.
Table A
Minimum Clearance To Combustibles Table
VENT ORIENTATION CLEARANCE
Horizontal Single Wall: 0" for ue temperatures up to 194*F (90*C).
1/4" (6mm) for ue temperatures up to 230*F (110*C).
Flex: N/A- NOT ALLOWED
Vertical Single Wall: 0"
Flex: 0" (Must be enclosed)
GENERAL INSTALLATION NOTES
Reference the Installation Instructions
provided with Duravent's rigid pipe (L273)
for general instructions. PP Flex must be
enclosed, and used in conjunction with
rigid PP pipe to connect to an appliance.
• When used to conduct ue gases, PP ex
must not be installed at an angle greater
than 45 degrees from vertical. This will
ensure proper condensate ow back
towards the appliance outlet.
• PP Flex may be used to bring
combustion air into the appliance. In
these instances, pipe can be unenclosed
and oriented in a vertical or horizontal
position.
• PP ex must be treated carefully to
prevent damage when being installed
during low temperatures (<41°F, < 5 °C).
In colder weather, pre-warm ex prior
to installation. When relining, it may be
easier to insert ex from the bottom up

5
rather the top down.
• Always use soapy water to lubricate
gaskets prior to joint assembly. Do
not use Petroleum based lubricants!
• Plastic venting systems shall not pass
through rated re separations.
ADDITIONAL INSTRUCTIONS FOR
TERMINATION
Duravent's PP Flex terminations are
specically designed for use with high-
eciency appliances that are known to
produce high volumes of uid due to
condensation of moisture within ue gases.
DO NOT modify these terminations.
IMPORTANT: Unless the appliance is designed
to address ow of condensates from the
vent system, a drain must be incorporated
within the vent to allow condensates and
rainwater to escape. This drain must include
a trap to prevent combustion gases from
entering living spaces. Be sure to check
the appliance manufacturer's installation
instructions closely in regards to condensate
management.
INSTALLATION OF FLEX GASKET:
PP Flex pipe must always have gaskets
installed on both ends of any installation.
Gaskets are installed on the ex pipe, with the
gasket seating inside the ex pipe grooves
(Fig.1). Use soapy water to assist installation.
1. Cut PP ex pipe (knife, saw, etc) to
desired length. Special care should be taken
to ensure cut is square, and the edge is
deburred.
2. Place Flex Gasket over Flex pipe and install
in the rst whole groove nearest the end.
3. Open the locking tabs (x2) of the
appropriate ex tting to accept the ex pipe
(Fig.2)
4. Apply soapy water to the gasket, and push
pipe/gasket into appropriate ex tting,
seating pipe down until it bottoms out
(Fig.2).
PP FLEX PIPE
PP FLEX GASKET
FLEX ADAPTER
(CLICK!)
FLEX TO CORRECT
LENGTH, CLEAN EDGE
INSTALL GASKET, USE
SOAPY WATER
INSERT INTO
ADAPTER
LOCK PIPE TO
ADAPTER
Figure 2, Installing Gasket / Flex Adapter
Figure 1, Mounting the Gasket
GASKET IN
FIRST
GROOVE

5. Close locking tabs on ex adapter so
tabs seat in the ex pipe. Slight adjustment
of pipe may be needed to ensure proper
engagement.
that is lined with a clay or concrete liner,
check to see if a short portion of the tile is
sticking out of the top of the chimney. If so,
this short top portion must be broken o to
permit the termination's ashing to sit down
ush on the chimney's crown. It is best to do
this prior to beginning the installation.
1. Determine the required location of the
opening within the enclosure. Ensure the ue
access cut-out meets the minimum specied
size to allow manual assembly of connections
within the ue. With masonry chimneys, the
breech opening may have to be enlarged
FLEX CHIMNEY LINING KIT
1
6
13
12
11
10
7
9
8
7
5
4
3
2
1. Wall Plate
2. Support Elbow
3. Flex Chimney Support
4. Flex Male Adapter
5. Clamp (or Tie)
6. Flex Coupler
7. Gasket
8. Flex Liner
9. Spacer
10. Support Bracket
11. Flex
Female Adapter
12. Flex Chimney
Cap Flashing
13. Termination
Pipe
FLEX PULLER
A ex puller is an optional component
available to help ease installation of PP
Flex through enclosures (Fig.3). The
2"(60mm) version is of dierent design than
3"-5"(80mm-130mm).
2" Dia: Unscrew ceramic holder from cone.
Install ceramic holder around PP Flex pipe,
and re-install into cone.
3"-5" Dia: Connected using bayonet style
connection with a rotating movement of 1/4
turn to lock in.
MASONRY / SHEET ROCK
ENCLOSURE:
Examine the chimney or enclosure
carefully for obstructions prior to starting
an installation. Any structural defects or
potential safety problems must be repaired
prior to relining, and the enclsoure should be
clean. If working with a masonry chimney
Figure 3, Flex Puller
ROPE
6

7
to permit proper access. If this is the case,
patch up the opening after the installation
is completed using best practices. The slope
of the rigid connecting ue pipe must have a
minimum of 3° (equivalent 5cm/m) (5/8" per
foot).
2. Fix the Flex Chimney Support
(Fig.4) with 4 screws on the wall of the
enclosure.
Figure 4, Mounting Flex Chimney Support
6. Install PP Flex liner into the enclosure. A
second person is required to help feed the
exible liner into position (feeding either
from the top or bottom of the enclosure).
This will also help prevent damage from
occurring.
7. After installing the required length of liner,
remove the Flex Puller (if applicable)
8a. Position the Support Elbow on the Flex
Chimney Support (see 2 and 3, Fig.5)
8b. Secure the Support Elbow with the clamp
around the Flex Male Adapter and through
the slot of the Flex Chimney Support (see 1,
Fig.6).
Figure 5,
Installation
Support Elbow
Figure 6,
Securing
Support Elbow
1
2
3
1
3. The length of the exible liner can be
determined in two ways: use a rope with
a weight to measure the shaft length, add
16" (40cm) extra length for each bend. The
exible liner can be shortened with a saw or
scissors by cutting in a groove. The correct
length can also be determined after installing
the liner in the shaft and cutting it at the top
of the chimney, see Fig.8, dimension B.
4. Mount the Gasket into the ex pipe, and
attach to the appropriate coupler as detailed
above.
5. Mount the Spacers with a maximum
distance between them of 6 feet (2m).
9. Mount the Wall Plate on the wall of the
shaft (Fig.7). Pay attention to the correct
slope of 3°. The pipe of the Support Elbow
must be in the centre of the hole in the Wall
Plate.
10. The Support Elbow can be shortened if
required- For single wall, Dim A (Fig.7) must
have a minimum length of 1.6" (40mm).
11. At the top of the shaft, shorten the
exible liner to the required length and make
sure that dimension B in Fig.8 is between 1½
- 2½" (between 38 and 64 mm).

8
Figure 8, Required Liner Length
1
B
Figure 7, Mounting the Wall Plate
A
==
=
=
1
Figure 9, Installing Vent Cap
1
2
3
Figure 10, Installing Termination Pieces
1
2
13. Fit the Support Bracket (see 1, Fig.8)
over the liner and let it rest on the wall of the
shaft. Mount the Gasket as detailed above
(see Fig.1). Push the Flex Female Adapter on
the liner and close the latching tabs. Allow
the assembly to rest on the Support Bracket.
14. Seal the edge of the chimney shaft with
water-resistant sealant (see 1, Fig.9) and push
the Flex Chimney Flashing (see 2, Fig.9) on
the shaft and x it with four masonry anchors
(see 3, Fig.9).
15. Install the Termination Pipe(see 1 ,
Fig.10). Assemble the storm collar portion of
the Flex Chimney Flashing (see 2, Fig.10).
16. Connect the appliance to the exible
vent system with DuraVent rigid PolyPro vent
system.

9
B VENT RELINE:
From within the room where the appliance is located, remove any existing horizontal or angled
sections of B Vent. PP Flex cannot be installed at an angle greater than 45 degrees from vertical.
The B Vent Adapter-Lower will t over the bottom of the existing B Vent's vertical stack at or
near the ceiling. Carefully inspect the B Vent to ensure integrity. Ensure any visible screws or
obstructions are removed. PP Rigid pipe must be used to complete install to the appliance-
Instructions- 2" (60mm) PP Flex in B Vent
1. Remove existing B Vent termination cap
2. Carefully feed ex down through B Vent so
approx 2' of ex extends beyond the bottom
of the B Vent (Flex puller or rope aid optional)
3. Cut to length the top of Flex pipe and
insert ex through B Vent Adapter- Upper, and
through the Termination Base.
4. Install the PP Flex Gasket and Flex Female
Adapter onto Flex pipe using instructions in
previous pages.
5. Lower the B Vent Adapter- Upper onto the
top of the existing B Vent and secure using
screws (x3) supplied with the hardware kit.
6. Attach the Termination Top to the
Termination Cap (clicks when engaged),
then insert the Flex Female Adapter into the
Termination Cap. Push the assembly onto the
Termination Base (clicks when engaged, see
Fig.12).
7. Push the completed assembly down onto
the B-Vent Adapter- Upper. When level, secure
with three screws provided.
8. At the bottom end, cut the PP Flex to
length 3" below the bottom of the vertical B
Vent still portruding from the ceiling.
Figure 12
(CLICK!)
TERMINATION TOP
TERMINATION CAP
FLEX FEMALE ADAPTER
FLEX MALE ADAPTER
2" (60MM) FLEX GASKET
B VENT ADAPTER- LOWER
TERMINATION BASE
B VENT ADAPTER- UPPER
B VENT PIPE
2" (60MM) FLEX
2" (60MM) FLEX GASKET
MOUNTING HARDWARE
MOUNTING HARDWARE
Figure 11- (2" Flex / B Vent)
9. Install the Flex Gasket
and Flex Male Adapter onto
the Flex pipe
10. Install B Vent Adapter-
Lower. (Flex Male Adapter
should protrude beyond
per Fig.13)
11. Secure the B Vent
Adapter- Lower to the B
Vent using three screws
from the supplied
hardware.

10
Instructions- 3" (80mm) PP Flex in B Vent
1. Remove existing B Vent termination cap
2. Carefully feed ex down through B Vent so
approx 2' of ex extends beyond the bottom
of the B Vent (Flex puller or rope aid optional)
3. Cut to length the top of Flex pipe and
insert ex through B Vent Adapter- Upper
4. Install PP Flex Gasket and Flex Female
Adapter onto Flex pipe per instructions
detailed above
5. Lower B Vent Adapter- Upper to the top
of the B Vent and secure with screws (x3)
supplied
6. Install C Support Bracket as shown in Fig.14
and lower Flex Female Adapter into B Vent
Adapter- Upper
7. Attach Termination Top to Termination Cap
(clicks when engaged), insert 3" Rigid Pipe
into Termination Cap, and attach Termination
Insert into Termination Cap (clicks). Then
connect Termination Insert to Termination
Transition (click).
8. Line up inner pipe connections and push
termination assembly down onto B Vent
Adapter- Upper and secure with screws (x3)
provided
9. Cut Flex to length 3" below the bottom of
the B Vent
10. Install Flex Gasket and Flex Male Adapter
on Flex
11. Install B Vent Adapter- Lower. (Flex Male
Adapter should protrude beyond per Fig.13)
12. Secure B Vent Adapter- Lower to B Vent
with hardware provided
Figure 13
B VENT PIPE
FLEX MALE
ADAPTER
B VENT
ADAPTER-
LOWER
MOUNTING
HARDWARE
TERMINATION CAP
FLEX MALE ADAPTER
3" (80MM) FLEX GASKET
B VENT ADAPTER- LOWER
TERMINATION TRANSITION
B VENT ADAPTER- UPPER
B VENT PIPE
TERMINATION INSERT
3" (80MM) RIGID PIPE
C SUPPORT BRACKET
MOUNTING HARDWARE
FLEX FEMALE ADAPTER
3" (80MM) FLEX
3" (80MM) FLEX GASKET
Figure 15- (3" Flex / B Vent)
TERMINATION TOP
Figure 14
B VENT
PIPE
B VENT
ADAPTER-
UPPER
FLEX
FEMALE
ADAPTER
C SUPPORT
BRACKET

11

PolyPro®are registered trademarks of DuraVent, Inc.
All rights reserved, ©2012 , 2017
Customer Service Support 800-835-4429 707-446-4740 FAX www.duravent.com
L272_820005296_Install Instructions_PolyPro Flex_07-07-17
POLYPRO WARRANTY
DuraVent, Inc. (“DuraVent”) provides this warranty for PolyPro® for ten years. Subject to the limitations set forth below,
DuraVent warrants that its products will be free from defects in material or manufacturing, if properly installed, maintained and
used. DuraVent products are fully warranted if installed only by a professional installer. This Warranty is transferable from the
original homeowner to the buyer of the home within the warranted ten years. This warranty does not cover normal wear and
tear, smoke damage or damage caused by chimney res, acts of God, or any product that was: (1) purchased other than from an
authorized DuraVent dealer, retailer or distributor; (2) modied or altered; (3) improperly serviced, inspected or cleaned; or (4)
subject to negligence or any use not in accordance with the installation instructions included with the product as determined by
DuraVent.
Installation instructions are available online at www.duravent.com under Support/Literature and through our Customer Service
Department 800-835-4429 or customerser[email protected].
DuraVent provides the following warranties for PolyPro: One Hundred Percent (100%) MSRP 10 years from the date of purchase.
All warranty obligations of DuraVent shall be limited to repair or replacement of the defective product pursuant to the terms and
conditions applicable to each product line. These remedies shall constitute DuraVent’s sole obligation and sole remedy under
this warranty. This warranty provides no cash surrender value. The terms and conditions of this warranty may not be modied,
altered or waived by any action, inaction or representation, whether oral or in writing, except upon the express, written
authority of an executive ocer of DuraVent.
This product is intended for venting only category IV appliances burning Natural Gas, Propane and Oil. All other fuels are not
covered under this warranty.
LIMITATIONS ON POLYPRO INTERNET SALES: Notwithstanding any other terms or conditions of this PolyPro Warranty, DuraVent
provides no warranty for PolyPro® if it is not installed by a qualied professional installer.
DuraVent must be notied and given the opportunity to inspect defective product prior to replacement under the terms of this
limited lifetime warranty. All warranty claims must be submitted with proof of purchase. Labor and installation costs are not
covered under this warranty. To obtain warranty service contact: DuraVent Warranty Service, 877 Cotting Ct., Vacaville CA 95688,
or call 800-835-4429.
WHERE LAWFUL, DURAVENT DISCLAIMS ALL OTHER WARRANTIES, INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES
OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT WILL DURAVENT BE LIABLE FOR INCIDENTAL,
CONSEQUENTIAL, PUNITIVE OR SPECIAL DAMAGES OR DIRECT OR INDIRECT LOSS OF ANY KIND, INCLUDING BUT NOT LIMITED TO
PROPERTY DAMAGE AND PERSONAL INJURY. DURAVENT’S ENTIRE LIABILITY IS LIMITED TO THE PURCHASE PRICE OF THIS PRODUCT.
SOME STATES DO NOT ALLOW LIMITATIONS ON IMPLIED WARRANTIES, OR THE EXCLUSION OR LIMITATION OF INCIDENTAL OR
CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATIONS AND EXCLUSIONS MAY NOT APPLY TO YOU. THIS LIMITED WARRANTY
GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS THAT VARY FROM STATE TO STATE.
For the most up-to-date installation instructions, see www. duravent.com
REV 3.22.2012