Mestek 200i User manual

is manual is intended only for use by a qualied heating installer/technician. Read and follow this manual, all supplements and related

instructional information provided with the boiler. Install, start and service the boiler only in the sequence and methods given in these

instructions. Failure to do so can result in severe personal injury, death or substantial property damage.

Do not use the boiler during construction. Construction dust and particulate, particularly drywall dust, will cause contamination of

the burner, resulting in possible severe personal injury, death or substantial property damage. e boiler can only be operated with a dust-

freeairsupply.Follow the instruction manualprocedurestoductairtotheboilerairintake.Iftheboiler has been contaminatedbyoperation

with contaminated air, follow the instruction manual guidelines to clean, repair or replace the boiler if necessary.

Ax these instructions near to the boiler/water heater. Instruct the building owner to retain the instructions for future use by a qualied

service technician, and to follow all guidelines in the User’s Information Manual.

Vent/air manual

Installation instructions

for vent and air piping

Also read and follow:

200iBoiler manual

200iControl manual

M2i-VAM-4

Cast iron condensing boiler

200i

Cast iron condensing boiler

Cast iron condensing boiler — Vent/air manual

The Mestek 200iboiler — Vent and air piping options

Vent and air piping, general

Pages 2 and 3 are a brief overview of the options for vent and air piping congurations. Page 3 gives a

summary and brief list of requirements for each of the vent/air conguration options.

When air is taken from the boiler room (no air pipe connected to the boiler air inlet ing), follow the

instructions in the 200i Boiler manual to ensure the boiler room has proper openings for combustion air

and ventilation.

Vent piping

Category II & IV venting only

Category IVIndividualVent: All200iboilers requireventpipinglistedforusein pressurized, condensing

operation. Use only the materials specied in this manual. Category II Common Vent: Consult factory

when common venting multiple boilers and/or use an engineered venting system solution.

Vent pipe options

Useonly3inch Heat-fabSaf-TVent® EZSealventpipeandcomponents.Youwillndspeciccomponent

information for each conguration in this manual.

Vent pipe joint assembly

EZ Seal vent piping use a silicon rubber ring-style gasket in each joint. Joints are secured using metal tabs

that wrap around a ring on the adjacent piping component for Heat-fab vent pipe, or gear clamps for vent

pipe. Never use screws in the vent piping. Screws are only applied to the air piping portion of Heat-fab SC

concentric vent, used for concentric vent/air sidewall terminations.

Air piping

Air options

Combustion air can be piped through the side wall or through the roof of the building. Sidewall air intake

can be done with either through-the-roof or sidewall venting. See the next page for a summary of each

conguration.

Air piping materials

e best choices for air piping are 3 inch PVC, CPVC or ABS. ese materials are easy to work with and

yield a clean nal appearance. Joint sealing is easier than other methods because it only requires use of

the standard joint sealant for the type of plastic pipe used. And there are not horizontal seams requiring

sealing like on metal air piping.

Other materials suitable for combustion air venting are 3 inch galvanized pipe, aluminum pipe and

exible aluminum pipe. All joints, including the seams, of these piping materials must be sealed with

silicone adhesive sealant, such as Dow Corning 732.

Terminations

Through-the-roof terminations

Both vent and air piping must terminate with a Heat-fab 5300CI or rain cap.

Sidewall terminations

Vent and air pipes can be individually terminated using Heat-fab 9314TERM termination elbows with

built-in screen, or concentrically terminated using Heat-fab type SC concentric vent/air pipe (only when

using Heat-fab vent piping) termination components as given in this manual.

Heat-fab

EZ Seal

Joint

Assembly

Cast iron condensing boiler

Cast iron condensing boiler — Vent/air manual

3 Vent & air piped through the roof

(separate vent and air terminations)

Vent components Heat-Fab

Vent piping/components

(incl. supports, thimbles, etc.)

EZ-Seal

3-inch

Rain cap vent termination 5300CI

Joint sealant, required GE RTV106 or equivalent

Air components Heat-Fab

Rain cap termination

Termination pipe section (3 ft)

5300CI

9307

Note 1: Standard air piping termination pipe section is 3 feet. A longer

length can be used if needed.

Air piping/components

(incl. supports, thimbles, etc.)

3-inch PVC, CPVC, ABS,

galvanized or aluminum

1 Vent piped through the roof

(combustion air from the boiler room)

Vent components Heat-Fab

Vent piping/components

(incl. supports, thimbles, etc.)

EZ-Seal

3-inch

Rain cap vent termination 5300CI

Joint sealant, required GE RTV106 or equivalent

See pages 4 – 5

4 Vent piped through a side wall

(combustion air from the boiler room)

Vent components Heat-Fab

Vent piping/components

(incl. supports, thimbles, etc.)

EZ-Seal

3-inch

Joint sealant, required GE RTV106 or equivalent

Termination elbow

Termination pipe section (1 ft)

Termination thimble

Gear clamp (hose clamp)

9314TERM

9302

9393S

3-inch clamp

See pages 14 – 17

5 Vent & air piped through a side wall

(separate vent and air terminations)

Vent components Heat-Fab

Vent piping/components

(incl. supports, thimbles, etc.)

EZ-Seal

3-inch

Termination elbow

Termination pipe section (1 ft)

Termination thimble

Gear clamp (hose clamp)

9314TERM

9302

9393S

3-inch clamp

Joint sealant, required GE RTV106 or equivalent

Air components Heat-Fab

Termination elbow Same as vent termination

Air piping/components

(also supports, thimbles, etc.)

3-inch PVC, CPVC, ABS,

galvanized or aluminum

6 Vent & air piped through a side wall

(concentric vent/air termination)

Vent components Heat-Fab

Ventpiping/components

(incl.supports, thimbles,etc.)

EZ-Seal, 3-inch piping

Saf-TVent SC ttings for

termination assembly

Termination assembly:

• Single-wall adapter

• Air intake tee

• 6-inch straight section or

12-inch straight section

• Wall plate (2 required)

• Termination adapter

• Mitered termination

SC03ADEZ

SC03TAD3

SC03L6

SC03L12

SC03FS

SC03HT

9390

Joint sealant, required GE RTV106 or equivalent

Air components Heat-Fab

Air piping/components

(also supports, thimbles, etc.)

3-inch PVC, CPVC, ABS,

galvanized or aluminum

2 Vent piped through the roof

(air piped through side wall)

Vent components Heat-Fab

Vent piping/components

(incl. supports, thimbles, etc.)

EZ-Seal

3-inch

Joint sealant, required GE RTV106 or equivalent

Rain cap vent termination 5300CI

Air components Heat-Fab

Termination elbow

Termination pipe section (1 ft)

Termination thimble

Gear clamp (hose clamp)

9314TERM

9302

9393S

3-inch clamp

Air piping/components

(also supports, thimbles, etc.)

3-inch PVC, CPVC, ABS,

galvanized or aluminum

The Mestek 200iboiler — Vent and air piping options

See pages 18 – 21See pages 6 – 9

See pages 22 – 25See pages 10 – 13

Cast iron condensing boiler

Cast iron condensing boiler — Vent/air manual

Vent piped through the roof (combustion air from the boiler room)1

Figure 1 Vertical venting

Vent piping (see Figure 1)

1 — Boiler vent connection

❑e vent connection at the boiler is for 3 inch Heat-Fab EZ-Seal vent piping only.

EZ-Seal vent aachment

EZ-Seal connection: Insert EZ-Seal pipe male end into the boiler connection

(Do not cover combustion test port). Make sure the locking tabs slide under

the EZ-Seal locking ring. Bend back locking tabs to complete the joint. Follow EZ-

Seal instructions to complete the vent piping installation.

Read before proceeding

The vent piping operates with positive pressure. e vent

piping must be completely sealed and securely supported.

Use only the vent components listed in this manual. Use

of any other materials could result in vent system failure.

Exposed vent pipe poses a potential burn hazard to people and

pets. Insulate or shield the pipe where necessary to prevent

risk.

Never drill through, or install screws into, the vent pipe or

vent components.

Seal test hole with high temperature silicone aer each

combustion test and annual inspection to prevent gases and

condensation from leaking during appliance operation.

Failure to properly install the vent piping could result in ue

gas leakage, causing possible severe personal injury, death or

substantial property damage.

Code compliance — Follow all applicable local codes when

installing the vent system. Where codes dier from this

manual, follow code requirements. Contact Mestek if you have

any questions regarding the installation.

Terminate the vent following the guidelines in this manual.

Avoid vent termination locations likely to be aected by

winds, snowdris, people and pets. Protect building materials

and vegetation from degradation caused by the ue gases and

condensation.

Cast iron condensing boiler

Cast iron condensing boiler — Vent/air manual

Vent piped through the roof (combustion air from the boiler room) (cont.)1

Vent components Heat-Fab

Vent piping/components

(incl. supports, thimbles, etc.)

EZ-Seal

3-inch

Rain cap termination 5300CI

Joint sealant, required GE RTV106 or equivalent

Table 1 Vent system components

Figure 2 Vent termination minimum clearances

❑Slope horizontal runs toward the boiler. All horizontal runs of vent pipe

must slope continuously at least ¼ inch per foot (21 mm per meter) to ensure

condensate drains completely back to the boiler. DO NOT install the vent piping

with any sections that could trap condensate.

2 — Vent piping components

❑See Table 1 for acceptable vent components. NO OTHER vent materials are

acceptable.

❑Carefully follow the instructions supplied by the vent piping manufacturer.

❑e vent joints seal with elastomer rings in the pipe and ings. Avoid damaging

these seals.

❑Adjustable lengths of EZ-Seal pipe —Lengthadjustmentswith EZ-Seal piping

are made with slip-t adjustable length sections, not by cuing the pipe. Make sure

the adjustable length does not jut into elbows or terminations. is could block

ue gas and condensate ow.

❑Maximum vent piping length — See the table in Figure 3 for the maximum

allowable length. Each elbow causes the same pressure drop as 10 feet of vent pipe,

so the allowable length reduces 10 feet for each elbow used in the piping. When

45° elbows are used, two 45° elbows are equivalent to one 90° elbow.

❑Insulate the vent piping where it passes through unheated areas to prevent

condensate freeze-up.

❑If the pipe passes through an occupied space, install a chase around the pipe,

following the vent pipe instructions and applicable codes.

❑Clearance from combustible materials — Provide minimum clearance to all

combustible materials of at least 2 inches (51 mm).

❑Using an existing chimney as a chase —event piping can beroutedthrough

an existing UNUSED and STRAIGHT chimney. DO NOT vent directly into the

chimney. Install the vent piping so it can be inspected aer installation. Follow vent

pipe manufacturer’s instructions for chimney-as-chase installations.

3 & 4 — Support the vent piping completely

❑DO NOT use the boiler vent connection to support the vent piping. Provide

support straps from the ceiling and pedestal supports from the oor; utilize non-

combustible saddle. is is required on ALL installations, regardless of the length

of the horizontal piping connected to the boiler.

❑Ventpipingcannotbe supportedfromabove(suchasrelyingonroofjacksections).

You must install supports on the horizontal piping before the vent turns upward.

Provide a support on the horizontal piping within 6 inches of every upturned

elbow to support the vertical run.

❑Install at least one support on every horizontal run. For horizontal runs

longer than 5 feet (1.5 m), install a support every 3 feet (0.9 m).

❑Follow the vent pipe manufacturer’s instructions for placement and installation of

supports.

5 — Floor and wall penetrations

❑Followapplicablecodesand the ventpipe instructionstoinstallrestops,thimbles

or other devices at all oor and wall penetrations.

❑Provide minimum 2 inches (51 mm) clearance to all combustible construction.

6 — Roof penetrations

❑Followapplicablecodesandtheventpipeinstructions toinstallaroofjack, ashing

and support. Long extensions of vent pipe above the roof may require the use of

guy supports as specied in the vent pipe instructions.

7 — Rain cap termination

❑Use only the rain caps listed in Table 1.

❑e rain cap exhaust opening must be at least 2 feet (0.6 m)

above the highest roof point within 10 feet, as shown in

Figure 1. See the National Fuel Gas Code, ANSI/NFPA 54

for details on pitched roof applications.

❑See Figure 2 for additional minimum clearances.

Combustion air openings

❑Combustion air must be supplied from the boiler room as

shown in Figure 1. Make sure the installation provides air

openings as required by applicable codes and the Boiler

manual.

Multiple boiler installations

❑Install multiple vents through the roof following all guide-

linesforsingle-ventinstallations.

❑Install the vents so they are no closer than 12 inches on

centers.

Cast iron condensing boiler

Cast iron condensing boiler — Vent/air manual

Vent piped through the roof (air piped through side wall)2

Figure 3 Vertical venting/sidewall air

Read before proceeding

The vent piping operates with positive pressure. e vent

piping must be completely sealed and securely supported.

Use only the vent components listed in this manual. Use

of any other materials could result in vent system failure.

Exposed vent pipe poses a potential burn hazard to people and

pets. Insulate or shield the pipe where necessary to prevent

risk.

Never drill through, or install screws into, the vent pipe or

vent components.

Seal test hole with high temperature silicone aer each

combustion test and annual inspection to prevent gases and

condensation from leaking during appliance operation.

Failure to properly install the vent piping could result in ue

gas leakage, causing possible severe personal injury, death or

substantial property damage.

Code compliance — Follow all applicable local codes when

installing the vent system. Where codes dier from this

manual, follow code requirements. Contact Mestek if you have

any questions regarding the installation.

Terminate the vent and air piping following the guidelines

in this manual. Avoid vent termination locations likely to be

aected by winds, snowdris, people and pets. Protect building

materials and vegetation from degradation caused by the ue

gases and condensation.

Vent piping (see Figure 3)

1 — Boiler vent connection

❑e vent connection at the boiler is for 3-inch Heat-Fab EZ-Seal vent piping only.

EZ-Seal vent aachment

EZ-Seal connection: Insert EZ-Seal pipe male end into the boiler connection

(Do not cover combustion test port). Make sure the locking tabs slide under

the EZ-Seal locking ring. Bend back locking tabs to complete the joint. Follow EZ-

Seal instructions to complete the vent piping installation.

Cast iron condensing boiler

Cast iron condensing boiler — Vent/air manual

Vent components Heat-Fab

Vent piping/components

(incl. supports, thimbles, etc.)

EZ-Seal

3-inch

Joint sealant, required GE RTV106 or equivalent

Rain cap vent termination 5300CI

Air components Heat-Fab

Termination elbow

Termination pipe section (note 1)

Termination thimble

Gear clamp (hose clamp)

9314TERM

9302

9393S

3-inch hose clamp

Air piping/components

(also supports, thimbles, etc.)

3-inch PVC, CPVC, ABS,

galvanized or aluminum

Note 1: Standard termination pipe section is 1 foot. A longer length can be used if

needed.

Vent piped through the roof (air piped through side wall) (continued)2

Table 2 Vent and air system components

Figure 4 Vent termination minimum clearances

❑Slope horizontal runs toward the boiler. All horizontal runs of vent pipe

must slope continuously at least ¼ inch per foot (21 mm per meter) to ensure

condensate drains completely back to the boiler. DO NOT install the vent piping

with any sections that could trap condensate.

2 — Vent piping components

❑SeeTable2foracceptableventcomponents.NO OTHER ventmaterialsareacceptable.

❑Carefully follow the instructions supplied by the vent piping manufacturer.

❑e vent joints seal with elastomer rings in the pipe and ings. Avoid damaging

these seals.

❑Adjustable lengths of EZ-Seal pipe —Lengthadjustmentswith EZ-Seal piping

are done with slip-t adjustable length sections, not by cuing the pipe. Make sure

the adjustable length does not jut into elbows or terminations. is could block

ue gas and condensate ow.

❑Maximum vent piping length — See the table in Figure 3 for the maximum

allowable length. Each elbow causes the same pressure drop as 10 feet of vent pipe,

so the allowable length reduces 10 feet for each elbow used in the piping. When

45° elbows are used, two 45° elbows are equivalent to one 90° elbow.

❑Insulate the vent piping where it passes through unheated areas to prevent

condensate freeze-up.

❑If the pipe passes through an occupied space, install a chase around the pipe,

following the vent pipe instructions and applicable codes.

❑Clearance from combustible materials — Provide minimum clearance to all

combustible materials of at least 2 inches (51 mm).

❑Using an existing chimney as a chase —event piping can beroutedthrough

an existing STIGHT chimney. DO NOT vent directly into the chimney.

Install the vent piping so it can be inspected aer installation. Follow vent pipe

manufacturer’s instructions for chimney-as-chase installations.

3 & 4 — Support the vent piping completely

❑DO NOT use the boiler vent connection to support the vent piping. Provide

support straps from the ceiling and pedestal supports from the oor; utilizing

noncombustible saddle. is is required on ALL installations, regardless of the

length of the horizontal piping connected to the boiler.

❑Install at least one support on every horizontal run. For horizontal runs

longer than 5 feet (1.5 m), install a support every 3 feet (0.9 m).

❑Ventpipingcannotbe supportedfromabove(suchasrelyingonroofjacksections).

You must install supports on the horizontal piping before the vent turns upward.

Provide a support on the horizontal piping within 6 inches of every upturned

elbow to support the vertical run.

❑Follow the vent pipe manufacturer’s instructions for placement and installation of

supports.

5 — Floor and wall penetrations

❑Followapplicablecodesand the ventpipe instructionstoinstallrestops,thimbles

or other devices at all oor and wall penetrations.

❑Provide minimum 2 inches (51 mm) clearance to all combustible construction.

6 — Roof penetrations

❑Followapplicablecodesandtheventpipeinstructions toinstallaroofjack, ashing

and support. Long extensions of vent pipe above the roof may require the use of

guy supports as specied in the vent pipe instructions.

7 — Rain cap termination

❑Use only the rain caps listed in Table 2.

❑e rain cap exhaust opening must be at least 2 feet (0.6 m)

above the highest roof point within 10 feet, as shown in

Figure 3. See the National Fuel Gas Code, ANSI/NFPA 54

for details on pitched roof applications.

❑See Figure 4 for additional minimum clearances.

Cast iron condensing boiler

Cast iron condensing boiler — Vent/air manual

Vent piped through the roof (air piped through side wall) (continued)2

Figure 3 (partially repeated from page 6)

Figure 5 Sidewall air pipe termination assembly

Combustion air must be uncontaminated

Construction dust: If the boiler is operated while the building

isunderconstructionitmustbeprotectedfromwood,concrete,

sheet rock and other types of dust. Failure to properly protect

the boiler from construction dust will damage the boiler.

Combustion air contaminated with uorocarbons or

other halogenated compounds, such as laundry products,

cleaning solvents and refrigerants will result in the formation of

acids in the combustion chamber and vent piping. ese acids

will cause premature failure of the boiler and vent, causing

possible severe personal injury, death or substantial property

damage.

If the boiler room, or any room through which the air piping

travels, may contain contaminants as listed above, you MUST

sealair pipejointswith siliconeRTVtopreventcontaminants

from entering the boiler combustion air. e nished air piping

installation must be air-tight and water-tight.

Air piping (see Figure 3)

8 — Air pipe connection

❑Before installing the air piping, install the air pipe sidewall termination assembly

(item 10, Figure 3). See instructions following.

❑Construct the air piping from 3-inch PVC, CPVC or ABS plastic, or 3-inch galva-

nized or aluminum metallic pipe (including exible aluminum duct if desired).

When using metallic piping — seal all of the longitudinal seam joints in

addition to the component joints.

❑Aach the air piping to the boiler air connection, requiring use of silicone RTV

to seal the connection. If the boiler room air is free of contaminants you can use

metallic duct tape to seal the joints. With age, however, duct tape adhesives can

loosen, so duct tape is not as reliable as silicone RTV.

❑Iftheinstallationisrequiredtomeetdirectvent (sealedcombustion)requirements,

seal all joints with silicone RTV. e air pipe installation must be air-tight and

water-tight.

❑Maximum air piping length — See the table in Figure 3, page 6, for the maxi-

mum allowable length. Each elbow causes the same pressure drop as 10 feet of

vent pipe, so the allowable length reduces 10 feet for each elbow used in the piping.

When 45° elbows are used, two 45° elbows are equivalent to one 90° elbow.

9 — Supporting air piping

❑DO NOT use the boiler air connection to support the air piping. Provide

support straps from the ceiling or install wall brackets.

❑Provide at least one support on all air pipe installations.

❑Provide a support every 3 feet for air pipe lengths greater than 5 feet horizontally.

❑Provide a support on the horizontal piping within 6 inches of every upturned

elbow to support the vertical run.

10 —Air pipe termination (see Figure 5)

❑See Table 2 for part numbers of the sidewall termination components required

for EZ-Seal air pipe installations. e air piping termination must be constructed

using the stainless steel vent materials listed in Table 2 to ensure the conguration

is correct. DO NOT terminate the air piping with any other method.

Cast iron condensing boiler

Cast iron condensing boiler — Vent/air manual

Vent piped through the roof (air piped through side wall) (continued)2

Figure 6 Minimum clearances to air termination

Figure 7 Using external piping to raise the termination

❑Termination assembly components:

A. Wall thimble — Use only the thimble listed in Table 2. e hole in the

thimble will prevent the pipe length (B) from being pushed inward. e

raised portion of the pipe female end is too large to pass through the hole in

the thimble. Follow the vent pipe manufacturer’s instructions supplied with

the thimble. If the wall thimble isn’t long enough for the application, follow the

vent manufacturer’s instructions to add an extension.

Alternate construction — e air pipe can be inserted through a 3½ inch

hole without using a thimble. For this option, attach a storm collar on

both the inside and outside walls at the penetration. Before aaching

the collars, seal around the air pipe thoroughly with silicone RTV to prevent

air leakage or insect access. e storm collar tightens around the vent pipe

with a gear clamp. is prevents movement of the nished assembly. You will

still need to use the length of vent pipe and the termination elbow described

below. Storm collar part numbers are 4326SS for EZ-Seal.

B. Length of vent pipe — Use a 1 foot length of vent pipe as listed in Table 2

unless the wall penetration requires a longer length. If a longer length is

required, use a length of EZ-Seal long enough for the application.

Insert the pipe from OUTSIDE, male end rst. e pipe will stop at the raised

section of the female end.

C. Gear clamp — Use a 3 inch hose clamp or a gear clamp manufactured by the

vent manufacturer (see Table 2).

Slide the clamp over the male end of the pipe aer the pipe has been inserted

from outside.

From the inside, pull the pipe so it is rmly against the outside plate.

Push the gear clamp against the inside plate and tighten securely. is will

prevent the termination assembly from being pushed outward.

D. Termination elbow — Use only the termination elbow listed in Table 2. e

elbow must be pointed downward.

Before inserting the male end of the elbow into the pipe, apply a bead of

silicone RTV and spread around the end.

Insert the termination elbow and secure using the vent pipe manufacturer’s

joint assembly procedure.

Termination location — Install the air pipe termination where it meets the

minimum clearances shown in Figure 6.

Appliance exhaust outlets — Install the air intake at least 2 feet below and 5

feet horizontally from any appliance vent outlet.

Exiting below grade or minimum height — See Figure 7. When the air

pipe must exit the building below grade or below the minimum height for

the termination elbow, install vertical piping as necessary for the termination

elbow to be high enough to meet the minimum clearances of Figure 6. Make

sure to support the piping using wall brackets available from the vent pipe

manufacturer.

Multiple boiler installations

Venting multiple boilers

❑Install multiple vents through the roof following all guidelines for single-vent

installations.

❑Install the vents so they are no closer than 12 inches on centers.

Air piping for multiple boilers

❑Air for each boiler must be individually piped. DO NOT use

combined air piping.

❑Install multiple air pipes through the side wall following all

guidelines for single-air pipe installations.

❑Install the terminations so they are no closer than 12 inches

on centers.

Cast iron condensing boiler

Cast iron condensing boiler — Vent/air manual

Vent and air piped through the roof (separate terminations)3

Figure 8 Vertical venting/sidewall air

Read before proceeding

The vent piping operates with positive pressure. e vent

piping must be completely sealed and securely supported.

Use only the vent components listed in this manual. Use

of any other materials could result in vent system failure.

Exposed vent pipe poses a potential burn hazard to people and

pets. Insulate or shield the pipe where necessary to prevent

risk.

Never drill through, or install screws into, the vent pipe or

vent components.

Seal test hole with high temperature silicone aer each

combustion test and annual inspection to prevent gases and

condensation from leaking during appliance operation.

Failure to properly install the vent piping could result in ue

gas leakage, causing possible severe personal injury, death or

substantial property damage.

Code compliance — Follow all applicable local codes when

installing the vent system. Where codes dier from this

manual, follow code requirements. Contact Mestek if you have

any questions regarding the installation.

Terminate the vent and air piping following the guidelines

in this manual. Avoid vent termination locations likely to be

aected by winds, snowdris, people and pets. Protect building

materials and vegetation from degradation caused by the ue

gases and condensation.

Vent piping (see Figure 8)

1 — Boiler vent connection

❑e vent connection at the boiler is for 3 inch Heat-Fab EZ-Seal vent piping only.

EZ-Seal vent aachment

EZ-Seal connection: Insert EZ-Seal pipe male end into the boiler connection

(Do not cover combustion test port). Make sure the locking tabs slide under

the EZ-Seal locking ring. Bend back locking tabs to complete the joint. Follow EZ-

Seal instructions to complete the vent piping installation.

Cast iron condensing boiler

Cast iron condensing boiler — Vent/air manual

Vent and air piped through the roof (separate terminations) (continued)3

Table 3 Vent and air system components

Figure 9 Termination minimum clearances

❑Slope horizontal runs toward the boiler. All horizontal runs of vent pipe

must slope continuously at least ¼ inch per foot (21 mm per meter) to ensure

condensate drains completely back to the boiler. DO NOT install the vent piping

with any sections that could trap condensate.

2 — Vent piping components

❑See Table3 for acceptable vent components. NO OTHER vent materials are

acceptable.

❑Carefully follow the instructions supplied by the vent piping manufacturer.

❑e vent joints seal with elastomer rings in the pipe and ings. Avoid damaging

these seals.

❑Adjustable lengths of EZ-Seal pipe —Lengthadjustmentswith EZ-Seal piping

are done with slip-t adjustable length sections, not by cuing the pipe. Make sure

the adjustable length does not jut into elbows or terminations. is could block

ue gas and condensate ow.

❑Maximum vent piping length — See the table in Figure 8 for the maximum

allowable length. Each elbow causes the same pressure drop as 10 feet of vent pipe,

so the allowable length reduces 10 feet for each elbow used in the piping. When

45° elbows are used, two 45° elbows are equivalent to one 90° elbow.

❑Insulate the vent piping where it passes through unheated areas to prevent

condensate freeze-up.

❑If the pipe passes through an occupied space, install a chase around the pipe,

following the vent pipe instructions and applicable codes.

❑Clearance from combustible materials — Provide minimum clearance to all

combustible materials of at least 2 inches (51 mm).

❑Using an existing chimney as a chase — e vent piping and air piping can be

routed through an existing UNUSED and STRAIGHT chimney. DO NOT vent

directly into the chimney. Install the vent piping so it can be inspected aer

installation. Follow vent pipe manufacturer’s instructions for chimney-as-chase

installations.

3 & 4 — Support the vent piping completely

❑DO NOT use the boiler vent connection to support the vent piping. Provide

support straps from the ceiling and pedestal supports from the oor; utilize non-

combustible saddle. is is required on ALL installations, regardless of the length

of the horizontal piping connected to the boiler.

❑Install at least one support on every horizontal run. For horizontal runs

longer than 5 feet (1.5 m), install a support every 3 feet (0.9 m).

❑Ventpipingcannotbe supportedfromabove(suchasrelyingonroofjacksections).

You must install supports on the horizontal piping before the vent turns upward.

Provide a support on the horizontal piping within 6 inches of every upturned

elbow to support the vertical run.

❑Follow the vent pipe manufacturer’s instructions for placement and installation of

supports.

5 — Floor and wall penetrations

❑Followapplicablecodesand the ventpipe instructionstoinstallrestops,thimbles

or other devices at all oor and wall penetrations.

❑Provide minimum 2 inches (51 mm) clearance to all combustible construction.

6 — Roof penetrations

❑Followapplicablecodesandtheventpipeinstructions toinstallaroofjack, ashing

and support. Long extensions of vent pipe above the roof may require the use of

guy supports as specied in the vent pipe instructions.

7 — Rain cap termination

❑Use only the rain caps listed in Table 3.

❑e rain cap exhaust opening must be at least 2 feet (0.6 m)

above the highest roof point within 10 feet, as shown in Fig-

ure 8. See the National Fuel Gas Code, ANSI/NFPA 54 for

details on pitched roof applications.

❑See Figure 9 for additional minimum clearances. e vent

must always terminate at least 4 feet (1.2 m) above the air

intake termination.

Vent components Heat-Fab

Vent piping/components

(incl. supports, thimbles, etc.)

EZ-Seal

3-inch

Rain cap vent termination 5300CI

Joint sealant, required GE RTV106 or equivalent

Air components Heat-Fab

Rain cap air termination

Termination pipe section (note 1)

5300CI

9307

Air piping/components

(incl. supports, thimbles, etc.)

3-inch PVC, CPVC, ABS,

galvanized or aluminum

Note 1: Standard termination pipe section is 3 feet. A longer length can be used if

needed.

Cast iron condensing boiler

Cast iron condensing boiler — Vent/air manual

Figure 8 (repeated from page 10)

Combustion air must be uncontaminated

Construction dust: If the boiler is operated while the building

isunderconstructionitmustbeprotectedfromwood,concrete,

sheet rock and other types of dust. Failure to properly protect

the boiler from construction dust will damage the boiler.

Combustion air contaminated with uorocarbons or

other halogenated compounds, such as laundry products,

cleaning solvents and refrigerants will result in the formation of

acids in the combustion chamber and vent piping. ese acids

will cause premature failure of the boiler and vent, causing

possible severe personal injury, death or substantial property

damage.

If the boiler room, or any room through which the air piping

travels, may contain contaminants as listed above, you MUST

sealair pipejointswith siliconeRTVtopreventcontaminants

from entering the boiler combustion air. e nished air piping

installation must be air-tight and water-tight.

Air piping (see Figure 3)

8 — Air pipe connection

❑Construct the air piping from 3 inch PVC, CPVC or ABS plastic, or 3-inch galva-

nizedoraluminummetallicpipe(includingexible aluminum duct ifdesired).

When using metallic piping — seal all of the longitudinal seam joints in

addition to the component joints.

❑Aach the air piping to the boiler air connection, requiring use of silicone RTV

to seal the connection. If the boiler room air is free of contaminants you can use

metallic duct tape to seal the joints. With age, however, duct tape adhesives can

loosen, so duct tape is not as reliable as silicone RTV.

❑If the installation is required to meet direct vent (sealed combustion) require-

ments, seal all joints with silicone RTV. e air pipe installation must be air-tight

and water-tight.

❑e air piping connects to the stainless steel pipe section aached to the air intake

rain cap termination (item 10, Figure 8). See instructions following.

❑Maximum air piping length — See the table in Figure 8 for the maximum

allowable length. Each elbow causes the same pressure drop as 10 feet of vent pipe,

so the allowable length reduces 10 feet for each elbow used in the piping. When

45° elbows are used, two 45° elbows are equivalent to one 90° elbow.

9 — Supporting air piping

❑DO NOT use the boiler air connection to support the air piping. Provide

support straps from the ceiling or install wall brackets.

❑Provide at least one support on all air pipe installations.

❑Provide a support every 3 feet for air pipe lengths greater than 5 feet horizontally.

❑Provide a support on the horizontal piping within 6 inches of every upturned

elbow to support the vertical run.

Vent and air piped through the roof (separate terminations)3

Cast iron condensing boiler

Cast iron condensing boiler — Vent/air manual

10 —Air pipe termination (see Figure 8)

❑See Table 3 for part numbers of the vertical termination components required

for EZ-Seal air pipe installations. e air piping termination must be constructed

using the stainless steel vent materials listed in Table 3 to ensure the conguration

is correct. DO NOT terminate the air piping with any other method.

❑Termination assembly components:

A. Rain cap — Use onlytheraincaplistedinTable 3,the samecapas usedonthe

vent termination.

Install the rain cap so it meets the minimum clearances shown in Figure 9,

page 11.

B. Length of vent pipe — Use a 3 foot length of vent pipe as listed in Table 3

unless the roof penetration requires a longer length to meet minimum

clearances. If a longer length is required, use a length of EZ-Seal long enough

for the application.

Aach the air piping to the male end (boom end) of the stainless steel pipe.

C. Roof penetration components — Use the same components as used for

the vent penetration.

Multiple boiler installations

Venting multiple boilers

❑Install multiple vents through the roof following all guidelines for single-vent

installations.

❑Install the vents so they are no closer than 12 inches on centers.

❑Provide minimum 5 feet between the center line of any vent termination and any

air intake termination.

Air piping for multiple boilers

❑Air for each boiler must be individually piped. DO NOT use combined air piping.

❑Install multiple air pipes through the side wall following all guidelines for single-air

pipe installations.

❑Install the terminations so they are no closer than 12 inches on centers.

❑Provide minimum 5 feet between the center line of any vent termination and any

air intake termination.

Vent and air piped through the roof (separate terminations) (continued)3

Cast iron condensing boiler

Cast iron condensing boiler — Vent/air manual

Vent piped through a side wall (combustion air from the boiler room)4

Figure 10 Vertical venting/sidewall air

Table 4 Vent system components

Read before proceeding

The vent piping operates with positive pressure. e vent

piping must be completely sealed and securely supported.

Use only the vent components listed in this manual. Use

of any other materials could result in vent system failure.

Exposed vent pipe poses a potential burn hazard to people and

pets. Insulate or shield the pipe where necessary to prevent

risk.

Never drill through, or install screws into, the vent pipe or

vent components.

Seal test hole with high temperature silicone aer each

combustion test and annual inspection to prevent gases and

condensation from leaking during appliance operation.

Failure to properly install the vent piping could result in ue

gas leakage, causing possible severe personal injury, death or

substantial property damage.

Code compliance — Follow all applicable local codes when

installing the vent system. Where codes dier from this

manual, follow code requirements. Contact Mestek if you have

any questions regarding the installation.

Terminate the vent and air piping following the guidelines

in this manual. Avoid vent termination locations likely to be

aected by winds, snowdris, people and pets. Protect building

materials and vegetation from degradation caused by the ue

gases and condensation.

Vent piping (see Figure 10)

1 — Boiler vent connection

❑e vent connection at the boiler is for 3 inch Heat-Fab EZ-Seal vent piping only.

EZ-Seal vent aachment

EZ-Seal connection: Insert EZ-Seal pipe male end into the boiler connection

(Do not cover combustion test port). Make sure the locking tabs slide under

the EZ-Seal locking ring. Bend back locking tabs to complete the joint. Follow EZ-

Seal instructions to complete the vent piping installation.

Vent components Heat-Fab

Vent piping/components

(incl. supports, thimbles, etc.)

EZ-Seal

3-inch

Termination elbow

Termination pipe section (1 ft)

Termination thimble

Gear clamp (hose clamp)

9314TERM

9302

9393S

3-inch clamp

Joint sealant, required GE RTV106 or equivalent

Cast iron condensing boiler

Cast iron condensing boiler — Vent/air manual

Vent piped through a side wall (combustion air from the boiler room) (cont.)4

❑Slope horizontal runs toward the boiler. All horizontal runs of vent pipe

must slope continuously at least ¼ inch per foot (21 mm per meter) to ensure

condensate drains completely back to the boiler. DO NOT install the vent piping

with any sections that could trap condensate.

2 — Vent piping components

❑See Table4 for acceptable vent components. NO OTHER vent materials are

acceptable.

❑Carefully follow the instructions supplied by the vent piping manufacturer.

❑e vent joints seal with elastomer rings in the pipe and ings. Avoid damaging

these seals.

❑Adjustable lengths of EZ-Seal pipe —Lengthadjustmentswith EZ-Seal piping

are done with slip-t adjustable length sections, not by cuing the pipe. Make sure

the adjustable length does not jut into elbows or terminations. is could block

ue gas and condensate ow.

❑Maximum vent piping length — See the table in Figure 8 for the maximum

allowable length. Each elbow causes the same pressure drop as 10 feet of vent pipe,

so the allowable length reduces 10 feet for each elbow used in the piping. When

45° elbows are used, two 45° elbows are equivalent to one 90° elbow.

❑Insulate the vent piping where it passes through unheated areas to prevent

condensate freeze-up. Do not insulate the within 18 inches of the termination

when it passes through a combustible wall.

❑If the pipe passes through an occupied space, install a chase around the pipe,

following the vent pipe instructions and applicable codes.

❑Clearance from combustible materials — Provide minimum clearance to all

combustible materials of at least 2 inches (51 mm).

3 & 4 — Support the vent piping completely

❑DO NOT use the boiler vent connection to support the vent piping. Provide

support straps from the ceiling and pedestal supports from the oor; utilize non-

combustible saddle. is is required on ALL installations, regardless of the length

of the horizontal piping connected to the boiler.

❑Install at least one support on every horizontal run. For horizontal runs

longer than 5 feet (1.5 m), install a support every 3 feet (0.9 m).

❑Ventpipingcannotbe supportedfromabove(suchasrelyingonroofjacksections).

You must install supports on the horizontal piping before the vent turns upward.

Provide a support on the horizontal piping within 6 inches of every upturned

elbow to support the vertical run.

❑Follow the vent pipe manufacturer’s instructions for placement and installation of

supports.

❑Followapplicablecodesand the ventpipe instructionstoinstallrestops,thimbles

or other devices at all oor and wall penetrations.

❑Provide minimum 2 inches (51 mm) clearance to all combustible construction. continued on next page

Cast iron condensing boiler

Cast iron condensing boiler — Vent/air manual

Vent piped through a side wall (combustion air from the boiler room) (cont.)4

Figure 11 Termination minimum clearances

5 — Sidewall termination (see Figure 11)

❑See Table 4 for part numbers of the sidewall termination components required

for EZ-Seal vent pipe installations. e vent termination must be constructed

usingthestainlesssteelventmaterialslistedinTable 4toensurethe congurationis

correct. DO NOT terminate the air piping with any other method.

A. Wall thimble — Use only the thimble listed in Table 4. e hole in the

thimble will prevent the pipe length (B) from being pushed inward. e

raised portion of the pipe female end is too large to pass through the hole in

the thimble. Follow the vent pipe manufacturer’s instructions supplied with

the thimble. If the wall thimble isn’t long enough for the application, follow the

vent manufacturer’s instructions to add an extension.

Noncombustible walls — For noncombustible walls ONLY, you can omit

the thimble. e vent pipe can be inserted through a 3½ inch hole. For this

option, attach a storm collar on both the inside and outside walls at

the penetration. Before aaching the collars, seal around the vent pipe

thoroughly with silicone RTV to prevent air leakage or insect access. e

storm collar tightens around the vent pipe with a gear clamp. is prevents

movement of the nished assembly. You will still need to use the length of vent

pipe and the termination elbow described below. Storm collar part numbers

are 4326SS for EZ-Seal.

B. Length of vent pipe — Use a 1 foot length of vent pipe as listed in Table 4

unless the wall penetration quires a longer length. If a longer length is required,

use a length of EZ-Seal long enough for the application.

Insert the pipe from OUTSIDE, male end rst. e pipe will stop at the raised

section of the female end.

C. Gear clamp — Use a 3 inch hose clamp or a gear clamp manufactured by the

vent manufacturer (see Table 4).

Slide the clamp over the male end of the pipe aer the pipe has been inserted

from outside.

From the inside, pull the pipe so it is rmly against the outside plate.

Push the gear clamp against the inside plate and tighten securely. is will

prevent the termination assembly from being pushed outward.

D. Termination elbow — Use only the termination elbow listed in Table 4. e

elbow must be pointed downward.

Before inserting the male end of the elbow into the pipe, apply a bead of

silicone RTV and spread around the end.

Insert the termination elbow and secure using the vent pipe manufacturer’s

joint assembly procedure.

Termination location — Install the vent pipe termination where it meets the

minimum clearances shown in Figure 12.

Exiting below grade or snow line — See Figure 13. When the vent pipe

must exit the building grade or below the minimum height for the termination

elbow, install vertical piping as necessary for the termination elbow to be high

enough to meet the minimum clearances of Figure 12. Make sure to support

the piping using wall brackets available from the vent pipe manufacturer.

If the pipe extends more than 3 feet, insulate the external portion of the pipe

and ings with at least ½ inch closed-cell foam polyolen pipe insulation.

Combustion air openings

❑Combustion air must be supplied from the boiler room as

shown in Figure 1. Make sure the installation provides air

openings as required by applicable codes and the Boiler

manual.

Multiple boiler installations

❑Install multiple vents through the side wall following all

guidelines for single-vent installations.

❑Install the vents so they are no closer than 12 inches

(305mm) on centers.

Cast iron condensing boiler

Cast iron condensing boiler — Vent/air manual

Figure 12 Termination minimum clearances

Vent piped through a side wall (combustion air from the boiler room) (cont.)4

Figure 13 Using external piping to raise the termination

To convert to metric dimensions:

meters = feet x 0.3

millimeters = inches x 25.4

Cast iron condensing boiler

Cast iron condensing boiler — Vent/air manual

Vent and air piped through a side wall (separate terminations)5

Figure 14 Vertical venting/sidewall air

Table 5 Vent and air system components

Read before proceeding

The vent piping operates with positive pressure. e vent

piping must be completely sealed and securely supported.

Use only the vent components listed in this manual. Use

of any other materials could result in vent system failure.

Exposed vent pipe poses a potential burn hazard to people and

pets. Insulate or shield the pipe where necessary to prevent

risk.

Never drill through, or install screws into, the vent pipe or

vent components.

Seal test hole with high temperature silicone aer each

combustion test and annual inspection to prevent gases and

condensation from leaking during appliance operation.

Failure to properly install the vent piping could result in ue

gas leakage, causing possible severe personal injury, death or

substantial property damage.

Code compliance — Follow all applicable local codes when

installing the vent system. Where codes dier from this

manual, follow code requirements. Contact Mestek if you have

any questions regarding the installation.

Terminate the vent and air piping following the guidelines

in this manual. Avoid vent termination locations likely to be

aected by winds, snowdris, people and pets. Protect building

materials and vegetation from degradation caused by the ue

gases and condensation.

Vent piping (see Figure 14)

1 — Boiler vent connection

❑e vent connection at the boiler is for 3 inch Heat-Fab EZ-Seal vent piping only.

EZ-Seal vent aachment

EZ-Seal connection: Insert EZ-Seal pipe male end into the boiler connection

(Do not cover combustion test port). Make sure the locking tabs slide under

the EZ-Seal locking ring. Bend back locking tabs to complete the joint. Follow EZ-

Seal instructions to complete the vent piping installation.

Vent components Heat-Fab

Vent piping/components

(incl. supports, thimbles, etc.)

EZ-Seal

3-inch

Termination elbow

Termination pipe section

(1 ft)

Termination thimble

Gear clamp (hose clamp)

9314TERM

9302

9393S

3-inch clamp

Joint sealant, required GE RTV106 or equivalent

Air components Heat-Fab

Termination elbow Same as vent termination

Air piping/components

(also supports, thimbles, etc.)

3-inch PVC, CPVC, ABS,

galvanized or aluminum

Cast iron condensing boiler

Cast iron condensing boiler — Vent/air manual

Vent and air piped through a side wall (separate terminations) (cont.)5

❑Slope horizontal runs toward the boiler. All horizontal runs of vent pipe

must slope continuously at least ¼ inch per foot (21 mm per meter) to ensure

condensate drains completely back to the boiler. DO NOT install the vent piping

with any sections that could trap condensate.

2 — Vent piping components

❑See Table 5 for acceptable vent components. NO OTHER vent materials are

acceptable.

❑Carefully follow the instructions supplied by the vent piping manufacturer.

❑Install the sidewall vent termination before installing the vent piping.

❑e vent joints seal with elastomer rings in the pipe and ings. Avoid damaging

these seals.

❑Adjustable lengths of EZ-Seal pipe —Lengthadjustmentswith EZ-Seal piping

are done with slip-t adjustable length sections, not by cuing the pipe. Make sure

the adjustable length does not jut into elbows or terminations. is could block

ue gas and condensate ow.

❑Maximum vent piping length — See the table in Figure 14 for the maximum

allowable length. Each elbow causes the same pressure drop as 10 feet of vent pipe,

so the allowable length reduces 10 feet for each elbow used in the piping. When

45° elbows are used, two 45° elbows are equivalent to one 90° elbow.

❑Insulate the vent piping where it passes through unheated areas to prevent

condensate freeze-up. If the vent terminates through a combustible wall, leave the

last 18 inches of vent pipe uninsulated.

❑If the pipe passes through an occupied space, install a chase around the pipe,

following the vent pipe instructions and applicable codes.

❑Clearance from combustible materials — Provide minimum clearance to all

combustible materials of at least 2 inches (51 mm).

3 & 4 — Support the vent piping completely

❑DO NOT use the boiler vent connection to support the vent piping. Provide

support straps from the ceiling and pedestal supports from the oor; utilize non-

combustible saddle. is is required on ALL installations, regardless of the length

of the horizontal piping connected to the boiler.

❑Install at least one support on every horizontal run. For horizontal runs

longer than 5 feet (1.5 m), install a support every 3 feet (0.9 m).

❑Vent piping cannot be supported from above (such as relying on roof jack

sections). You must install supports on the horizontal piping before the vent turns

upward. Provide a support on the horizontal piping within 6 inches of every up-

turned elbow to support the vertical run.

❑Follow the vent pipe manufacturer’s instructions for placement and installation of

supports.

❑Followapplicablecodesand the ventpipe instructionstoinstallrestops,thimbles

or other devices at all oor and wall penetrations.

❑Provide minimum 2 inches (51 mm) clearance to all combustible construction. continued on next page

5 — Air pipe connection

❑Before installing the air piping, install the air pipe sidewall

termination assembly (item 7, Figure 14). See instructions

on next page.

❑Construct the air piping from 3 inch PVC, CPVC or ABS

plastic, or 3 inch galvanized or aluminum metallic pipe

(including exible aluminum duct if desired).

When using metallic piping — seal all of the

longitudinal seam joints in addition to the

component joints.

❑Aach the air piping to the boiler air connection, requiring

use of silicone RTV to seal the connection. If the boiler

room air is free of contaminants you can use metallic duct

tape to seal the joints. With age, however, duct tape

adhesives can loosen, so duct tape is not as reliable as

siliconeRTV.

❑If the installation is required to meet direct vent (sealed

combustion) requirements, seal all joints with silicone RTV.

e air pipe installation must be air-tight and water-tight.

❑Maximum air piping length — See the table in Figure 14

for the maximum allowable length. Each elbow causes the

same pressure drop as 10 feet of vent pipe, so the allowable

length reduces 10 feet for each elbow used in the piping.

When 45° elbows are used, two 45° elbows are equivalent

to one 90° elbow.

6 — Supporting air piping

❑DO NOT use the boiler air connection to support the

air piping. Provide support straps from the ceiling or install

wall brackets.

❑Provide at least one support on all air pipe installations.

❑Provide a support every 3 feet for air pipe lengths greater

than 5 feet horizontally.

❑Provide a support on the horizontal piping within 6 inches

of every upturned elbow to support the vertical run.

7 — Sidewall termination assemblies

❑See next page.

Cast iron condensing boiler

Cast iron condensing boiler — Vent/air manual

Vent and air piped through a side wall (separate terminations)5

Figure 15 Termination minimum clearances

7 — Sidewall termination assemblies (see Figure 15)

❑See Table 5 for part numbers of the sidewall termination components required

for and EZ-Seal vent pipe installations. e vent termination must be constructed

using the stainless steel vent materials listed in Table 5 to ensure the conguration

is correct. DO NOT terminate the air piping with any other method.

A. Wall thimble — Use only the thimble listed in Table 5. e hole in the