Northline Express DuraFlex SS User manual

1.
DuraFlex SS
INSTALLATION INSTRUCTIONS FOR
RELINING MASONRY CHIMNEYS
FOR USE WITH GAS, OIL, PELLET, OR
SOLID FUEL APPLIANCES
APPLICATION
StainlesssteelDuraFlexSSChimneyReliningSystemisanOMNI-TestLaboratories
listed for relining masonry chimneys which are intended to be used for venting oil,
pellet, or solid-fuel burning appliances, as well as gas appliances (category I only).
Theseinstructionscoverinstallationfromtheapplianceventconnectorthroughthe
wall of the masonry chimney, or through the damper, up to the termination cap.
IMPORTANT
Readallinstructionscarefullybeforestartingtheinstallation. Failuretofollowthese
instructions may create a fire or other safety hazard, and will void the warranty. It
is important to follow the appliance manufacturer's installation instructions and to
checkthelabelontheappliancetoconfirmtheappliancecategoryandanyrestrictions
orlimitations.
If DuraFlex SS is used for gas appliances, then the DuraFlex AL Cap Assembly,
DuraCap, or High-Wind Cap must be used for proper listing of the vent.
INSTALLATION PRECAUTIONS
The Simpson Dura-Vent DuraFlex SS is an engineered product that has been
designed and tested for use as specified above. The Simpson Dura-Vent warranty
will be voided, and serious fire, health, or other safety hazards may result from any
ofthefollowingactions:
• Installation of any damaged component.
• Unauthorized modification of any Dura-Vent product.
• Installation of any component part not manufactured or approved by
Simpson Dura-Vent.
• Installation other than as instructed by Simpson Dura-Vent and the
appliance manufacturer.
Consult your local building codes before beginning the installation. Contact local
BuildingorFire officials aboutrestrictionsandinstallation inspection in yourarea.
143-P-02-2
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CAUTION: Make sure you have the proper equipment for the job, including
adequatesafety protectionforworkingat elevatedheights.Always wearglovesand
safety glasses when handling sheet metal parts.
SIZING REQUIREMENTS
Proper sizing of the relining system to the appliance is very important. For gas
appliances, refer to the National Fuel Gas Code or the Simpson Dura-Vent Sizing
Handbookforcompletesizinginstructions(thesetablesarenotintendedforCategory
II,IIIorIVappliancesorOilburningappliances). Failuretoproperlysizetheventing
systemmayresultindraft hood spillage, back pressure, and corrosivecondensation
inthereliningsystem.
Ifyouareburningsolidorliquidfueltheventingsystemmaybesizedtotheoutletof
theappliance.Donotdownsizethelinerforwoodoroilapplianceswithoutconsulting
theappliancemanufacturer. Somepelletburningappliancesmayrequireanincrease
indiametersizeforhigheraltitudes,butyoushouldconsulttheappliancemanufacturer
for proper sizing of the liner.
PRIOR TO INSTALLATION
BeforeinstallingtheDura/FlexSSLinersystem,thechimneypassagewayshouldbe
examined to check for cracked, loose, or missing bricks, mortar, or other materials
that could inhibit correct installation of the lining system. The Chimney should be
cleaned and any tar glaze creosote removed. Verify that the existing masonry
chimneyhas at least 1" clearance from exterior of thechimney to combustibles and
it meets current NFPA 211 requirements as well as any local code requirements.
Makesuretheconstructionofyourmasonrychimneymeetsthefollowingrequirements
foryourrelinerinstallation:
Minimumbrick thickness: 31/2inches
Maximumheight:65 feet
MinimumHeight:10feet
Clearances from combustible materials for single-wall connectors on Residential-
Type Appliances (from NFPA 211):
Gas appliances without draft hoods 18inches
Oilandsolid-fuelappliances 18inches
Unlisted gas appliances with draft hoods 9 inches
Oil appliances listed for use with L-Vent 9 inches
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3.
Boilers and furnaces equipped with listed 9 inches
gas burners and with draft hoods
Listed gas appliances with draft hoods 6 inches
Other Cat I appliances able to use B-vent 6 inches
Note:Whenusingalistedconnector, theclearancesspecifiedonthatconnectormay
be used, unless a different clearance is specified by the Appliance manufacturer.
The masonry chimney will also need to satisfy the NFPA 211 requirements for
clearances to the top of the chimney.
Forsolid-fuelventing,youwillneedto
beatleast3-feetabovethepenetration
through the roof, and at least 2-feet
higher than anything within 10-feet
around the chimney. For gas, oil, or
pellet venting, you need to be at least
2-feet above the penetration through
the roof, and also 2-feet higher than
anything within 10-feet around the
chimney (Figure 1).
CHIMNEY LINER SELECTION
TheDuraFlexSSChimneyLinerSystemconsistsofacontinuousFlexibleLinerfrom
the top of the chimney to the appliance connection. (Figure 2) This system is
relatively easy to install, even in masonry chimneys that are constructed with an
offset. This single-wall DuraFlex SS Liner system is intended for installation in
masonry chimneys which comply with NFPA 211 requirements and local codes.
IfyouareinstallingagasburningCategoryIordrafthoodequippedapplianceincold
climates,youmaywanttoswitchtodouble-wall,(air)insulatedTypeBgasventnear
the top exposed portion of the chimney. (Figure 3) At the top of the chimney, the
fluegashaslostmuchofitsheat,andbecomessusceptibletocorrosivecondensation
and poor draft. This is very true with fan-assisted (Category I) gas appliances.
Table 1: Clearances Required
Fuel Minimum Clearance Minimum Clearance from Insulation
Burned from Liner to Masonry Masonry to Combustibles Required
Gas/LP 0" 0" None
Pellet,Oil 1" 1" None
Wood,Coal 1" 1" None
Wood,Coal 0" 0" 2-plySleeve
2-FT MINIMUM ABOVE
ANY PART OF THE
ROOF WITHIN 10-FT
3 FT MINIMUM FOR SOLID
FUEL APPLIANCES, 2-FT
MINIMUM FOR GAS, OIL,
OR PELLET APPLIANCES.
Fig 1
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4.
BASIC DURAFLEX SS LINER INSTALLATION
The type of fuel you are burning, and what clearances you have available, will
determine if you need to use the 2-ply Insulation Sleeve or Spacers with your liner
installation. RefertotheTable1todetermineiftheInsulationSleeveisrequiredwith
the clearances you have available. If the Insulation Sleeve is required, please refer
to the Insulation Sleeve Installation section.
Step1. MeasureandrecorddimensionstodeterminetotalFlexLinerrequirements.
Step 2. After locating where the appliance flue connection will be made in the
chimney wall, break out sufficient masonry to form a hole large enough for the
MortarSleeveorFlexLinertopassthrougheasily. IfaTeeapplicationisnecessary,
a larger hole may be required. (See Tee Installation Section)
Step 3. Remove Flex Liner from packaging and
straightencoiledFlexLiner. IfInsullationSleevesare
not used, you will need to attach Spacers to the Flex
Liner to insure the liner maintains at least the 1"
clearancerequiredtotheinsideofthemasonry(Figure
5). Place Spacers every 5 feet on the Liner.
Step4. SecurearopetotheFlex Pullerandattachthe
FlextoDuraFlexSSLinerasshowninFigure4. One
personshouldfeedthelinerthroughthechimney,and
another person should pull the liner from the bottom,
usingtheropetoguidethelinerthoughtothechimney
bottom. The reason for using two people is that care
Fig 4
FLEX LINER
FLEX PULLER
ROPE (NOT
INCLUDED)
Fig 2 Fig 3
Fig 5
STAINLESS FLEX
FLEX SPACER
INSTALL FLEX
SPACERS EVERY
5-FEET AND
WHERE NEEDED
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5.
must be taken not to tear or otherwise damage the Flex Liner.
Step 5. After carefully feeding the Flex Liner down the chimney to the bottom and
form a 90° angle, and bring the Flex Liner through the hole in the chimney wall.
Step6. SlidetheMortar Sleeve over the FlexLiner,untiltheMortarSleeve is flush
withthewallofthemasonrychimney(Figure6). OncetheMortarSleeveisinplace,
the space between the Mortar Sleeve and the masonry may be filled with grout.
Step 7. The Flex Liner should extend at least 2 inches beyond the Mortar Sleeve.
If you are using rigid connector pipe to connect between the Flex Liner and the
Appliance, you will need a Flex Connector. Be sure the flow arrow on the Flex
Connectorisinthesamedirectionoftheexhaustflow(Figure7). FittheFlexLiner
intotheFlex Connector andtightenthefast connect band. Slide theotherendof the
Flex Connector into the connector pipe and tighten with the fast connect band.
TEE INSTALLATION INSTRUCTIONS
Step 1. If a tee is required, and the masonry chimney has no
offsets, remove Tee Branch and attach the body of the Tee to the
Flex Liner as shown in Figure 8, and tighten the fast connect
band. Attach a rope securely to the body of the Tee (wrapping
ropetightlyabovebrancharea or around indented section of tee)
and proceed as described in Step 4 of the Basic DuraFlex SS
LinerInstallationsection.
Step2. Ifthemasonryhasanoffset,pulltheFlexdownasinStep
Fig 6
MORTAR
SLEEVE
Fig 7
MORTAR SLEEVE
FLEX
CONNECTOR
2-3 INCHES
Fig 8
TEE
BODY
FLEX
LINER
DIRECTION OF
EXHAUST FLOW
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6.
4 (Basic section) to it's proper location, even with the opening in the chimney wall.
Disconnect the rope (Figure 9). It may be necessary to rotate the Flex Liner and
Tee to get the opening for the branch in the proper location.
Step 3. When the Tee is in its final location, attach the Branch to the main body of
the Tee using the fast connect band provided on the removable Branch. Loosen the
fastconnectbandandpositionitaroundtheTeebody,andtightenband. (Figure10)
Step 4. After the Tee and Branch are installed, connector pipe can be attached
directlytotheTeeBranchwith a minimum of three stainless steel screws. Slide the
MortarSleeveoverboththeconnectorpipeandBranch,andfillinaroundtheMortar
Sleevewith grout,keepingthe Teecenteredin themasonrychimney, andtheend of
the Mortar Sleeve even with the wall of the chimney.
Step 5. Complete the run of connector pipe and attach it to the appliance.
PENETRATING THROUGH A COMBUSTIBLE WALL INTO A
MASONRY CHIMNEY
If your installation needs to pass through a combustible wall immediately prior to
enteringthemasonrychimney,therearesomestepsthatneedtobetakendepending
on whether the appliance is gas, oil, pellet or solid-fuel burning.
Step 1. If you are using a gas, oil, or pellet appliance, simply use either a Gas Vent
Wall Thimble (gas appliances), or a Pellet Vent Wall Thimble (oil and pellet
appliances)installedtopassthroughthecombustiblewallandcontinuetoinstallthe
FlexLinerasindicatedintheseinstructions. Notethatyouneedtouserigidpipewhen
you penetrate through the combustible wall as the Liner is only allowed within the
ROTATE TEE BODY
TO LINE UP WITH
OPENING IN
MASONRY
FLEX
LINER
Fig 9
FLEX LINER
STRAP
TEE
BRANCH
TEE BODY
CAP
Fig 10
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7.
masonry (Figure 11)
Step2. If you have a solid-fuel burning appliance, you will need to use a Wall Pass
Thru to penetrate through the combustible wall safely and connect to the DuraFlex
SS liner inside the masonry (Figure 12). You will need to determine where the
penetrationthroughthewallwillbelocated(besuretoaccountforrequiredclearance
to combustibles for the connector pipe). You will also need to refer to L403
instructions included with the Wall Pass Thru itself.
Step 3. Once the location of the penetration is determined, use a sabre-saw to cut
a14-1/2"diameter(7-1/4"radius)openinginthecombustiblewall. Centeredonthe
opening, cut a 6-1/2" or 8-1/2" opening in the masonry (see L403 for instructions).
Step 4. Refer to the Insulation Sleeve section of these instructions to prepare the
FlexLiner. Oncethe Linerisinsulated,feed liner downchimneyasindicated inthe
Basic Instruction section.
Step 5. Attach a Flex Coupler to the end of the Flex Liner (be sure the flow arrow
is in the correct direction). Connect the other end of the Flex Coupler to the Wall
Pass Thru (Figure 12).
Step 6. Secure the Wall Pass Thru in place as directed in L403 Instructions.
RELINING INSTRUCTIONS FOR FIREPLACE INSERTS
VENTING INTO AN EXISTING MASONRY CHIMNEY
Step 1. If you are using a solid-fuel appliance and you do not have the clearances
requiredbyTable1,youwillneedtouseInsulationSleevestomaintainproperlisting.
COMBUSTIBLE
WALL
FRONT HALF OF
WALL THIMBLE
RIGID
VENT PIPE
MORTAR SLEEVE
FLEX
CONNECTOR
Fig 11 Fig 12
FLEX
CONNECTOR
INSULATED FLEX LINER
COMBUSTIBLE
WALL
WALL PASS
THRU
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8.
Refer to the Insulation Sleeve Instruction section.
Step 2. Measure and record the dimensions to
determine total Flex Liner requirements.
Step 3. Unpack and unroll the Flex Liner. Attach
SpacerstotheFlexLinertoinsurethelinermaintains
the1"clearancerequiredtotheinsideofthemasonry.
Place Spacers every 5 feet on the Liner.
Step 4. Secure a rope to the Flex Puller and attach
theFlex Pullertothe DuraFlexSS FlexLiner. One
personshouldfeedthelinerthroughthechimneyfromthetop,whileanothershould
pull the liner from the bottom (Figure4). Two people are needed to be sure that the
Flex Liner is not damaged or torn.
Step 5. After the Flex Liner is pulled through the damper area, attach the Flex
Connector (be sure the Flow arrow points up, the direction of the exhaust flow) to
theFlexLinerandtightenthefastconnectband.Positionappliance,theninsertFlex
Connector into the flue outlet on top of the fireplace insert, tighten the fast connect
banddirectlytoapplianceoutletorcollar. Tofurtherinsuretheconnectionbetween
the Liner and the Appliance, use (2) 3/8" screws to secure the Flex Connector to
applianceoutlet,penetratingthroughboththebandandapplianceoutlet(Figure13).
TERMINATIONS
Step1. WhenterminatingyourFlexLinerinstallation,insuretheFlexLinerextends
4-5inchesoverthetopofthemasonrychimney,asshowninFigure14.Trimorbend
the base of the Top Plate to fit on the masonry chimney as needed.
Step2. SlidetheTopPlateovertheFlexLinerandsealtheTopPlatetothemasonry
Fig 13
STAINLESS
STEEL FLEX
LINER
FIREPLACE
FLEX
CONNECTOR
Fig 15
Fig 14
FLEX LINER
TOP PLATE
SEALANT
EXISTING
MASONRY
CHIMNEY
4-5 INCHES
EXISTING
MASONRY
CHIMNEY
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9.
chimneyusingabeadofnon-hardening
sealantaroundthe topofthechimney
and underside of Top Plate (Figure
15).
Step3. Aftersealingthe Top Plate to
the masonry chimney, attach the
DuraFlex SS Cap Assembly (or
DuraFlex AL Cap Assembly if used
on a gas appliance) to the Flex Liner
and tighten the fast connect band, as
shown in Figure 16. Push the Liner
Cap down until it rests upon the Top
Plate.
TYPE B GAS VENT OR TYPE L VENT TERMINATION
ThisinstallationprocedureisforusewithTypeBgasventorTypeL(oil/pellet)vent
nearthetopofthemasonrychimney,orforextendingtheheightoftheventingsystem
above the masonry chimney.
Step1. InadditiontotheFlexyouwillneedaPelletVentCap(foroilorpelletvents)
or a Gas Vent Termination Cap (Standard or High Wind), Storm Collar, Top Plate,
Flex Connector, and rigid pipe to extend the cap as needed. (Figures 17, 18)
Step 2. Attach the Flex Connector to the Flex Liner and secure the fast connect
band,theninsertPipeSectionintothelargeendoftheFlexConnector.Besureinner
linersareproperlyaligned,thenpushthetwotogetheruntiltheouterdiameterofrigid
pipe is firmly against large end of Flex Connector, then secure upper fast connect
band, as shown in Figure 17.
Step 3. After attaching a suitable double-wall Type
B or L Vent Pipe Section to the Flex Liner with the
Flex Connector, seal the Top Plate to the masonry
chimney using non-hardening sealant. Slide the
appropriateStormCollaroverthePipeSection,until
theproperlengthofpipeextendsabovethechimney.
Always have a minimum of 12 inches of rigid pipe
below the Top Plate for stability. Attach the Storm
CollartotherigidPipeSectionwith(4)1/4-inchlong
Fig 16
TOP
PLATE
FLEX LINER
USE DURAFLEX
SS CAP
ASSEMBLYFOR
OIL, PELLET OR
WOOD
APPLIANCES
USE DURAFLEX AL
CAP ASSEMBLY
FOR VENTING GAS
APPLIANCES
Fig 17
FLEX
COUPLER
FLEX
LINER
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10.
sheet metal screws equally spaced at 90 degrees (do not penetrate inner liner). The
Storm Collar will rest on the Top Plate and serves as the support for the Flex Liner
system. This system is listed by OMNI Test Laboratories to support up to 50 feet
of Flex Liner or rigid Pipe Sections. See Figure 18.
Step 4. Seal the Storm Collar where it meets the Pipe Section using 500RTV non-
hardening sealant, then twist-lock the appropriate Termination Cap to the Pipe
Section. Asanalternative tothestandardcap, you maywantto install aHigh-Wind
TerminationCap(gasonly)in areas where wind may be a concern. (Figure18,19)
Step5. Forimproveddraft, the liner may beextendedinheightabove the top of the
masonrychimneybysimplyaddingadditionalPipeSections.Iftheventismorethan
3feetabovethetopofthechimney,secureitwithalocallyfabricatedbrace,asshown
in Figure 19.
INSULATION SLEEVE INSTALLATION
If your DuraFlex Liner installation does not have a 1"clearance from the outside of
the masonry to combustibles, as well as 1" clearance from the liner to the inside of
themasonry, thenyouwillneedtoinstallthe LinerwithInsullationSleevesin order
to insure a proper installation. If however, your installation can meet the required
clearances, you will not need to use Insullation Sleeves.
Step1. Remove Flex Liner from packaging and straighten Flex Liner and measure
Fig 18
GAS VENT OR
PELLET VENT
PIPE (DEPEND-
ING ON
APPLIANCE)
STORMCOLLAR
TOP
PLATE
SEALANT
Fig 19
PELLET
VENT CAP
(FOR OIL
AND
PELLET
VENT)
ROOF
SUPPORT
OPTIONAL
HIGH WIND
CAP FOR GAS
VENT ONLY
OPTIONAL
HIGH WIND
CAP FOR GAS
VENT ONLY
PELLET VENT CAP
(FOR OIL AND
PELLET VENT)
FLEX
CONNECTOR
STAINLESS
STEEL FLEX
LINER
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11.
Liner as shown in the Basic Installation section.
Step2. BegintoslidetheappropriateInsulationSleeve
(single-plyordouble-ply,dependingonyourmasonry
chimney)overtheFlexLiner. Ifyoulinerwillbegoing
throughaMortarSleeve,leavethatportionoftheLiner
uncoveredbythe sleeve. Secure the InsulationSleeve
in place with an Insulation Clamp at one end.
Step 3. Continue adding Insulation Sleeves along the
length of the Flex Liner, being sure that the previous
Sleeve overlaps the next Sleeve. Secure the overlap
with an Insulation Clamp (Figures 20, 21).
Step 4. Once you have the length of Liner insulated,
continue with Step 4 of the Basic Installation.
FLEX EXTENSIONS
Fortallerchimneyinstallationswheremorethanone
lengthofFlexLinerisrequired,additionallengthsof
Flex Liner may be purchased in 5-foot or 35-foot
lengths. Two lengths of flex may be connected
togetherusing theFlexConnector(Figure22). Itis
very important that the Flex Connector be installed
intheproperdirectionwiththeFlowarrowpointing
DOUBLE
PLY
INSULATION
SLEEVE
INSULATION
CLAMP AT BOTH
ENDS OF SLEEVE
Fig 20
Fig 22
DURAFLEXSS
LINER
FLEX COUPLING
(MAKE SURE
FLOW ARROW IS
IN PROPER
DIRECTION)
DIRECTION
OF EXHAUST
FLOW
MULTIPLE
INSULATION
SLEEVES WRAPPED
AROUND THE FLEX
LINER. USE
INSULATION
CLAMPS WHERE
SLEEVES OVERLAP
Fig 21
SLIDE INSULATION
SLEEVE INTO
PLACE OVER FLEX
LINER
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12.
(800)-835-4429
(707)-446-4740(FAX)
SIMPSON DURA-VENT, INC.
Vicksburg, MS
Oct 2003
L253
www.DuraVent.com
in the same direction of the exhaust flow. The Flex Connector should always be
installed with the "cup" end towards the top of chimney. Under no circumstances
should this be reversed. The DuraFlex Flex Connector may also be used to utilize
lengths of Flex Liner that are left over at the end of previous job.
CHIMNEY LINER MAINTENANCE
The chimney liner should be inspected by a qualified chimney inspector or licensed
priortoeach heating season. When woodisburnedslowly,it produces tar andother
organicvapors,whichcombinewithexpelledmoisturetoformcreosote. Asaresult,
creosote residue accumulates on the chimney liner. When ignited, this creosote
makes an extremely hot fire. If you are burning solid fuel, the chimney liner system
needs to be inspected at least once every two months during the heating season, to
determine if a crosote or soot buildup has occurred. If creosote or soot has
accumulated, it should be removed to reduce the risk of a chimney fire.
Toremovecreosoteandsoot,useawireorpolychimneybrush. Thesizeofthebrush
should be the same diameter size as the liner or up to 1/8" larger. Thoroughly brush
theliner to removeanybuildup that mayhaveoccurred. To accesstheliner,remove
the top portion of the cap by removing the screws on the legs. Be sure to reattach
the cap after cleaning liner. WARRANTY
Simpson Dura-Vent warrants DuraFlex SS for a period of 10 years from date of
installation. The warranty includes all components and fittings except caps. Caps
carry a five-year warranty. All warranties, whether expressed or implied, shall be
limited to replacement (exclusive of installation costs) of the product found to be
defective under this warranty and shall be conditional upon compliance with all
recommended installation and maintenance procedures and intended use of the
product. All products must be maintained by periodic inspection and cleaning as
needed, including vent exposed to weather containing corrosive elements.
PO Box 1510
Vacaville, CA 95696-1510
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