Weil-McLain Evergreen 220 User manual

Part No. 550-100-268/1220
Hazard defi nitions
e following dened terms are used throughout these Instructions to bring attention to the presence of hazards of
various risk levels or to important information concerning the life of the product.
Indicates presence of hazards that can cause severe personal injury, death or substantial property damage.
Indicates special instructions on installation, operation or maintenance that are important but not related
to personal injury or property damage.
Vent Category II Addendum Boiler Manual
KEEP THIS ADDENDUM WITH BOILER MANUAL
This Addendum adds to and supercedes items in the “Evergreen Boiler Manual”
(Part Number 550-100-131) and previously released Addenda’s.
Evergreen Boilers (EVG 220, EVG 299/300, and EVG 399) can now be vented in a Category II
configuration.
In addition to the Evergreen boiler’s Category IV rating (positive pressure, likely to condense), Evergreen
boilers are approved for Category II (negative pressure, likely to condense) as well.
This new venting option includes / requires:
• The Vent system for a Category II Evergreen boiler is considered a Designed / Engineered vent system
and should be designed by a professional using accepted engineering practices in accordance to local
authority having jurisdiction.
• Vertical Vent only.
• Must not be installed into an existing common vent system with other appliances.
• Combustion air must come from the boiler room. See Boiler Room Air opening requirements in this
Addendum.
• Must increase venting to 6” using a 6” to 4” bell reducer at boiler vent adapter for Category II Vent
Connection.
• The Vent System should be designed so that the pressure in the 6” vent pipe immediately following
the bell reducer is between the ranges provided in the Table 1, page 2, during all running (burner lit)
conditions (i.e., High Fire through Low Fire).
• Flue gas temperature should not exceed 210°F; the boiler will shut down and recycle if it does. The
flue gas temperature should typically be within 20°F of the return water temperature of the boiler.
If there is the potential for a wide variation in return water temperatures, the lowest possible tem-
perature should be used for any calculations.
- continued on next page
CONDENSING GAS BOILER
220/299/300/399

Part number 550-100-268/1220
2
CONDENSING GAS BOILER — VENT ADDENDUM
- continued
• Stack / Vent Flow Rate for each individual boiler model is listed in the table below. This flow rate is
based on the unit running at 9.25% CO2and the maximum flue gas temperature of 210°F.
The values can vary depending on the location of the installation and operating conditions.
• A carbon monoxide detector(s) is required in the boiler room for Evergreen boilers installed in a
Category II configuration. The carbon monoxide detector must be wired on the same electrical
circuit as the boiler. Check your local codes for any additional requirements of carbon monoxide
detectors.
Improper Installation of a Category II vent system resulting in positive pressure in the vent system can
result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.
Weil-McLain recommends the use of a Variable Speed Chimney Fan/ Power venter to ensure that the
appropriate negative pressure is maintained for Category II venting. This is recommended because, as a
result of the boiler’s efficiency, the exhaust gas temperatures can be quite low resulting in less natural draft.
A flow proving switch should be wired into the Proof of Closure jumper circuit on the boiler control. See
the boiler manual for additional information. The use of this device should be considered in any Engi-
neered Vent system.
Weil-McLain recommends the use of a Double Acting Barometric Damper or Modulating Damper to en-
sure the appropriate negative pressure range is kept for Category II venting. The use of this device should
be considered in any Engineered Vent system.
When using a damper of any kind, it is recommended to use a thermal spill switch to detect any exhaust
flow into the boiler room. Verify the temperature range on the thermal spill switch is adequate for the Flue
gas temperature from the Evergreen boiler. The use and set-point of this shall be determined by the sys-
tem designer. The Auto reset input on the Boiler’s control can be used to wire in the thermal spill switch.
Increasing the negative pressure in the vent pipe will slightly increase the firing rate at low fire, thus reduc-
ing the boiler’s true modulation range. Consider this factor during system design.
Code Compliance
Venting / Combustion air piping – Installations must provide provisions for combustion and
ventilation air in accordance with the section “Venting of Equipment”, of the National Fuel Gas Code,
ANSI Z223.1 / NFPA 54, or “Venting Systems and Air Supply for appliances” of the Natural Gas and
Propane Installation Code, CAN/CSA B149.1, or applicable provisions of the local building codes.
See Evergreen boiler manual for approved vent material.
TABLE 1 Rating & Vent Data
Boiler
Model
Input
Btuh
Stack / Vent
fl ow rate
scfm
Negative Pressure to be
maintained at
Vent Connection of the boiler
Inches w.c.
Evergreen Vent
Adapter
required for
Category II
EVG 220 220,000 61 -0.001 to -0.100 6”
EVG 299 299,000 83 -0.001 to -0.100 6”
EVG 300 300,000 83 -0.001 to -0.100 6”
EVG 399 399,000 111 -0.001 to -0.100 6”

Part number 550-100-268/1220 3
CONDENSING GAS BOILER — VENT ADDENDUM
Direct Exhaust (Category II Only) Venting – general
Evergreen Boilers must be vented
and supplied with combustion and
ventilation air using piping and
methods described in this adden-
dum.
Inspect finished vent and air piping thor-
oughly to ensure all are water-tight and
comply with the instructions provided
and with all requirements of applicable
codes.
Failure to provide a properly-installed
vent and air system will cause severe
personal injury or death.
If the vent/air piping configurations
covered in the Evergreen boiler manual
and this addendum cannot be applied
for a particular installation, contact Weil-
McLain for assistance. Other configura-
tions may be available.
Installations must comply with local
requirements and with the National
Fuel Gas Code, ANSI Z223.1 for U.S.
installations or CSA B149.1 or B149.2 for
Canadian installations.
Use only the materials listed in the Boiler
manual for vent and air pipe and fittings.
Failure to comply could result in severe
personal injury, death or substantial
property damage.
If used, a masonry chimney can
ONLY be used as a PIPE CHASE for
vent pipe — The vent piping must be in-
stalled as instructed in this manual and all
joints must be sealed. The chimney must
be used only for boilers. NO OTHER
appliance or fireplace can be connected
to the chimney.
The chimney must be straight, with
no offsets, and the vent and air piping
materials must comply with this instruc-
tion manual. The chimney must be fitted
with a sealed access opening, through
which the interior of the chimney can
be inspected. The chimney (and liner, if
installed) must be inspected at least once
annually to verify condition.
Failure to comply could result in severe
personal injury, death or substantial
property damage.
Vent piping
Boiler flue gases must be piped from the boiler to outside, following
the instructions in the Boiler manual and this addendum, and
compliant with all applicable codes.
Combustion and ventilation air openings
(direct exhaust installations)
Combustion and ventilation air are provided from the boiler room
on direct exhaust installations. Follow all instructions in the Boiler
manual and this addendum, plus all applicable codes, to provide
required air openings.
Vent termination options
Vent piping must terminate out through the roof of the building,
using only one of the methods described in the Boiler manual and
this addendum.
Vent pipe diameter
A 6” vent pipe diameter must be used.
Vent pipe minimum length
Direct exhaust — no minimum.
Vent and air piping materials
See the Evergreen Boiler Manual for approved vent and air piping
materials, for direct exhaust.
Use the same vent or air piping material through-
out. — Do not connect different types of piping to-
gether.
Install a bird screen in each vent pipe termination (coupling or elbow).
Bird screens are not supplied with the Evergreen boiler. Purchase
separately from Weil-McLain.

Part number 550-100-268/1220
4
CONDENSING GAS BOILER — VENT ADDENDUM
Direct Exhaust (Category II Only) Boiler room air opening
Combustion air openings for direct exhaust
Provide combustion air openings to boiler
room and building. Combustion and ventilation
air for direct exhaust boilers is provided from the
boiler room. Follow all instructions in the Boiler
manual and this addendum plus all applicable
codes, providing combustion air openings as speci-
fied. Failure to comply could result in severe per-
sonal injury, death or substantial property damage.
1. Combustion air must be supplied through openings into the
boiler room, following the instructions in this addendum
and compliant with all applicable codes. Read the warning in
Figure 1, page 5, and ensure the air and boiler room will not
contain contaminated air.
2. Where the boiler shares a space with other appliances, the
combustion air openings must be sized to handle the com-
bined requirements of all appliances in the space.
Sizing combustion air openings
Air openings provide for ventilation (as well as combustion air)
to prevent overheating of the boiler controls and boiler space.
Air is also needed for other appliances located in the same space.
Use Figure 2, page 6, selecting the appropriate installation condi-
tions.
Air openings must be sized to handle all appliances
and air movers (exhaust fans, etc.) using the air
supply.
The sizing given in Figure 2, page 6, is based on the National
Fuel Gas Code, ANSI Z223.1, allowing adequate air openings for
gravity-vented gas appliances (Category I) in addition to that
needed for the Evergreen boiler.
The air openings recommended in Figure 2, page 6, will allow
adequate ventilation and combustion air provided the boiler room
is not subjected to negative pressure due to exhaust fans or other
mechanical ventilation devices.
Refer to the National Fuel Gas Code for dealing with other con-
ditions.
Free area — louver allowance
The free area of openings means the area after reduction for any
installed louvers or grilles. Be sure to consider this reduction when
sizing the air openings.
Special considerations
Tight construction
ANSI Z223.1 defines unusually tight construction where:
1. Walls and ceilings exposed to the outside atmosphere have a
continuous water vapor retarder with a rating of 1 perm or
less with openings gasketed, and . . .
2. Weather-stripping has been added on openable windows and
doors, and . . .
Every vent pipe requires a bird screen at its
termination. Bird screens are not supplied with
the Evergreen boiler. Purchase separately from
Weil-McLain.
3. Caulking or sealants are applied to areas such as joints around
windows and door frames, between sole plates and floors, be-
tween wall-ceiling joints, between wall panels, at penetrations
for plumbing, electrical, and gas lines, and in other openings.
For buildings with such construction, provide air openings into
the building from outside, sized per the appropriate case in Fig-
ure 2, page 6, if appliances are to use inside air for combustion
and ventilation.
Exhaust fans and air movers
The appliance space must never be under a negative pressure
unless all appliances are installed as direct vent. Always provide
air openings sized not only to the dimensions required for the
firing rate of all appliances, but also to handle the air movement
rate of the exhaust fans or air movers using air from the build-
ing or space.
Motorized air dampers
If the air openings are fitted with motorized dampers, electrically
interlock the damper to:
• Prevent the boiler from firing if the damper is not fully open.
• Shut the boiler down should the damper close during boiler
operation.
The Evergreen control provides a Proof of Closure function
which will prevent the boiler from firing if the damper is not fully
open or closes during boiler operation. Please refer to the Boiler
Manual for installation and wiring instructions.
Ensure that the combustion air will not contain

Part number 550-100-268/1220 5
CONDENSING GAS BOILER — VENT ADDENDUM
Direct Exhaust (Category II Only) Boiler room air opening
Figure 1 Corrosive contaminants and sources
Products to avoid
Spray cans containing chloro/fluorocarbons
Permanent wave solutions
Chlorinated waxes/cleaners
Chlorine-based swimming pool chemicals
Calcium chloride used for thawing
Sodium chloride used for water softening
Refrigerant leaks
Paint or varnish removers
Hydrochloric acid/muriatic acid
Cements and glues
Antistatic fabric softeners used in clothes dryers
Chlorine-type bleaches, detergents, and cleaning solvents found in
household laundry rooms
Adhesives used to fasten building products and other similar
products
Excessive dust and dirt
Areas likely to have contaminants
Dry cleaning/laundry areas and establishments
Swimming pools
Metal fabrication plants
Beauty shops
Refrigeration repair shops
Photo processing plants
Auto body shops
Plastic manufacturing plants
Furniture refinishing areas and establishments
New building construction
Remodeling areas
Garages with workshops
any of the contaminants in Figure 1, page 5.
Do not pipe combustion air near a swimming
pool, for example. Avoid areas subject to exhaust
fumes from laundry facilities. These areas will
always contain contaminants.
Contaminated combustion air will damage the
boiler, resulting in possible severe personal injury,
death or substantial property damage.

Part number 550-100-268/1220
6
CONDENSING GAS BOILER — VENT ADDENDUM
Figure 2 MINIMUM combustion air openings for direct exhaust applications – ALL OPENINGS ARE FREE AREA
Provisions for combustion and ventilation air to be in accordance with the section “Air for Combustion and
Ventilation,” of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or applicable provisions of the local building
codes.
Direct Exhaust (Category II Only) Boiler room air opening
Air openings
The required air opening sizes below are FREE AREA,
after reduction for louver obstruction. Note the excep-
tion below for large spaces.
Evergreen™boiler
WITH other
appliances in room
Evergreen™boiler
WITHOUT other
appliances in room
TWO openings, each at least:
1square inch per 1,000 Btuh
of all other appliances in the room
TWO openings, each at least:
1square inch per 4,000 Btuh
of all other appliances in the room
TWO openings, each at least:
1square inch per 4,000 Btuh
of all other appliances in the room
— OR —
ONE opening **, each at least:
1square inch per 3,000 Btuh
of all other appliances in the room
TWO openings, each at least:
1square inch per 4,000 Btuh
of all other appliances in the room
— OR —
ONE opening **, each at least:
1square inch per 3,000 Btuh
of all other appliances in the room
TWO openings, each at least:
1square inch per 2,000 Btuh
of all other appliances in the room
— OR —
ONE opening **, each at least:
1square inch per 3,000 Btuh
of all other appliances in the room
TWO openings, each at least:
1square inch per 4,000 Btuh
of all other appliances in the room
— OR —
ONE opening **, each at least:
1square inch per 3,000 Btuh
of all other appliances in the room
TWO openings, each at least:
1square inch per 4,000 Btuh
of all other appliances in the room
— OR —
ONE opening **, each at least:
1square inch per 3,000 Btuh
of all other appliances in the room
TWO openings, each at least:
1square inch per 4,000 Btuh
of all other appliances in the room
— OR —
ONE opening **, each at least:
1square inch per 3,000 Btuh
of all other appliances in the room
** NOTICE:
Requirements for using the SINGLE air opening
option.
A single combustion air opening can be used for cases b, c, or dabove, sized as listed,
provided that:
• The single opening must communicate directly to the outdoors or to a space that
communicates directly with outdoors (NOT to an interior space).
• The top of the opening must be within 12 inches of the ceiling.
• The free area of the opening must be at least equal to the sum of the areas of all
equipment vent connectors in the space.
SPECIAL EXCEPTION FOR LARGE SPACES
NO combustion air openings are needed if the boiler (and other appliances) are installed
in a space with a volume NO LESS than 50 cubic feet per 1,000 Btuh of all appliances in
the space. That is, total the input of all appliances in MBH (1,000’s of Btuh), then multiply
this total times 50. The building MUST NOT be of tight construction.
Example: For a total input of 500 MBH (500,000 Btuh), the minimum volume would be
50 x 500 = 25,000 cubic feet.

Part number 550-100-268/1220 7
CONDENSING GAS BOILER — VENT ADDENDUM
Direct Exhaust (Category II Only) – Vertical
Figure 3 DIRECT EXHAUST vertical termination Determine location for vertical termination
1. Locate the vent termination using the following guide-
lines:
2. The vent piping must terminate in a coupling as shown
in Figure 4, page 8.
3. Consider the surroundings when terminating the vent:
a. Position the vent termination where vapors will not
damage nearby shrubs, plants or air conditioning
equipment or be objectionable.
b. The flue products will form a noticeable plume as
they condense in cold air. Avoid areas where the
plume could obstruct window views.
c. Prevailing winds could cause freezing of condensate
and water/ice buildup where flue products impinge
on building surfaces or plants.
d. Avoid possibility of accidental contact of flue prod-
ucts with people or pets.
e. Do not locate the termination where wind eddies
could affect performance or cause recirculation,
such as inside building corners, near adjacent build-
ings or surfaces, window wells, stairwells, alcoves,
courtyards or other recessed areas.
f. Locate or guard vent to prevent condensate damage
to exterior finishes.
4. Maintain clearances as shown in the illustrations in this
manual section. Also maintain the following:
a. Vent must terminate:
• At least 12 inches above roof or snow line as
shown in Figure 4, page 8.
• At least 6 feet from adjacent walls.
• No closer than 5 feet below roof overhang.
• At lease 3 feet above any forced air intake within
10 feet.
• No closer than 48 inches below or horizontally
from any door or window or any other gravity
air inlet.
b. Do not terminate closer than 4 feet horizontally
from any electric meter, gas meter, regulator, relief
valve or other equipment.
5. Where the vent penetrates the roof, the annular space
around the penetration must be permanently sealed
using approved materials to prevent entry of combus-
tion products into the building.
6. Locate terminations so they are not likely to be damaged
by foreign objects, such as stones or balls, or subject to
buildup of leaves or sediment.
7. Do not connect any other appliance to the vent pipe.
Prepare roof penetration
1. Vent pipe penetration:
a. Cut a hole for the vent pipe.For either combustible or
noncombustible construction, size the vent pipe hole
at least 0.5”larger than the vent pipe diameter – use a
7” hole for 6” PVC.
b. Insert a galvanized metal thimble in the vent pipe
hole.
2. Follow all local codes for isolation of vent pipe when
passing through floors, ceilings and roofs.
3. Provide flashing and sealing boots sized for the vent
pipe and air pipe.
DIRECT EXHAUST — Vertical termination —
installation sequence overview
Step 1 Install the boiler.
Step 2 Determine the proper location for wall penetration for each
termination.
• Prepare roof penetrations before installing vent piping.
• Finish by attaching external pipe and fittings as shown in the
termination instructions.
• Install terminations as described in this manual.
• Support vertical runs on the outside of the building with
brackets as shown in the termination instructions.
Step 3 Install vent piping from boiler to termination.
• Install a hanger support within 6 inches of any upturn in
the piping.
• Install pipe supports every 5 feet on both the horizontal and
vertical runs.
• Slope horizontal piping downward toward the boiler at least
1/4 inch per foot.
Step 4 Connect the vent piping at the boiler per manual instructions.
6” to 4”
bell reducer
EV-3505E-bw
VENT
VENT
Max. 5 feet apart
(Support, typical)
Vertical support, typical
within 6 inches of any
upturn and Max. 5 feet
apart (by others if needed)
*Double Acting
Barometric Damper
(by others
if needed)
*Thermal
Spill Switch
(by others if needed)
*Variable Speed
Vent Inducer
(by others if needed)
Backflow Preventer
(as needed) per Para.1

Part Number 550-100-268/1220
Weil-McLain
500 Blaine Street
Michigan City, IN 46360-2388
http://www.weil-mclain.com
8
CONDENSING GAS BOILER — VENT ADDENDUM
Termination and fi ttings
1. Prepare the vent termination coupling (Figure 4) by
inserting a bird screen. Bird screens are not sup-
plied with the Evergreen boiler. Purchase separately
from Weil-McLain.
2. The vent piping must terminate in a coupling as shown
in Figure 4.
3. Maintain the required dimensions of the finished ter-
mination piping as shown in Figure 4.
4. Do not extend exposed vent pipe outside of building
more than shown in Figure 4. Condensate could freeze
and block vent pipe.
Multiple vent terminations
When terminating multiple Evergreen boilers, terminate
each vent connection as described in this section. Space
terminations as required for best installation practices and
required maintenance.
Complete termination preparation
Install vent terminations before proceeding. See previous
pages for instructions.
Installing direct exhaust vent piping
1. For reference in the following see:
a. Vertical terminations: see Figure 3, page 7.
2. Work from the boiler to vent or air termination. Do
not exceed the lengths given in the previous pages for
either the air or vent piping.
a. You must install appropriate pipe reducers, where
required, at the boiler vent connection.
3. See page 36 of Evergreen Boiler Manual for attaching
vent and air pipes at the boiler.
4. Cut pipe to required lengths.
5. Deburr inside and outside of pipe ends.
6. Chamfer outside of each pipe end to ensure even cement
distribution when joining.
7. Clean all pipe ends and fittings. Dry thoroughly.
8. Dry assemble entire vent or air piping to ensure proper
fit before assembling any joint.
9. For each joint:
a. Handle fittings and pipes carefully to prevent con-
tamination of surfaces.
b. Apply primer liberally to both joint surfaces — pipe end
and fitting socket.
c. While primer is still damp, lightly apply approved cement
to both surfaces in a uniform coating.
d. Apply a second coat to both surfaces. Avoid using too much
cement on sockets to prevent cement buildup inside.
e. With cement still wet, insert pipe into fitting, twisting ¼
turn. Make sure pipe is fully inserted.
f. Wipe excess cement from joint. Check joint to be sure a
smooth bead of cement shows around the entire joint.
10. Install pipe supports as shown on Figure 3, page 7.
11. Slope vent and air piping continuously toward boiler, with at
least 1/4 inch drop per foot of run. Do not allow sags at any
point.
12. Maintain minimum clearance of 3/16 inch between vent pipe
and any combustible wall or material.
13. Seal wall or floor penetration openings following local code
requirements.
Figure 4 DIRECT EXHAUST — Vertical termination
Direct Exhaust (Category II Only) – Vertical (continued)