Watts Aerco Modulex EXT Series User guide

Modulex EXT Vent and Combustion Air Application Guide GF-136-V

TAG-0054-0F AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 Page 1of 28

GF-136-V Phone: 800-526-0288 09/25/2017

Venting & Combustion Air Guide

Modulating Condensing Hot Water Boilers

Latest Update: 09/25/2017

TECHNICAL APPLICATION GUIDE

APPLIES TO THE FOLLOWING

LIGHT COMMERCIAL MODELS

•MLX EXT 321

•MLX EXT 450 / MLX EXT 481

•MLX EXT 600 / MLX EXT 641

•MLX EXT 800 / MLX EXT 802

•MLX EXT 962

•MLX EXT 1100 / MLX EXT 1123

COMMERCIAL MODELS

•MLX EXT 1500 / MLX EXT 1530

•MLX EXT 1912

•MLX EXT 2295 / MLX EXT 2300

•MLX EXT 2600 / MLX EXT 2677

•

MLX EXT 3000 / MLX EXT 3060

Modulex EXT Vent and Combustion Air Application Guide

Page 2of 28 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 TAG-0054-0F

09/25/2017 Phone: 800-526-0288 GF-136-V

TABLE OF CONTENTS:

CHAPTER 1: CODES, SAFETY, AND VENTING SYSTEMS...............................................3

1.1. APPLICABLE FEDERAL CODES ...............................................................................3

1.2. GAS VENT CATAGORIES..........................................................................................4

1.3. CERTIFIED VENTING MATERIALS FOR FLUE PIPE SYSTEMS..............................4

1.3.1. OPTION 1: AL29-4C Stainless Steel.....................................................................5

1.3.2. OPTION 2: VP1738A Stainless Steel....................................................................5

1.3.3. OPTION 3: Polypropylene.....................................................................................5

1.3.4. OPTION 4: PVC/CPVC.........................................................................................5

1.4. FACTORY SUPPLIED INLET AND VENT COMPONENTS ........................................6

1.4.1. Exhaust Manifold Assembly (Supplied) .................................................................6

1.4.2. European-to-American Flue Adaptor (Supplied)....................................................6

1.4.3. Flue Exhaust Piping Starter Pieces.......................................................................7

1.4.4. Air Intake Connector (Supplied).............................................................................8

CHAPTER 2: COMBUSTION AIR SYSTEM.........................................................................9

2.1. COMBUSTION AIR REQUIREMENTS........................................................................9

2.2. COMBUSTION AIR PIPE SIZING.............................................................................12

2.3. COMMON COMBUSTION AIR PIPE SIZING............................................................13

CHAPTER 3: VENT SYSTEM.............................................................................................16

3.1. VENT INSTALLATION..............................................................................................16

3.2. INSTALLATION PROCEDURE FOR VENTING SYSTEM THROUGH WALLS.........22

3.3. INSTALLATION PROCEDURE FOR VERTICAL VENTING......................................24

3.4. VENT PIPING SIZE...................................................................................................25

3.5. COMMON VENT PIPING SIZE.................................................................................26

Modulex EXT Vent and Combustion Air Application Guide

TAG-0054_0F AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 Page 3of 28

GF-136–V Phone: 800-526-0288 09/25/2017

CHAPTER 1: CODES, SAFETY, AND VENTING SYSTEMS

1.1. APPLICABLE FEDERAL CODES

United States:

NFPA 54/ANSI

Z223.1:

National Fuel Gas Code

NFPA/ANSI 211:

Chimneys, Fireplaces, Vents and Solid Fuel Burning Appliances

Canada:

CAN1-B149.1:

Installation Codes for Gas-Burning Equipment

B149.2:

Installation Codes for Gas-Burning Equipment

The above listed codes contain information for gas vented appliances requiring Category II, III and

IV, vent sizing, location, air space clearances to combustibles and safe installation practices. The

gas vent installer must be familiar with the above codes, as well as Local Codes and Regulations.

WARNING!

All installations of boilers and venting should be done only by qualified venting systems personnel

and in accordance with the manufacturer’s recommendations. Installing or venting a boiler or any

other gas appliance with improper methods or materials may result in serious injury or death due to

fire or to asphyxiation from poisonous gases (carbon monoxide is odorless and invisible).

WARNING!

•For correct installation of vent system, read all of these instructions and refer to the vent pipe

manufacturer’s instructions.

•Failure to use the venting system described in this document will void the manufacturer’s

warranty and may result in rapid deterioration of the venting system, creating a potential health

hazard.

•Faulty vent installation can allow toxic fumes to be released into living areas. This may cause

serious bodily injury or property damage. Improper assembly may also affect vent performance.

•Install separate vents for forced exhaust appliances and natural draft appliances. A common

vent between natural draft and forced exhaust appliances may cause toxic gases to exhaust

through the natural draft appliance rather than to outside air. Breathing exhaust gases will

cause serious personal injury or death.

Modulex EXT Vent and Combustion Air Application Guide

Page 4of 28 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 TAG-0054-0F

09/25/2017 Phone: 800-526-0288 GF-136-V

1.2. GAS VENT CATAGORIES

WARNING!

The Modulex boiler is approved for a Category IV vent configuration as well as for sealed

combustion installations. Make provisions for combustion and ventilation air in accordance with

Section 5.3, (Air for Combustion and Ventilation) of the National Fuel Gas Code - ANSI Z223.1, or

Sections 7.2, 7.3, or 7.4 of CAN/CGA B149, Installation Codes, or applicable provisions of the local

building codes.

Federal Codes have categorized gas appliances by the vented flue gas pressure and temperature:

•Category I, being a gas appliance that operates with a non-positive vent (or natural drafted vent)

connector with a flue gas pressure and temperature at least 140°F (60°C) above its dew point.

•Category II, being a gas appliance that operates with a non-positive vent (or natural drafted vent)

connector with a flue gas pressure and temperature less than 140°F (60°C) above its dew point.

•Category III, being a gas appliance that operates with a positive vent (fan forced vent) connector

with a flue gas pressure and temperature at least 140°F (60°C) above its dew point.

•Category IV, being a gas appliance that operates with a positive vent (fan forced vent) connector

with a flue gas pressure and temperature less than 140°F (60°C) above its dew point.

•Direct Vent, a gas appliance is constructed and installed so that all air for combustion is derived

directly from the outdoors and all flue gases are discharged to the outdoors.

1.3. CERTIFIED VENTING MATERIALS FOR FLUE PIPE SYSTEMS

Acceptable materials and manufacturers for flue vent pipe systems are listed below in Option #1 –

Option #4.

WARNING!

The Vent Pipe Systems below are used for venting gas burning Category IV appliances. Do not

use these vent pipe systems for venting appliances burning fuels such as wood, coal, oil or

kerosene.

Maintain clearances from combustible construction for boiler, vent connector, and steam and hot-

water pipes.

Do not use these vent pipe systems for incinerators of any kind.

Do not vent Modulex systems using the same vent piping as being used for either Benchmark or

KC boilers.

Modulex EXT Vent and Combustion Air Application Guide

TAG-0054_0F AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 Page 5of 28

GF-136–V Phone: 800-526-0288 09/25/2017

1.3.1. OPTION 1: AL29-4C Stainless Steel

•Security Chimneys International, Secure Seal, SS, SSD, and SSID (available through AERCO)

•Flex-L International Inc., StaR 34 Vent

•Heat-Fab Inc., Saf-T Vent

•Protech System Inc., Fas N Seal Vent

•Metal-Fab Inc., Corr/Guard Vent

•Z-Flex Z-Vent

1.3.2. OPTION 2: VP1738A Stainless Steel

•Van-Packer Company, Inc., Model CS Special Gas Vent

1.3.3. OPTION 3: Polypropylene

•DuraVent, Polypro Commercial (Available through AERCO)

•Centrotherm ECO Systems, InnoFlue Single Wall Commercial

1.3.4. OPTION 4: PVC/CPVC

Use Schedule 40 or thicker, Single-Wall, Uninsulated Pipes

When using Non-Metallic (Plastic) vent systems for Canadian installations, per CSA B149.1, use vent

systems that are certified to the Standard for Type BH Gas Venting Systems, ULC-S636. The plastic

components, primers and glues of the certified vent system must be from a single system

manufacturer and not inter-mixed with other manufacturers vent system parts.

PVC

•ASTM F891

•ASTM D2665

•ASTM D1785

•ASTM D2241

CPVC

•ASTM D2846

•ASTM F441

•ASTM F442

Modulex EXT Vent and Combustion Air Application Guide

Page 6of 28 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 TAG-0054-0F

09/25/2017 Phone: 800-526-0288 GF-136-V

1.4. FACTORY SUPPLIED INLET AND VENT COMPONENTS

For installation flexibility, venting connectors are provided for left hand, right hand, and rear

connections. Basic drawings of the connection components and optional assemblies are shown in

Figures 1 through 4.

1.4.1. Exhaust Manifold Assembly (Supplied)

The exhaust manifold and necessary parts are supplied with the unit, and can be positioned on the

right, left, or rear of the unit. Two flue exhaust opening covers with gaskets are used to cover the

unused manifold openings. Assembly of the exhaust manifold is described in detail in Chapter 3. See

Figure 1 for image of the exhaust manifold parts.

Figure 1: Exhaust Manifold Components for Exhaust Outlet (Supplied)

1.4.2. European-to-American Flue Adaptor (Supplied)

The exhaust manifold supplied with the unit requires the use of an adaptor to connect to American

flue systems. This adaptor comes standard with the unit, and is pictured in Figure 2. Assembly of this

adaptor is described in detail in Chapter 3.

Figure 2: European-to-American Flue Adaptor (Supplied)

FOR EXT MODELS 1500 3060

FOR EXT MODELS 321 – 1123

EXHAUST

MANIFOLD

GASKET

MANIFOLD

ADAPTER GASKET

NUTS (6)

EXHAUST

MANIFOLD

GASKET

MANIFOLD

ADAPTER GASKET

NUTS (10)

FOR EXT MODELS 321 – 1123

FOR EXT MODELS 1500 – 3060

Modulex EXT Vent and Combustion Air Application Guide

TAG-0054_0F AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 Page 7of 28

GF-136–V Phone: 800-526-0288 09/25/2017

1.4.3. Flue Exhaust Piping Starter Pieces

Table 1 lists the exhaust vent adaptors available for each Modulex EXT model. Instructions for

assembling the vent adaptors are in Chapter 3.

TABLE 1: EXT Vent Adaptors

BOILER MODELS DIAMETER MATERIAL KIT PART NUMBER

EXT

321, 450, 481 4”

Stainless Steel Contact vent manufacturer directly

Polypropylene

P/N 39006-1 (for Duravent PolyPro.

For other brands, contact manufacturer

directly.

PVC P/N 49051 (included)

EXT

600 – 1123 6”

Stainless Steel Contact vent manufacturer directly

Polypropylene

P/N 39006-2 (for Duravent PolyPro.

For other brands, contact manufacturer

directly.

PVC P/N 49050 (included)

EXT

1500, 1530, 1912 10” Stainless Contact vent manufacturer

Polypropylene Contact vent manufacturer

PVC 58115-1

EXT

2295 – 3060 12” Stainless Contact vent manufacturer

Polypropylene Contact vent manufacturer

PVC 58115-2

While the MLX EXT 1500 – 3060 are approved for use with PVC venting, this option can be

extremely heavy and expensive. AERCO strongly recommends Polypropylene or Stainless Steel

venting for these models.

FOR EXT MODELS 1500 – 3060 FOR EXT MODELS 321 – 1123

Figure 3: Flue Piping Starter Pieces

ADAPTER

CONNECTOR

BOLTS

WASHERS

WORM-DRIVEN

HOSE CLAMP

ADAPTER

GASKET

Modulex EXT Vent and Combustion Air Application Guide

Page 8of 28 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 TAG-0054-0F

09/25/2017 Phone: 800-526-0288 GF-136-V

1.4.4. Air Intake Connector (Supplied)

Air is drawn into the EXT through the air inlet on the left side of the unit (Figure 4). A connector is

included installed and ready to use for connecting the appropriate air intake piping for EXT 321–

1123/450–1100. For EXT 1530–3060/1500–3000, the combustion air intake adapter is shipped loose.

This adapter is designed for spiral ducting only. For PVC ducting, order either P/N 58115-1 or 58115-

2 as per Table 1.

Figure 4: Air Intake Connection

NOTE:

See Chapter 3 for instructions for assembling the flue piping, including the exhaust manifold, Euro-to-

USA Adaptor, and Diameter Reduction Kits.

When using sealed combustion, observe the following requirements:

•Sealed combustion is only available on the left of the unit only.

•If using side-by-side minimum installation clearances, the center facing air inlet is not

available. See “Multi-Unit Installation Clearances (SD-A-968)” for further details.

Please note the following:

•EXT Models 321 – 1123 are set up for PVC inlet piping.

•EXT Models 1500 – 3060 come with an air intake adaptor for spiral ducting.

FOR EXT MODELS 321 – 1123

FOR EXT MODELS 1500 – 3060

Modulex EXT Vent and Combustion Air Application Guide

TAG-0054_0F AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 Page 9of 28

GF-136–V Phone: 800-526-0288 09/25/2017

CHAPTER 2: COMBUSTION AIR SYSTEM

WARNING!

Air openings to combustion area must not be obstructed. Using Table 2, air openings may be

specified so that adequate combustion air can be maintained.

2.1. COMBUSTION AIR REQUIREMENTS

WARNING!

•Non-Motorized louvers and grilles must be fixed in an open position.

•Minimum screens mesh size shall not be smaller than 1/4” (inch) mesh.

Table 2, below, shows the minimum required air openings in square inches (square centimeters) freely

communicating with the outdoors for boiler room combustion and ventilation air for each boiler. For

multiple boiler installations, sum the openings for the specific boiler sizes.

TABLE 2: Min. Required Air Openings Freely Communicating With the

Outdoors for Boiler Room Combustion & Ventilation Air

MODEL

TWO SEALED

COMBUSTION OR

VERTICAL DUCTS EACH

HAVING AN OPENING IN

SQ. IN. (SQ.CM) OF:

TWO HORIZONTAL

DUCTS EACH HAVING AN

OPENING IN SQUARE

INCHES OF:

SINGLE

PERMANENT

OPENING

EXT 321

80 in

(516 cm

) 161 in

(1039 cm

) 107 in

(690 cm

)

EXT 481/450

120 in

(774 cm

) 241 in

(1555 cm

) 160 in

(1032 cm

)

EXT 641/600

160 in

(1032 cm

) 321 in

(2071 cm

) 214 in

(1381 cm

)

EXT 802/800

201 in

(1297 cm

) 401 in

(2587 cm

) 267 in

(1723 cm

)

EXT 962

241 in

(1655 cm

) 481 in

(3103 cm

) 321 in

(2071 cm

)

EXT 1123/1100

281 in

(1813 cm

) 562 in

(3626 cm

) 374 in

(2413 cm

)

EXT 1530/1500 383 in

(2471 cm

) 765 in

(4935 cm

) 510 in

(3290 cm

)

EXT 1912 478 in

(3084 cm

) 956 in

(6168 cm

) 637 in

(4110 cm

)

EXT 2295/2300 574 in

(3703 cm

) 1148 in

(7406 cm

) 765 in

(4935 cm

)

EXT 2677/2600 669 in

(4316 cm

) 1339 in

(8639 cm

) 892 in

(5755 cm

)

EXT 3060/3000 765 in

(4936 cm

) 1530 in

(9871 cm

) 1020 in

(6581 cm

)

1. The combustion air must be free of chlorine, halogenated hydrocarbons or other chemicals that

can become hazardous when used in gas-fired equipment. Common sources of these

compounds are swimming pools, degreasing compounds, plastic processing, and refrigerants.

Whenever the environment contains these types of chemicals, combustion air MUST be

supplied from a clean area outdoors for the protection and longevity of the equipment and

warranty validation.

2. Ventilation of the boiler room must be adequate enough to provide sufficient air to properly

support combustion.

Modulex EXT Vent and Combustion Air Application Guide

Page 10 of 28 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 TAG-0054-0F

09/25/2017 Phone: 800-526-0288 GF-136-V

3. When combustion air is brought from outside the building and the boiler room is provided with

two permanent openings, one shall commence 12 inches from the top and the other shall

commence within 12 inches from the bottom of the room (see Figure 5). The openings shall

communicate directly, or by ducts, freely with the outdoors. One of the following methods must

be made to provide adequate air for ventilation and combustion.

Figure 5: Combustion-Air Makeup-Air Vent Locations

oWhen directly communicating with the outdoors, each opening shall have a minimum free area

of 1 square inch per 4,000 BTU per hour of total input rating of all equipment in the room.

oWhen communicating with the outdoors by means of vertical ducts, each opening shall have a

minimum free area of 1 square inch per 4,000 BTU per total input rating of all appliances in the

room.

oIf horizontal ducts are used, each opening and duct shall have a minimum free area of 1

square inch per 2,000 BTU per hour of total input rating of all appliances in the room.

4. When calculating free area using louvers and grilles, the required size of the openings for

combustion, ventilation, and dilution air shall be based on the total free area of each opening.

5. If the free area through a designed louver or grille is known, it shall be used in calculating the size

of the opening required to provide the free area specified.

6. If the louver and grille design free areas are not known, the following will be assumed for wooden

louvers a 25 percent free area, and for metal louvers and grilles a 75 percent free area opening.

12” (305 mm)

MAKEUP AIR

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