08/13

INSTALLATION AND SERVICE MANUAL

VERTICAL COMBUSTION AIR INLET KITS

CATEGORY III VENTING FOR SEPARATED COMBUSTION

TUBULAR GAS FIRED UNIT HEATERS

VCAK-IOM-3

J30-09023

USE 5 INCH KIT FOR UNITS WITH CAPACITIES 100,000 TO 250,000 BTU/HR

USE 6 INCH KIT FOR UNITS WITH CAPACITIES 300,000 TO 400,000 BTU/HR

Supplement to unit installation instructions – STPIM or STBII

Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury or death. Read this supplement and the unit heater installation, operating and maintenance instructions thoroughly before installing or servicing this equipment.

This Combustion Air Inlet Kit utilizes one 5 or 6 inch termination in which both the discharge fl ue gas and the combustion air inlet pass.

The location of the vent terminal must be in accordance with the National Fuel Code ANSI Z223.1 (NFPA 54) in the U.S. or the Natural Gas Installation Code CSA-B149.1 or the Propane Gas Installation Cade CSA-B149.2 in

Canada. Minimum clearances are shown in Table 1.

KIT CONTENTS:

Figure 1a – 5 Inch Combustion Air Inlet Kit

#1 – Part No. 11J37R02222-002

(1) Flue Vent Terminal

#2 – Part No. 11507R08560

(1) Combustion Air Inlet Box

Assembly (see Figure 2a for dimensional data)

#3 – Part No. 11J37R08964

(1) Air Inlet Vent Cap

#4 – Part No. 11507R08568

1

Also Included:

(1) Part No. J30-09023

Installation Instructions

(1) Part No. 11H03R03612-002

Tube of High Temp Silicone

Sealant

2

3

4

Figure 1b – 6 Inch Combustion Air Inlet Kit

#1 – Part No. 11J37R02222-003

(1) Flue Vent Terminal

#2 – Part No. 11507R08951

(1) Combustion Air Inlet Box

Assembly (see Figure 2b for dimensional data)

#3 – Part No. 11J37R08963

(1) Air Inlet Vent Cap

#4 – Part No. 11507R09011

1

Also Included:

(1) Part No. J30-09023

Installation Instructions

(1) Part No. 11H03R03612-002

Tube of High Temp Silicone

Sealant

2

4

3

D9013B

D8980B

260 NORTH ELM ST., WESTFIELD, MA 01085

TEL: (413) 568-9571 FAX: (413) 562-8437 www.mestek.com

DIMENSIONAL DATA

Figure 2a – 5 Inch Combustion Air Inlet Box Assembly

5.75"

(146.1mm)

8"

(203.2mm)

12"

(304.8mm)

5"

(127mm)

Figure 2b – 6 Inch Combustion Air Inlet Box Assembly

5"

(127mm)

15"

(381mm)

D9015B

2

6.75"

(171.45mm)

14.125"

(358.8mm)

6"

(152.4mm)

7.125"

(181mm)

10"

(254mm)

17.125"

(435mm)

D9016B

VENTING – GENERAL GUIDELINES

All unit heaters must be vented! All Venting installations shall be in accordance with the latest edition of Part 7,

Venting of Equipment of the National Fuel Gas Code, ANSI Z223.1 (NFPA 54), or applicable provisions of local building codes. Refer to notes* below for Canadian installations.

CARBON MONOXIDE! Your venting system must not be blocked by any snow, snow drifts, or any foreign matter. Inspect your venting system to ensure adequate ventilation exists at all times! Failure to heed these warnings could result in Carbon Monoxide Poisoning (symptoms include grogginess, lethargy, inappropriate tiredness, or fl u-like symptoms).

When an existing heater is removed or replaced in venting system, the venting system may not be properly sized to vent the attached appliances. An improperly sized vent system can cause formulation of condensate or leakage or spillage of fl ue gases.

The following steps shall be followed with each appliance connected to the venting system placed in operation, while any other appliances connected to the venting system are not in operation:

1. Seal any unused openings in the venting system.

2. Inspect the venting system for proper size and horizontal pitch, as required in the National Fuel

Gas Code, ANSI Z223.1 (NFPA 54) and these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other defi ciencies, which could cause an unsafe condition.

3. In so far as practical, close all building doors and windows and all doors between the space in which the appliance(s) connected to the venting system are located and other spaces of the building. Turn on clothes dryers and any exhaust fans, such as range hoods and bathroom exhausts, so they shall operate at maximum speed. Do not operate a summer exhaust fan. Close fi replace damper.

4. Follow the lighting instructions. Place the appliance being inspected in operation. Adjust thermostat so that the appliance will operate continuously.

5. After it has been determined that each appliance connected to the venting system properly vents when tested as outline above, return doors, windows, exhaust fans, fi replace dampers, and any other gas-burning appliance to their previous condition of use.

6. If improper venting is observed during any of the above tests, the venting system must be corrected immediately so that the system conforms with the

National Fuel Gas Code, ANSI Z223.1 (NFPA 54).

When resizing any portion of the venting system, the venting system should be resized to approach the minimum size as determined using the appropriate tables in Appendix G of the National Fuel Gas Code,

ANSI Z223.1 (NFPA 54).

The unit heater shall be connected to a factory built chimney or vent complying with a recognized standard, or a masonry or concrete chimney lined with a lining material acceptable to the authority having jurisdiction.

Venting into an unlined masonry chimney is prohibited.

ADDITIONAL REQUIREMENTS FOR CANADIAN INSTALLATIONS

*The following instructions apply to Canadian installations in addition to installation and operating instructions.

1. Installation must conform with local building codes, or in the absence of local codes, with current

CSA-B149.1, Installation Codes for Natural

Gas Burning Appliances and Equipment, or

CSA-B149.2, Installation Codes for Propane

Gas Burning Appliances and Equipment.

2. Any reference to U.S. standards or codes in these instructions are to be ignored and the applicable

Canadian standards or codes applied.

3

VENTING – GENERAL GUIDELINES (continued)

Do not damper or add heat recovery devices to the fl ue piping. Failure to open such a damper prior to operating the gas unit heater will result in the spillage of fl ue gas into the occupied space.

Avoid installing units in areas under negative pressure.

When required, a fl ue vent fan should be installed in accordance with the instructions included with the fan.

ANSI now organizes vented appliances into four categories:

Venting Categories

Non

Condensing Condensing

Negative

Vent Pressure

Positive

Vent Pressure

I

III

II

IV

Vent connectors serving Category I and Category

II heaters shall not be connected into any portion of mechanical draft systems operating under positive vent pressure.

Maintain 1-inch (25.4mm) clearance between the vent pipe and combustible materials.

Category I

Includes non-condensing appliances with negative vent pressure, like the traditional atmospheric unit heater.

Category II

Groups condensing appliances with negative vent pressure.

Category III

Appliances are non-condensing and operate with a positive vent pressure.

Category IV

Covers condensing appliances with positive vent pressure.

NOTICE: Category II and IV do not apply to equipment specifi ed within this manual.

4

Table 1

Door, window or gravity vent inlet or combustion air inlet for other appliances

Forced air inlet within 10 ft.

Adjoining building or parapet

Adjacent public walkways

Above grade level*

Vent Systems Termination Clearance Requirements

Structure/Object

Electric, gas meters & regulators

4 ft. below

4 ft. horizontally

1 ft. above

3 ft. above

10 ft.

7 ft. above grade

1 ft.

USA

Minimum Clearances for

Termination Locations

CANADA

4 ft. horizontal

1 ft. (0.3m) for 100,000 BTUH input or less. 3 ft. (0.9m) for input exceeding 100,000

BTUH

6 ft. (1.8m)

10 ft. (3.04m)

7 ft. (2.1m) above grade

3 ft. (0.9m) horizontally from meter/regulator assembly.

6 ft. (1.8m), any direction, from a gas service regulator vent outlet

1 ft. (0.3m)

* Minimum above maximum snow depth, or per local code, whichever is greatest.

INSTALLATION

VERTICAL TERMINATION, 5 INCH KIT

FOR USE WITH 100-250 MBH UNITS ONLY

Select a location on the roof for vent terminal ensuring adequate space inside for combustion air inlet box.

Vent terminal must be at least 10 feet (3.04m) from any wall or adjoining building. See Table 1 and Figure 3a.

Cut hole through the roof for 8 inch (203mm) combustion air pipe. The combustion air inlet box is to be suspended from the underside of the roof using suitable brackets

(fi eld supplied). Before mounting vent box, cut a length of 8 inch UL 1738 listed pipe so that dimension “A” Figure

4, Step 1 is equal to the roof thickness plus 18 inches

(457mm) or the roof thickness plus the expected snow depth, which-ever is greater. Fasten the 8 inch pipe to the combustion air inlet on the combustion air inlet box. Seal the joint and fasten with sheet metal screws.

Insert a length of 5 inch UL 1738 listed vent pipe in the direction of fl ow pointing upward through the air inlet vent cap. Vent pipe should be inserted into the combustion air inlet box so that the pipe extends a minimum of

6 inches (152mm) below the vent box for connection purposes. This will allow room to seal the fl ue pipe.

Secure the UL 1738 listed pipe in position with 3 small, evenly spaced sheet metal screws. With high temperature silicone, seal the space between the UL 1738 listed pipe and the combustion air inlet box as well as the space between the UL 1738 listed pipe and the air inlet terminal (See Figure 4, Step 4).

Insert the pipe through the roof and fasten vent box into place (See Figure 4, Step 2). Flash and/or caulk 8 inch pipe to roof (See Figure 4, Step 3). Install the inlet air cap and fasten with sheet metal screws.

Install the vent cap to the UL 1738 listed pipe using sheet metal screws. Ensure there is a minimum of 12 inches (305mm) between the bottom of the fl ue vent terminal and the top of the air inlet vent cap (See

Figure 3a and Figure 4, Step 4). Connect fl ue pipe and combustion air pipe from the combustion air inlet box to the unit, following instructions in the manual provided with the unit and Combustion Air and Exhaust Venting instructions on pages 7 and 8.

Never use pipe other than 5 inch diameter. Never use PVC, ABS or any other nonmetallic pipe for venting! To do so may result in serious damage to the unit and or severe personal injury or death!

Figure 3a – Vertical 5 Inch Combustion Air Inlet Kit Installation

Note: Separated Combustion Blower Type Unit Shown

**

Seal All Joints. Secure with a min. of 3 corrosion resistant screws!

12"

(304.8mm)

Approved Breidert Type L or Fields StarKap

Flue Vent Terminal

Combustion Air Inlet Cap

5" (127mm) Dia. UL 1738

Listed Flue Pipe

2Feet (0.609m) plus

Max Snow depth for area

8" (203.2mm) Dia.

Combustion Air Pipe

Thimble

60" Max.

(1524mm)

Combustion Air Inlet Box

Combustion Air Inlet Box

** End of UL 1738 Listed Flue Pipe must protrude min of 6" (152.4mm) below

Combustion Air Inlet Box

D9020C

Side View

Rear View

5

INSTALLATION (continued)

VERTICAL TERMINATION, 6 INCH KIT

FOR USE WITH 300-400 MBH UNITS ONLY

Select a location on the roof for vent terminal ensuring adequate space inside for combustion air inlet box.

Vent terminal must be at least 10 feet (3.04m) from any wall or adjoining building. See Table 1 and Figure 3b.

Cut hole through the roof for 10 inch (254mm) combustion air pipe. The combustion air inlet box is to be suspended from the underside of the roof using suitable brackets (fi eld supplied). Before mounting vent box, cut a length of 10 inch UL 1738 listed pipe so that dimension

“A” Figure 4, Step 1 is equal to the roof thickness plus 18 inches (457mm) or the roof thickness plus the expected snow depth, whichever is greater. Fasten the 10 inch pipe to the combustion air inlet on the combustion air inlet box. Seal the joint and fasten with sheet metal screws.

Insert the pipe through the roof and fasten vent box into place (See Figure 4, Step 2). Flash and/or caulk 10 inch pipe to roof (See Figure 4, Step 3). Install the inlet air cap and fasten with sheet metal screws.

vent cap. Vent pipe should be inserted into the combustion air inlet box so that the pipe extends a minimum of 6 inches (152mm) below the vent box for connection purposes. This will allow room to seal the fl ue pipe. Secure the UL 1738 listed pipe in position with 3 small, evenly spaced sheet metal screws. With high temperature silicone, seal the space between the

UL 1738 listed pipe and the combustion air inlet box as well as the space between the UL 1738 listed pipe and the air inlet terminal (See Figure 4, Step 4).

Install the vent cap to the UL 1738 listed pipe using sheet metal screws. Ensure there is a minimum of 12 inches (305mm) between the bottom of the fl ue vent terminal and the top of the air inlet vent cap (See

Figure 3b and Figure 4, Step 4). Connect fl ue pipe and combustion air pipe from the combustion air inlet box to the unit, following instructions in the manual provided with the unit and Combustion Air and Exhaust Venting instructions on pages 7 and 8.

Insert a length of 6 inch UL 1738 listed vent pipe in the direction of fl ow pointing upward through the air inlet

Never use pipe other than 6 inch diameter. Never use PVC, ABS or any other nonmetallic pipe for venting! To do so may result in serious damage to the unit and or severe personal injury or death!

Figure 3b – Vertical 6 Inch Combustion Air Inlet Kit Installation

Note: Separated Combustion Blower Type Unit Shown

**

Seal All Joints. Secure with a min. of 3 corrosion resistant screws!

Approved Breidert Type L or Fields StarKap

Flue Vent Terminal

12"

(304.87mm)

Combustion Air Inlet Cap

6"(152.4mm) Dia. UL1738

Listed Flue Pipe

2 Feet (0.609m) plus max. snow depth for area Thimble

60" Max.

(1524mm)

10" (254mm) Dia.

Combustion Air Pipe

Combustion Air Inlet Box

Combustion Air Inlet Box

*End of UL 1738 Listed Flue Pipe

Must Protrude a min. of 6" below the Combustion Air Box.

D9021C

6

Side View

Rear View

INSTALLATION (continued)

Figure 4 – Vertical Combustion Air Inlet Kit Installation

12" Min.

SEALANT

A

SNOW

CLEARANCE

STEP 1 STEP 2

STEP 3 STEP 4

D9022

COMBUSTION AIR VENTING

Never operate unit heaters without combustion air and fl ue gas piping in place or severe personal injury or death may occur!

CARBON MONOXIDE!

Your venting system must not be blocked by any snow, snow drifts, or any foreign matter. Inspect your venting system to ensure adequate ventilation exists at all times! Failure to heed these warnings could result in Carbon Monoxide Poisoning (symptoms include grogginess, lethargy, inappropriate tiredness, or fl u-like symptoms).

Never use pipe other than 5 or 6 inch diameter with respective Combustion Air Inlet Kits.

Never use PVC, ABS or any other nonmetallic pipe for venting! To do so may result in serious damage to the unit and or severe personal injury or death!

1. The combustion air system installation must be in accordance with the current edition of the National

Fuel Gas Code-NFPA 54 or ANSI Z223.1 National

Fuel Gas Code. In Canada, installation must be in accordance with CSA-B149.1 “Installation Code for

Natural Gas Burning Appliances and Equipment” and CSA-B149.2 “Installation Code for Propane

Burning Appliances and Equipment.”

2. The combustion air inlet box, inlet air screen, defl ector disk, and vent terminal provided with the unit heater must be installed at the termination point of the combustion air/vent system. See

Figures 1a/1b, 2a/2b, 3a/3b and 4.

3. Each unit heater MUST have its own combustion air system. It MUST NOT be connected to other air intake systems.

4. Use UL 1738 listed single wall pipe for the vent system. For installations in Canada, use corrosion resistant and gas-tight, listed vent pipe conforming with local building codes, or in the absence of local building codes, with current CSA-B149.1, Installation

Codes for Natural Gas Burning Appliances and

Equipment or CSA-B149.2, Installation Codes for

Propane Gas Burning Appliances and Equipment.

For residential installations in the United States, vent pipe approved for Category III appliances must be used between the appliance and the combustion air inlet box.

7

INSTALLATION (continued)

5. Long runs of single wall combustion air piping passing through an unheated space may require insulating if condensation becomes noticeable.

6. The combustion air system must be installed to prevent collection of condensate. Pitch horizontal pipes downward 1/4 inch per foot (21 mm/m) toward the inlet cap to facilitate drainage.

7. The equivalent length of the combustion air system must not be less than 5 feet (1.5m) and must not exceed 50 feet (15.2m). Equivalent length equals the total length of straight pipe plus 10 feet (3.05m) for each 90° elbow and 4 feet (1.22m) for each 45° elbow.

NOTICE: For optimum performance keep the combustion air system as straight as possible.

8. Each joint must be secured with at least three corrosion resistant screws. Two full turns of 3M

#425 Aluminum Foil Tape or its equivalent must then be used to seal each joint. General Electric

RTV-108, Dow-Corning RTV-732 or an equivalent silicone sealant with a temperature rating of 500°F may be used instead of the tape.

EXHAUST VENTING

Never operate unit heaters without combustion air and fl ue gas piping in place or severe personal injury or death may occur!

4. Use UL 1738 listed single wall pipe for the vent system. For installations in Canada, use corrosion resistant and gas-tight, listed vent pipe conforming with local building codes, or in the absence of local building codes, with current CSA-B149.1, Installation

Codes for Natural Gas Burning Appliances and

Equipment or CSA-B149.2, Installation Codes for

Propane Gas Burning Appliances and Equipment.

For residential installations in the United States, vent pipe approved for Category III appliances must be used between the appliance and the combustion air inlet box.

5. Any run of single wall vent pipe passing through an unheated space must be insulated with insulation suitable to 550°F.

6. The vent system must be installed to prevent collection of condensate. Pitch horizontal pipes downward 1/4 inch per foot (21mm per meter) toward the vent cap to facilitate drainage.

7. The equivalent length of the vent system must not be less than 5 feet (1.5m) and must not exceed 50 feet

(15.2m). The equivalent length equals the total length of straight pipe plus 10 feet (3.05m) for each

90° elbow and 4 feet (1.22m) for each 45° elbow.

8. Each joint must be secured with at least three corrosion resistant screws. Two full turns of 3M #425

Aluminum Foil tape or its equivalent must then be used to seal each joint. High temperature silicone sealant may be used instead of the tape. Silicone sealant must be used to seal the joint between the double wall vent pipe and the single wall pipe.

9. The exhaust vent system must remain at a minimum distance of 1 inch (25mm) from all combustible materials. Any part of the vent system that passes through a combustible material must be properly insulated.

1. Vent system installation must be in accordance with the current National Fuel Gas Code-NFPA

54 or ANSI Z223.1 National Fuel Gas Code.

In Canada installation must be in accordance with CSA-B149.1 “Installation Code for Natural

Gas Burning Appliances and Equipment” and

CSA-B149.2. “Installation Code for Propane

Burning Appliances and Equipment”.

2. A factory supplied Combustion Air Inlet Kit (which includes a combustion air inlet box, air inlet screen, defl ector disk, vent terminal and inlet air collar)

MUST be installed at the termination point of the combustion air/vent system. See Figures 1, 2, 3, 4 and 5.

3. Each unit heater MUST have its own vent system.

It MUST NOT be connected to other vent systems or to a chimney.

NOTICE: Increasing the clearance distances may be necessary if there is a possibility of distortion or discoloration of adjacent materials.

8