SIDEWALL POWER VENTING SYSTEM Model: SWG-4G ITEMS INCLUDED IN KIT 1 - SWGII-4HD Sidewall Power Venter 1 - CK-43F Control Kit (includes 4" MG-1 Barometric Draft Control) 1 - Installation Instructions OPTIONAL COMPONENTS PEK-4HD Extension Kit. For installations in walls over 8" thick. GENERAL SYSTEM INFORMATION Designed for operation with natural gas and LP gas. 1. The thermostat calls for heat and energizes a relay which activates the power venter. After the venter motor has come up to speed, the pressure switch closes. This closes the circuit to the burner and allows the burner to fire. 2. After the heating requirement has been satisfied, the thermostat circuit will open and deactivate the burner. 3. The power venter operates for a period of time after the burner has shut off to purge remaining flue gases. DO NOT DESTROY THESE INSTRUCTIONS MUST REMAIN WITH EQUIPMENT WARNING: Bodily injury can result from high voltage electrical components, fast moving fans, and combustible gas. For protection from these inherent hazards during installation and servicing, the electrical supply must be disconnected and the main gas valve must be turned off. If operating checks must be performed with the unit operating, it is the technicians responsibility to recognize these hazards and proceed safely. INSTALLATION SAFETY INSTRUCTIONS CAUTION: The power venting system must be installed by a qualified installer. "Qualified Installer" means an individual who has been properly trained or a licensed installer. The installer must write or imprint his name, phone number, and date of installation on the installation tag. The tag should be attached to the power venting system control kit box or power venter unit. 1. Safety inspection of a venting system should be performed before and after installing a power venting system on an existing or new appliance. Procedures to follow are those recommended by the National Fuel Gas Code, ANSI Z223.1, CGA Standard B149.1-M91 or B149.2-M91, or refer to the General Installation Inspection section of this manual. 2. Plan the vent system layout before installation to avoid the possibility of accidental contact with concealed wiring or plumbing inside walls. 3. Single wall vent pipe (refer to Diagram B) may be used to join the appliance to the power venter. If proper clearances cannot be maintained from combustible material, Type B vent pipe should be used. Refer to national or local codes for guidelines. 4. Disconnect power supply before making wiring connections to prevent electrical shock and equipment damage. 5. This equipment is designed to overcome minor negative pressure conditions. To ensure extreme negative pressure does not exist, follow the General Installation Inspection section of this manual. 6. Air flow adjustment MUST be made to ensure appliance efficiency. This should be done at the appliance exhaust outlet with a velocity meter or draft gauge. 7. On gas-fired furnaces, a barometric draft control must be installed to regulate proper air flow and fluctuations in the system's air flow during operation. Fluctuations may come from wind loads on the outlet of the power venter or house depressurization during windy days. 8. The air pressure switch must be adjusted to assure safe operation. Failure to adjust the air pressure switch as specified later in these instructions, could lead to improper operation of the venting system and furnace which will result in product damage, personal injury, or death. INSTALLATION OF SWG POWER VENTER WARNING: Failure to install, maintain and/or operate the power venting system in accordance with the manufacturer's instructions may result in fire, personal injury, or death. PROCEDURE FOR CALCULATING TOTAL EQUIVALENT PIPE LENGTH IN FEET 1. Calculate the total equivalent feet for each type of fitting used in the venting system from Table 1 below. 2. Calculate the total amount of feet for the straight lengths of vent pipe. 3. Add the equivalent feet for the fittings with the total amount of feet of straight lengths. This will approximate the total equivalent feet of the vent system. The total equivalent feet must be less than the maximum equivalent vent length as shown in OEM instructions. Table 1 EQUIVALENT LENGTH (FEET) OF VENT PIPE FOR VENT PIPE FITTINGS VENT PIPE FITTINGS 90° ELBOW 45° ELBOW 4" VENT PIPE DIAMETER 7 4 Example: System Pipe Size = 4" Step 1 Two 4" 90° Elbows @ 7 feet each = 14 Ft. Step 2 Ten 2 Foot Lengths of 4" Pipe = 20 Ft. Step 3 Total Equivalent Feet = 14 Ft. + 20 Ft. = 34 Ft. Page 2 Figure 1 Diagram A INSTALLATION FOR THE SWG POWER VENTER 1. Remove power venter from box and inspect unit for damage. If the carton has been crushed or mutilated, check unit very carefully for damage. Rotate blower wheel to insure that the motor and blower wheel rotate freely. DO NOT install if any damage is apparent. Figure 2 2. Location of the termination of the venting system should be installed in accordance with the National Fuel Gas Code, ANSI Z223.1, CGA Standards B149.1-M91, B149.2-M91, manufacturer's recommendations, and/or local codes which are applicable. See requirements below or refer to installation location Diagram A for typical locations. a. The exit termination of mechanical draft systems shall not be less than 7' above grade when located adjacent to public walkways. b. A venting system shall terminate at least 3' above any forced air inlet located within 10'. For Canadian applications, a venting system shall terminate more than 6' away from a mechanical air supply inlet. c. The venting system of other than a direct vent appliance shall terminate at Figure 3 least 4' below, 4' horizontally from, or 1' above any door, window or gravity air inlet into the building. For Canadian applications, according to CAN/CGA Standards B149.1-M91 and B149.2M91, 12" clearance is required for inputs up to and including 100,000 BTU/HR and 3' for inputs exceeding 100,000 BTU/HR. d. The vent termination of a direct vent appliance with an input of 50,000 BTU's per hour or less, shall be located at least 9" from any opening through which vented gases could enter the building. With an input over 50,000 BTU's per hour, a 12" termination clearance shall be required. e. The vent termination point shall not be installed closer than 3' from an inside corner of an L-shaped structure. f. The vent termination should not be mounted directly above, or within 3' horizontally from an oil tank vent or gas meter. g. The bottom of the vent terminal shall be located at least 12" above finished grade or maximum expected snow height. 3. After determining the location of the venting system termination point (See Diagram A), cut a square hole through the wall 1" larger than the outer pipe diameter of the power venter. (See Figure 1) 4. Seal the back side of the base plate around the outer pipe of the venter and the conduit with a bead of high temperature silicone sealant. (See Figure 3) Mount the power venter through the wall, keeping the outer pipe centered in the hole. (See Figure 1) Fasten the power venter to the outside wall with appropriate fasteners. Seal the edges of the power venter base plate to the wall with a high temperature silicone sealant. NOTE: If mounting the power venter through a combustible wall material and the flue gas temperature is above 400°F at the power venter inlet, line the square hole with a piece of corrosion resistant sheet metal or non-combustible material. The liner piece should be the same width as the wall section. (See Figure 1) The power venter has a maximum flue gas temperature of 550°F at the venter inlet. For installation through walls over 8 inches thick, use an SWG Series Extension Kit, Model PEK-4HD. 5. Remove the end pipe cover screws on the sides of the outside pipe and remove end pipe cover. Then mount the backing plate over the outer pipe and route the flexible conduit and pressure switch tube through the holes provided in the backing plate. Fasten the backing plate to the inside wall with appropriate fasteners. (See Figure 3) Re-install cover and end pipe screws. Page 3 Diagram B CONNECTING POWER VENTER TO APPLIANCE The venting system should be installed and supported in accordance with the National Flue Gas Code, ANSI Z223.1, CGA Standards B149.1-M91, B149.2-M91, or in accordance with any local codes. A vent pipe connector shall be supported for the design and weight of the material employed, to maintain clearances, prevent physical damage and separation of joints. If mounting venting system near combustible materials, refer to Diagram B for allowable installation clearances. Always check local code requirements for code restrictions. Route the vent pipe from the appliance to the power venter using the minimum number of elbows necessary. The horizontal section of the vent pipe should have a slight upward slope from the appliance to the power venter. For clearances to combustible materials, multiple appliance venting, and other installation requirements, refer to the National Fuel Gas Code ANSI Z223.1, CGA Standards B149.1-M91, B149.2-M91, and/or any applicable local codes or appliance manufacturer's installation instructions. Table 3 INSTALLATION CLEARANCE WITH SINGLE WALL VENT PIPE DOUBLE PIPE SYSTEM Allowable Inlet Temperature 400°F Or Less 400°F To 550°F 400°F To 550°F Clearance (A) 1/2" Minimum 1" Minimum 1/2" Minimum With Sheet Metal Liner SINGLE PIPE VENTING SYSTEM Allowable Inlet Temperature 400°F Or Less 400°F To 550°F 400°F To 550°F Clearance (A) 1/2" Minimum 1" Minimum 1/2" Minimum With Sheet Metal Liner NOTE: Vent pipe joints should be secured with at least three sheet metal screws. Use a PEK series extension kit or follow installation method below for a double pipe system. When the outer pipe of the SWG is extended over the inner pipe, use the double pipe guidelines for determining clearances. INSTALLATION USING TYPE B VENT PIPE 1. Using a hand crimper or a like device, crimp the inner pipe of the SWG power venter approximately 1" long. (See Figure 4) 2. Attach the vent pipe over the crimped end of the SWG power venter inner pipe. 3. Secure the vent pipe to the SWG power venter inner pipe with at least (3) three #8 sheet metal screws. Pre-drilling the holes through both pipes will allow easier fastening. Figure 4 Page 4 PEK-4HD EXTENSION KIT INSTALLATION INSTRUCTIONS (Optional) (Includes an air adjustment damper plate) 1. Remove the End pan from the SWG Venter. (See Figure 5) 2. Using a pair of sheet metal cutters, cut the Damper Plate Adjustment Bracket. (See Figure 6) Then remove the Damper Plate and Adjustment Bracket. 3. Install the Extension by starting the inner pipe into the attaching section first, then lightly tap the end of the inner and outer pipe into the attaching section until the rib on the crimped end touches the attaching pipe. The lock seam of the pipe should be on the top of the pipe. NOTE: The Extension Kit can be added onto the SWG Venter directly or by attaching equal lengths of pipe to the inner and outer pipes, then the Extension Kit can be added closer to the heating unit. 4. Make sure damper plate rotates freely, then fasten the outer pipe with at least (3) three sheet metal screws. INSTALLATION INSTRUCTIONS FOR CK-43F CONTROL KIT Designed for use with the SWG Series Power Venter for controlling Natural Gas and L.P. Gas Draft Induced appliances. ITEMS INCLUDED IN CK-43F CONTROL KIT: 1) Junction box with mounted air pressure switch and post purge relay/timer. 1) 2 Ft. Length of 1/4 inch aluminum tubing. 1) 1/4 inch tubing connector 1) Flexible conduit connector 1) 4" MG-1 Barometric Draft Control DRAFT CONTROL INSTALLATION 1. Install a vent pipe reducer or increaser, if needed, into the tee and fasten using sheet metal screws. (See Figure 7) 2. If using a Type B Vent Tee, the opening of the Tee, at the draft control mounting location, should be sealed with a high temperature sealant or equivalent. 3. Insert the draft control into the tee. The front face of the control MUST be plumb and the bearing surfaces MUST be level whether the control is on a horizontal, vertical or sloping flue pipe. Use a spirit level and level accurately. Secure the control in tee by using sheet metal screws. NOTE: Do not install the draft control in a vent pipe tee in the configuration as shown in Figure 8. MOUNTING JUNCTION BOX The junction box can be mounted near the venter or remotely mounted up to 100 feet away from the venter. (See Figures 9 & 10) 1. Remove one of the knockouts from the side of the junction box where the pressure switch is mounted. Install the flexible conduit connector onto the CK-43F junction box and secure with fastening nut. If remote mounting the CK-43F junction box, mount the flexible conduit connector onto a 2" x 4" installer supplied junction box. (See Figure 10) 2. Fasten the flexible conduit from the SWG Venter into the conduit connector. Mount the CK-43F junction box or installer supplied junction box onto the ...