FIELD CONTROLS, LLC - CONTRACTOR PRODUCTS Combustion Air Systems

Combustion Air Systems

Effects of Insufficient Combustion Air on Draft and Heating Systems:

For the proper operation and venting of gas or oil heating appliances, sufficient outside air must be supplied to the structure to make up for the air lost from venting heating appliances, fireplaces, clothes dryers, exhaust fans and other building air losses. Insufficient combustion air can cause major problems for proper draft and operation of both gas and oil heating systems. For years it has been assumed that when a heating appliance was located in an unconfined area, there was sufficient air for both ventilation and combustion. Today, in most cases that is not true! With new construction, standards for building insulation and energy efficient windows and doors have reduced the amount of air changes per hour. The combustion and make up air requirements in the codes are based on 1/2 air changes per hour. For newer homes and conversion of electrically heated homes, the air changes could be reduced to 1/3 or less air changes per hour. Air problems are most notable on the coldest days when heat loss is the greatest and there is a chance that windows or doors are closed for an extended period of time.
When installing new equipment or troubleshooting problem equipment, the first determination that needs to be made is whether the equipment is located in a confined or unconfined space.

In accordance with NFPA 31 and NFPA 54, an unconfined space is defined as follows: Any space whose volume is equal to or greater than 50 cubic feet per 1,000 BTU (or 20 BTU/Cubic Foot).
This is calculated on the sum of the total input ratings of all fuel burning appliances installed in that space. Only areas connected to the space that have no doors or with fully louvered doors can be considered part of the unconfined space. If the actual free area of the louvers is not known, wood louvers are assumed to have a 20% to 25% free opening. Metal louvers or grills are assumed to have 60% to 70% free opening.

According to NFPA 31 and NFPA 54, an Engineered system such as a CAS-3, 4, 4Jr., 6 or 7 may be used to overcome a confined space.

Calculating Confined Space

To determine the maximum total input firing rate
allowable in this room:
Boiler room 30 x 20 x 8 = 4,800 cu ft.
4,800 cu. ft. x 1,000 BTU ÷ 50 cu. ft. = 96,000 BTU
96,000 BTU x 1 GPH #2 fuel ÷ 140,000 BTU = 0.69 GPH
Result: If you fire greater than 0.69 GPH or 96,000 BTU, you will need additional combustion air.

To add air from an adjacent room, two openings between the room could be made 12 inches above the floor and 12 inches below the ceiling. The size of these openings is based on 1 square inch per 1,000 BTU input.

To add air directly from the outside of the structure, two openings could be made. The size of these openings is based on 1 square inch per 4,000 BTU input. The above requirements are based on guidelines in NFPA 31 or NFPA 54. Alternately, if operating in a confined space, additional air may be added by a duct to the outside, sized on 1 square inch per 5,000 BTU input.

OR...Add air from outside via a
Field Combustion Air System.

According to NFPA 31 and NFPA 54, an Engineered system such as a CAS-3, 4, 4Jr., 6 or 7 may be used to overcome a confined space.

Combustion Air Systems

CAS-1 and CAS-2 (Oil)

Direct Connect
The CAS-1 and CAS-2 Field Combustion Air Systems provide controlled amounts of outside air for proper combustion of oil heating appliances. These models are designed specifically for use with Aero, Beckett, Carlin, Riello, or Wayne burners.


Field AirBoot®


Field BigBoot®

4" Vacuum Relief Valve (VRV)

4" Intake Air Hood

FurnaceBoot™
When to use the CAS
• Too tight construction.
• Provide source of fresh air for combustion.
• CAS-1 and CAS-2 connect directly to oil burners.
• CAS-3, CAS-4, CAS-6 and CAS-7 are for multiple appliances or when direct connection is not possible.

Longer intake air runs require the use of larger diameter pipe between the VRV and the intake air hood. Use a pipe increaser at the VRV and a reducer at the intake air hood.

AirBoot® / FurnaceBoot™

Pipe Diameter

Maximum Linear Feet

Feet/Elbow

4"

44'

7'

5"

60'

9'

6"

90'

11'

Field BigBoot®

6"

30'

11'

7"

60'

12'

8"

100'

14'


Model Fuel Burner Appliance Input Components
CAS-1 Oil Beckett AFII, NX, Riello 40BF Up to 2 gph 4" Intake Air Hood 4" Vacuum Relief Valve
CAS-2B
CAS-2C
CAS-2W
Oil Beckett AFG or AF, Carlin EZ-1, CRD, FRD, Wayne MSR Up to 2 gph 4" Intake Air Hood 4" Vacuum Relief Valve Field AirBoot®
CAS-2B-90E Oil Beckett AF and AFG, warm air furnaces Up to 1.5 gph 4" Intake Air Hood 4" Vacuum Relief Valve FurnaceBoot™
CAS-2BB Oil Beckett SF, SMG, CF-500, CF-800 Up to 4.5 gph 6" Intake Air Hood 6" Vacuum Relief Valve Field BigBoot®
CAS-2B375 Oil Beckett CF-375 and AFG Up to 3.5 gph 6" Intake Air Hood 6" Vacuum Relief Valve Field BigBoot®
CAS-2CB Oil Carlin, 99-FRD, 100-CRD, 102-CRD, EZ-3 Up to 4.5 gph 6" Intake Air Hood 6" Vacuum Relief Valve Field BigBoot®


Combustion Air Systems CAS-4Jr.™

CAS-3 (Oil) and CAS-4 (Gas)

These models are designed to provide combustion air for appliances when direct connection to the burner is not possible (when the appliance is located in a confined space). According to NFPA 54 and NFPA 31, an engineered system such as a CAS-3, 4, 6 or 7 may be used to overcome the lack of air in a confined space. The CAS-3 is designed for use with oil appliances. The CAS-4 is for use with gas appliances with 24 VAC gas valve controls. The CAS-4MV is for use with 750mV power pile gas appliances. Each is designed for optimum safety and includes a proving device that won’t allow the burner to engage without the Fan-in-a-Can® operating. Multiple units or additional controls are required for multiple appliance installations. Each is equipped with a two speed control for enhanced versatility.

How the CAS-3 and CAS-4 work

When the thermostat calls for heat, the Fan-in-a-Can® engages and begins drawing air into the structure. When air flow is established, the pressure switch closes. The CAS sends a signal to the appliance, allowing the burner to fire. The Fan-in-a-Can® diffuses the outside air into the room near the burner to ensure adequate air for efficient combustion.

Model

Fuel

Application

Appliance Input

Components

CAS-3

Oil

Any oil heating appliance 120V

See Installation Spec Chart below

4" Intake Air Hood
Fan-in-a-Can®
6" to 4" Reducer
Restrictor Plate

CAS-4

Gas

24V Gas Appliance

See Installation Spec Chart below

4" Intake Air Hood
Fan-in-a-Can®
6" to 4" Reducer
Restrictor Plate

CAS-4MV

Gas

750mV Power Pile Gas Appliance

See Installation Spec Chart below

4" Intake Air Hood
Fan-in-a-Can®
6" to 4" Reducer
Restrictor Plate

CAS-4P

Gas

Boiler with automatic vent damper

See Installation Spec Chart below

4" Intake Air Hood
Fan-in-a-Can®
6" to 4" Reducer
Restrictor Plate
ADA-1



For multiple appliances, the following additional controls should be used.

Model

Description

CK-20FV/FG

Additional 30mV gas water heater control for use with CAS-4 and CAS-4Jr.

CAC-24

Additional 24 Volt appliance for use with CAS-4, CAS-4Jr., CAS-6, and CAS-7

CAC-120

Additional 120 Volt appliance for use with CAS-3, CAS-6, and CAS-7

CAS-4Jr.

Installation Specifications

Total Input of Appliance(s)

Max. Equivalent Feet of Installation

CAS-3 OIL

CAS-4, 4mV, 4P GAS

4" duct & hood w/ Restrictor

4" duct & 4" hood

6" duct & 6" hood

(gph)

(BTU/hr)

HI

LOW

HI

LOW

HI

LOW

-

50,000

300

300

300

300

300

300

.50

75,000

300

300

300

300

300

300

.75

100,000

300

300

300

300

300

300

.90

125,000

300

220

300

220

300

300

1.00

150,000

174

108

232

118

300

300

1.25

175,000

99

48

152

63

300

300

1.35

200,000

52

14

102

32

300

300

1.55

225,000

20

NA

68

13

300

239

1.75

250,000

NA

NA

45

NA

300

150

2.00

300,000

NA

NA

16

NA

300

53

2.50

350,000

NA

NA

NA

NA

193

8

2.75

400,000

NA

NA

NA

NA

109

NA

3.25

450,000

NA

NA

NA

NA

56

NA

CAS-4Jr.™

The Fan-in-a-Can, Jr. is designed for gas appliances up to 110,000 BTU/hr input. A 4” intake Air Hood (IAH) is included along with mounting brackets to secure the Fan-in-a-Can, Jr. to a wall. It may be used with a residential water heater with the addition of control kit CK-20 FV/FG.





Total Input of Appliance(s)

Maximum Equivalent Feet of Duct Pipe

BTU/hr

4" Pipe

5" Pipe

6" Pipe

50,000

230

300

300

60,000

160

300

300

70,000

105

300

300

80,000

70

214

300

90,000

40

122

300

100,000

25

76

180

110,000

15

46

80




Fan-in-a-Drum®

Combustion Air Systems

CAS-6 and CAS-7

The Fan-in-a-Drum® is a commercial product designed to deliver combustion air into the mechanical room, boiler room or furnace location to overcome a confined space or inadequate air supply. CAS 6 & 7 are dual volt units for oil or gas applications.


StarKap®

How the CAS-6 and CAS-7 Work

When the thermostat calls for heat, the Fan-in-a-Drum® engages and begins drawing air into the structure. When air flow is established, the pressure switch closes. The CAS sends a signal to the appliance, allowing the burner to fire. The Fan-in-a-Drum® diffuses the outside air into the room near the burner to ensure adequate air for efficient combustion.

Max. Equivalent Length of Pipe, Including StarKap®

CAS-6 OIL(gph)

CAS-6 GAS(BTU/hr)

8" duct

10" duct

12" duct

3

420,000

410

1253

3119

3.25

455,000

344

1051

2616

3.5

490,000

291

890

2217

3.75

525,000

249

760

1893

4

560,000

214

653

1627

4.25

595,000

185

584

1405

4.5

630,000

160

489

1217

4.75

665,000

139

424

1057

5

700,000

121

369

919

5.25

735,000

105

321

800

5.75

805,000

79

241

601

6

840,000

58

176

519

6.50

910,000

49

151

377

CAS-7 OIL(gph)

CAS-7 GAS(BTU/hr)

10" duct

12" duct

14" duct

6

840,000

469

1167

2523

6.5

910,000

381

948

2050

7

980,000

311

776

1678

7.5

1,050,000

256

637

1378

8.25

1,155,000

191

476

1029

9

1,260,000

142

354

766

9.75

1,365,000

104

260

563

10.5

1,470,000

74

186

403

11.25

1,575,000

51

127

274

12

1,680,000

31

78

207

12.75

1,785,000

15

39

114

12.88

1,803,000

13

33

72



Make-Up Air System


• To provide fresh air for combustion
• To solve stale air problems
• To increase fresh air changes
• To replace air exhausted by bathroom fans, laundry
dryers, range hood fans and other exhaust devices.

How the MAS Works

The Make-Up Air System connects the HVAC system to the outside to allow controlled amounts of fresh air to enter the system when needed. The system automatically senses pressure changes and a need for air flow and opens to bring a precise, metered amount of fresh air into the air handler. Here the cold air is tempered as it mixes with warm air in the return duct. The air is then heated and distributed through the home via the central duct system. When the need for air is fulfilled, the system closes to prevent further air infiltration. The system must be installed by a qualified heating and air conditioning professional and is adjustable for homes from 1000 to 4000 square feet. It does not require any electricity or maintenance.

 




SWG “Sealed Combustion System”

For New Installation or Upgrade of Existing SWG Systems

SWG Illus 1. SWG Power Vent System: The patented design provides 100% negative pressure to prevent CO leakage and maintain consistent appliance draft.
2. CK-Control Kit: Operates the venter and burner motor simultaneously with optional delay oil valve.
3. Combustion Air Tee: Provides a middle pipe to insulate between hot exhaust gases and cooler combustion air, reducing potential for condensation formation and allowing for connection to SWG series power venters.
4. RC Draft Control: Maintains manufacturer’s overfire draft specifications for standard oil burning equipment.
5. Field AirBoot®: Allows for direct connection and quick setup on standard oil burners. Patented design provides accurate combustion airflow control for optimal operation of the burner.
6. VRV - Vacuum Relief Valve: Ensures safe operation in case combustion air inlet becomes blocked for any reason, and can be used to temper intake air.
7. FurnaceBoot™: This airboot features a telescopic function that allows it to fit inside closed burner furnace cabinets 18"-24". It is designed specifically for the Beckett AFG Burner.
8. WMO - Safety Switch: Supplied with Control Kit.

Follow steps A through D to select the proper components for the SWG Sealed Combustion System. If an SWG is already installed, start at step B.

A. Size the Venter Choose the model that matches GPH Intake.
Model Max Oil GPH Intake Vent Pipe Intake Pipe
SWG-4 HD SWG-4 HDs 1.10 4" 4"
SWG-5 SWG-5s 1.85 5" 4"

B. Select the Combustion Air Tee Select the CAT to match the Power Venter.
Model Part# Description
CAT-4HD 46335601 Fits SWG-4HD, 4HDs
CAT-5 46335602 Fits SWG-5,5s
NOTE: Control Kits are required for operation of the SWG. Do not exceed maximum oil GPH input.

C. Select the Control Kit
Select the Control Kit to match the application.
Model Application & Description
CK-61 Any oil appliance / Electronic post purge
CK-62 Any oil appliance / Thermal post purge
CK-63 Any oil appliance / Electronic post purge or operates the venter and burner motor simultaneously w/ optional delay oil valve

D. Select the Combustion Air System
Select the model that matches the burner.
Model Burner Appliance Input Components
CAS-1 Beckett AFII Burners, Riello 40BF, NX Up to 2 gph 4" Intake Air Hood 4" Vacuum Relief Valve
CAS-2B CAS-2C CAS-2W Beckett AFG or AF Burners Carlin EZ-1, CRD, FRD Wayne MSR Up to 2 gph 4" Intake Air Hood 4" Vacuum Relief Valve Field AirBoot®
CAS-2B90E Beckett AFG and AF Warm Air Furnaces Up to 1.5 gph 4" Intake Air Hood 4" Vacuum Relief Valve FurnaceBoot™



Control Kits

(Required to Operate
SWG/CV Power Venters)


Control Kits (CK) control the operation of SWG/CV Power Venters. See the chart below to select the proper kit for your application. Control Kits can also control the operation of Field Draft Inducers.

Applications
Model Draft Proving Switch Gas Pressure Switch Secondary Safety Switch Thermal Post Purge Adjustable Electronic Post Purge Fixed Post Purge Draft Control RJR-6
Oil
CK-61 All oil-fired systems.
Has adjustable electronic post purge.
CK-62 All oil-fired systems. Has thermally activated post purge.
CK-63 All oil-fired systems. (May require optional delay oil valve for simultaneous burner operation.)
Gas - 30 mv
CK-20FV
CK-20FG
30 millivolt gas-fired water heaters and gas-fired pool or spa heaters with a manual or internally mounted thermostat.
CK-21 Gas-fired instantaneous water heaters with pressure tap port in the burner manifold.
Gas - 24 v
CK-41F
CK-41P**
Furnaces, boilers, unit heaters and water heaters operating with a 24 VAC gas valve without factory mounted spillage switches.
CK-43 Draft induced 24 VAC gas valve systems. Includes a 4" MG-1 draft control and post purge.
Gas - 750 mv
CK-81*** 750 millivolt operated boilers, furnaces, water heaters, pool or spa heaters and gas-fired fireplaces when operated with a remote mounted thermostat or on/off switch. Operated off a 24 VAC circuit.
Gas - Co-venting Multiple Appliances
CK-91FV
CK-91FG
Gas-fired draft induced 24 VAC gas valve systems and a 30 millivolt operated water heater. Includes a 4" MG-1 draft control and post purge.
CK-92FV
CK-92FG
CK-92FVP**
CK-92FGP**
Gas-fired furnace or boiler and a 30 millivolt operated water heater. Includes post purge.
* Control Kits are ETL approved accessories when used in conjunction with the SWG Power Venter. ** Plugs into 24v electric damper *** A secondary safety switch should be used with a CK-81 F = Fixed Post Purge FV= right hand threaded TCA Safety Switch FG= left hand threaded TCA Safety Switch

Control Kit Installation

CK-41 CK-63
CK-41F mounted at venter. For use with a 24 VAC, gas-fired system (shown with cover off).

CK-63 remote mounted. For use with 120 VAC oil-fired systems. Electronic post purge is included (shown with cover off).