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EXHAUSTO - Presentation

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1 EXHAUSTO - Presentation

2 The First Fan The first chimney fan - a “first” worldwide and the foundation of EXHAUSTO’s existence

3 A 50-year Old Company Founded in 1957
300,000+ sq.ft. of manufacturing and administration Family-owned, well-managed with a very strong balance sheet. High-tech ISO 9001 certified manufacturing facilities

4 A Look Into the Plant

5 Automation Via Robots

6 Certifications

7 “Worldwide” Distribution
Subsidiaries in USA, England, Germany, Norway and Sweden Authorized distributors in Belgium, Netherlands, Finland, France, Iceland, Switzerland, Spain, Austria and Japan.

8 EXHAUSTO in North America
In Atlanta since 1990 16,000 sq.ft. office and warehouse 86 authorized sales and service offices in USA and Canada.

9 EXHAUSTO in North America
95% of products are in stock ready for immediate shipping. Inventory level of $800-1,000,000 Complete parts inventory

10 Code Development and Publication
Involved in code and standard development (NFPA 54, NFPA 211 etc.) Publish articles about venting and venting design. Make over 30 presentations at regional ASHRAE chapters and other organizations every year. Training and education of Building Officials.

11 EXHAUSTO: Venting Design

12 Appliance Categories ASHRAE Equation & Chimney Pressures Common Code Violations Chimney Automation Systems Combustion Air Supply Boiler Room Simulator Overdraft Damper System Dryer Venting

13 Appliance Categories ANSI Venting Categorization

14 Appliance Categorization
Atmospheric Fan Assisted Forced Draft Scotch Marine Draft Hood Draft Diverter I III Negative Positive Fan Assisted (high efficiency) Condensing II IV

15 Acceptable Venting Material
Atmospheric Fan Assisted Forced Draft B-Vent Masonry B-Vent Masonry (interior) UL103 P-Stack Welded Steel I III Negative Positive Fan Assisted (85+ efficiency) Condensing II IV (90+ efficiency) AL29-4C single wall CPVC (tested with appliance) (85 – 90 % efficiency) AL29-4C double wall AL29-4C double wall

16 Masonry Chimney Liners
Reference: ANSI Z and , NFPA Atmospheric Fan Assisted Forced Draft Clay tile liner Clay tile liner (interior chimney) Steel liner (exterior chimney) Exception: Clay tile liner can be used with exterior chimney if an Atmospheric appliance is connected to the same chimney Positive pressure steel liner Ex. Welded steel, Inner liner of pressure stack I III Negative Positive II IV Fan Assisted (85+ efficiency) Condensing AL29-4C Liner AL29-4C Liner

17 Z223.1-51 (Venting of equipment)
7.3.1 Minimum Safe Performance A venting system shall be designed and constructed so as to develop a positive flow adequate to remove flue or vent gases to the outside atmosphere. 7.3.2 Equipment Draft Requirement A venting system shall satisfy the draft requirement of the equipment in accordance with the manufacturer’s instructions.

18 Chimney Design Equation
1996 Edition INPUTS: Appliance Type Fuel Type MBH Input CO2% in Flue Gases Flue Gas Temperature Ambient Temperature Altitude Flue Layout Theoretical Draft (-) Pressure Losses (+) + RESULTS: Flue Gas Volume Flue Gas Velocity Theoretical Draft Total Pressure Losses Appliance Outlet Pressure Outlet Pressure

19 Boiler Efficiency versus Draft

20 Annual Draft Variations

21 Chimney Draft – Steady-State

22 Draft Variations During Operation
Vent = 30’ vert./10’ horiz., 18” diam. 4 Fan-assisted Cat I boilers with 1,000 MBH input each Constant ambient of 60°F Draft requirement: 0.05”WC

23 Modulating Boiler Systems
Gravity Stack Design

24 Chimney Automation Systems

25 CASV – Chimney Automation System

26 CASI – Chimney Automation System

27 Modulating Boiler Systems
Controlled Draft Design

28 Ordinary Stack Material Cost EXHAUSTO System Material Cost
First Cost Analysis Ordinary Stack Material Cost EXHAUSTO System Material Cost Item Qty List Price 20" pressure stack 35' $ 5,775 12" pressure stack 50' $ 4,600 16" pressure stack 5' $ 12" Tee 1 $ 14" pressure stack $ 12" end cap 2 $ 10" pressure stack $ 12" x 8" reducing Tee 4 $ 1,240 20" Tee $ 20 " end cap $ 20" x 8" reducing Tee $ 20" x 16" tapered reducer $ 16" x 8" reducing Tee $ 16" x 14" tapered reducer $ 14" x 8" reducing Tee $ 14" x 10" tapered reducer $ 10" x 8" reducing Tee $ 10" end cap $ 20" stack cap $ Total $ 11,210 $ 6,445

29 National Fuel Gas Code NFPA 54 IFGC ANSI Z 223.1 Horizontal distances
Large stack area Self venting connector rise Fan Min capacities Different type of appliances Existing masonry chimneys Location of draft inducer

30 Common Code Violations
Chimney Automation System (NFPA 54) Z (Venting of Equipment) The total horizontal distance of a vent plus the horizontal vent connector serving draft hood-equipped appliances shall not be greater than 75 % of the vertical height of the vent. Table 13.1 and The total horizontal length of the vent plus the vent connector for a single Category I appliance is: 100% of the height (vent 6 – 30 ft high); 30 ft (vent 31 – 50 ft high); 50% of the height (vent 51 – 100 ft high)

31 Common Code Violations
Chimney Automation System (NFPA 54) Z (Sizing of Venting Systems) The maximum vent connector horizontal length shall be 18 in./in of connector diameter. The length of the common vent manifold shall not exceed 18 in./in. of common vent diameter. The horizontal length of the common vent offset shall not exceed 18 in./in. of common vent diameter.

32 Common Code Violations
Chimney Automation System (NFPA 54) Z223 Sizing Tables

33 Common Code Violations
Chimney Automation System (NFPA 54) Z (Sizing of Venting Systems) Where two or more appliances are connected to a vertical vent or chimney, the flow area of the largest section of vertical or chimney shall not exceed seven times the smallest listed appliance categorized vent areas, flue collar area, or draft hood outlet area unless designed in accordance with approved engineering methods.

34 Common Code Violations
Chimney Automation System (NFPA 54) Z (Venting of Equipment) Vent connectors serving Category I appliances shall not be connected into any portion of mechanical draft systems operating under positive static pressure, such as those serving Category III or Category IV appliances.

35 Common Code Violations
Chimney Automation System (NFPA 54) Z Masonry chimneys shall be built and installed in accordance with NFPA 211. (NFPA 211) 4-2.2 Masonry chimneys shall be lined….Cat II, III and IV gas appliances - special gas vents listed for installation within masonry chimneys.

36 Common Code Violations
+ - (NFPA 54) Z (Mechanical Draft Systems) Forced draft systems and all portions of induced draft systems under positive pressure during operation shall be designed and installed so as to prevent leakage of flue or vent gases into a building. Vent connectors serving equipment vented by natural draft shall not be connected into any portion of mechanical draft systems operating under positive pressure.

37 Side-wall Venting Z223.1-51-2002 (Venting of Equipment)
Mechanical Draft Systems. The exit terminals of mechanical draft systems shall be not less than 7ft above grade where located adjacent to public walkways.

38 Side-wall Venting Z223.1-56 (Venting of Equipment)
7.8 Venting System Location. (a) A Venting system shall terminate at least 3 ft (0.9 m) above any forced air inlet located within 10 ft (3.1 m). Exception No. 1: This provision shall not apply to the combustion air intake of a direct-vent appliance. Exception No. 2: This provision shall not apply to the separation of circulating air inlet and flue gas discharge of listed outdoor appliances.

39 Side-wall Venting Z223.1-56 (Venting of Equipment)
7.8 Venting System Location. (b) The venting system of other than a direct-vent appliance shall terminate at least 4 ft (1.2 m) below, 4 ft (1.2 m) horizontally from, or 1 ft (30 cm) above any door, window, or gravity air inlet into any building. The bottom of the vent terminal shall be located at least 12 in. (30 cm) above grade.

40 Roof-top Venting Z (Venting of Equipment)

41 Gravity Stack Terminations
NFPA Fig. 12a NFPA Fig. 12b

42 Gravity Stack Terminations
Experience Shows

43 Mechanical Draft Systems Defined
Z Standard for Venting of Equipment Mechanical draft systems shall be listed and shall be installed in accordance with the terms of their listing and both the appliance and the mechanical draft system manufacturer’s instructions. Gas utilization equipment requiring venting shall be permitted to be vented by means of mechanical draft systems of either forced or induced draft design. Exception: Incinerators Where a mechanical draft system is employed, provision shall be made to prevent flow of gas to the main burners when the draft system is not performing so as to satisfy the operating requirements of the equipment for safe performance

44 Mechanical Draft Systems Defined
IFGC - Section 503 (Venting of Equipment) Mechanical draft. Chimney venting systems using mechanical draft shall be sized in accordance with approved engineering methods. Z Standard for Venting of Equipment Size of Chimneys. Chimney venting systems using mechanical draft shall be sized in accordance with approved engineering methods.

45 Why Chimney Automation?
Enhance Draft for Efficient Boiler Operation Reduce Emissions Clean Up Aesthetics Reduce Heating Cost Improve Safety

46 CASV – Chimney Automation System

47 RSV – Chimney Fan 3/16 “ Cast aluminum housing
Hinged for easy service and cleaning Direct drive Class H insulated motor - eliminates the need for secondary fan cooling Maintenance free 575 ºF Continuous Duty UL 378 – Draft Equipment The RSV fan can vent all appliance categories with or without barometric dampers Simple design with few components reduces the risk of failure and simplifies service RSV is of Type B, Spark Resistant Construction

48 RSV – Chimney Fan Cast aluminum impeller wheel 500-4000 CFM
Permanently attached balance weights Cooling vane mounted on the back of the impeller RSV are single phase 120 V AC RSV are three phase 208 or 400 V AC

49 Fan – Motor Characteristics
Source: NEMA

50 CASI – Chimney Automation System

51 RSIB – Power Venter SS16 construction Removable access door
Direct drive Class A insulated motor - eliminates the need for secondary fan cooling Maintenance free 575 ºF Continuous Duty UL 378 – Draft Equipment The RSIB fan can vent category I, II, III and IV appliances with or without barometric dampers Simple design with few components reduces the risk of failure and simplifies service RSIB is of Type B, Spark Resistant Construction

52 Installation Options - RSIB

53 EBC 30 Control - Functions
Quick reaction to changes in draft conditions “Plug-n-Play” Priority function Bearings cycle Rotation check Handles two 0-10VDC outputs and one 0-120VAC output Interlock with up 10 appliances Numerous programmable features 80% software and 20% hardware guarantees future improvements without replacing control

54 EBC 30 Control - Design Fan Control Module (optional) Main Board
Display and processor Relay Module (optional)

55 EBC 30 – Control Characteristics
Other Controls Quick reaction to changes in draft conditions (max. 20 seconds) Low draft cut-off Slow reaction to changes in draft conditions (up to 90 seconds) Low draft cut-off High draft cut-off

56 RSIF – Power Venter

57 New RSIF Power Venter Three Models 440, 740, & 1000 cfm
Rated to 400°F non-condensing applications Forward inclined impeller. Statically and dynamically balanced. Insulated housing in galvanized steel Hinged fan housing easily opens to provide easy access to duct and impeller Direct drive, variable speed, TEFC motor located outside housing for easy access.

58 New Products – EBC 5 Features
Controls RSV , all RSIF Fans, and BESB250 Activates on a V AC or DC signal Built-in Fan Speed Control Time delay and active response to avoid nuisance alarms Pre and Post – Purge cycle No built-in PDS

59 CASV Applications – Stack Downsizing
Hazen High School – Renton, WA Soldier Field - Chicago, IL

60 CASV Applications - Aesthetics
Rigel – South San Francisco, CA Getty Center – Los Angeles, CA

61 CASV Applications - Aesthetics
SBC Center – San Antonio, TX

62 CASV Applications National Landmarks Hospitals Resorts Museums Stadiums Arenas Schools

63 MODS Modulating Overdraft Damper System

64 Modulating Overdraft Damper System

65 MODS Components MDF Damper Sizes – 12 in. to 48 in. diameters
Multiple opposed blades made of 16 gauge type 316 stainless Pressure stack flange connections Rated to 700°F EBC30 Prime function Additional over-pressure protection for Forced-draft boilers

66 Kaiser Center - Oakland, CA Wells Fargo - Great Falls, MT
MODS Applications Kaiser Center - Oakland, CA Wells Fargo - Great Falls, MT Markham Road - Toronto

67 MCAS Mechanical Combustion Air Supply

68 Codes and Standards Code Requirements – Air for Combustion and Ventilation Z Outdoor Combustion Air. Two Permanent Openings Method. Two permanent openings, one commencing within 12 in. of the top and one commencing within 12 in. of the bottom of the enclosure, shall be provided. The openings shall communicate directly, or by ducts, with the outdoors or spaces that freely communicate with the outdoors as follows: Where directly communicating with the outdoors or through vertical ducts, each opening shall have a minimum free area of 1 in.²/4000 Btu of total input rating of all equipment in the enclosure. (2) Where communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of not less than 1in.²/2000 Btu of total input rating of all equipment in the enclosure

69 Codes and Standards Code Requirements – Air for Combustion and Ventilation Z Outdoor Combustion Air. One Permanent Opening Method: One permanent opening, commencing within 12 in. of the top of the enclosure, shall be provided. The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces that freely communicate with the outdoors and shall have a minimum free area of the following: 1 in.²/3000 Btu of the total input rating of all equipment located in the enclosure, and Not less than the sum of the areas of all vent connectors in the space.

70 Codes and Standards Sizing of Gravity Louvers Louver(s) Sizing:
1 sq.in./4000 Btu per louver 4000 MBH = 1000 in2 of free area per louver. Typical louver has 30-60% free area. Depending on louver design actual louver size will be: Using 45% free area louvers = Two 5’ x 4’ louvers 2000 MBH 2000 MBH

71 Codes and Standards Code Requirements – Air for Combustion and Ventilation – Mechanical Combustion Air Supply (MCAS) Z 8.3.6 Mechanical Combustion Air Supply. Where all combustion air is provided by a mechanical air supply system, the combustion air shall be supplied from outdoors at the minimum rate of 0.35 ft³/min per 1000 Btu/hr for all appliances located within the space. Where exhaust fans are installed, additional air shall be provided to replace the exhausted air. Each of the appliances served shall be interlocked to the mechanical air supply system to prevent main burner operation where the mechanical air supply system is not in operation.

72 Codes and Standards Sizing of Mechanical Combustion Air Louver Sizing:
Engineered using ASHRAE Chimney Design Equation. Flue Gas Volume corrected for temperature = 1,400 cfm of combustion air 1400 cfm/500 fpm = 2.8 ft2 of louver free area Using a 45% free area louver = One 3’ x 2’ louver 2000 MBH 2000 MBH

73 MCAS Mechanical Combustion Air Supply

74 MCAS – Modulating Combustion Air Supply System

75 MCAS Components – BESF/BESB Fan
Seven Models 450 – 5500 cfm Fan can be mounted indoors or outdoors. Impeller - statically and dynamically balanced. Insulated housing in galvanized steel Hinged fan housing easily opens to provide easy access to duct and impeller Direct drive, variable speed, TEFC motor located outside housing for easy access. Variable Frequency Drive is used on three phase models (VFD should be located inside the building).

76 MCAS Components – SFTA Fan
Seven Models 1,500 – 30,000 cfm Fan can be mounted indoors Impeller – cast allunimum. Housing in steel Direct drive, variable speed, TEFC motor located outside housing for easy access. Variable Frequency Drive is used on three phase models (VFD should be located inside the building).

77 EBC30 Modulating Control
Chimney Automation System Modulating Combustion Air Supply System

78 MCAS Mechanical Combustion Air Supply

79 SBC Center – San Antonio, TX
Two 16 inch ducted combustion air inlets Instead of Two 10 foot high by 15 foot long Louvers

80 Lifetime Fitness – Savage, MN

81 Marriott Waterfront – Annapolis, MD
One 24 inch ducted combustion air Instead of one 90 ft.² louver

82 MDVS Modulating Dryer Venting System

83 Why a MDVS? To extend the exhaust duct length of a single or multiple dryers To common exhaust multiple dryers To meet codes especially fire ratings To reduce drying times To reduce energy costs

84 Types of Clothes Dryers
Type 1 dryers: “Domestic” dryers to be used primarily in a family living environment. Residences Individual apartments or condominiums Type 2 dryers: “Public” dryers designed to be used in business with direct intercourse of the function with the public. Laundromats Laundry rooms (apartment complexes, dormitories, etc.) Business laundries (hotels, hospitals, health clubs, etc.)

85 Typical Dryer Manufacturer’s Requirements
Where possible use a single exhaust duct per dryer Dryers are to run with a positive outlet pressure. Type 1 dryers between and inch W.C. Type 2 dryers between and inch W.C. Maximum exhaust duct length: Type 1 dryers = 35 equiv. feet (each elbow = 5 feet) Type 2 dryers = 15 equiv. feet (each elbow = 5 feet)

86 Typical Dryer Manufacturer’s Requirements for Multiple Dryers
Vertical venting must not exceed 8 feet and can include up to 3 elbows Horizontal venting cannot exceed 15 feet and 1 elbow.

87 Use an MDVS to Extend Exhaust Duct
Exhaust duct can be extended to almost any length No need to locate dryer near a secluded outdoor wall Reduce drying times by holding the correct outlet pressure

88 Common Exhausting of Multiple Dryers
Common horizontal duct diameter is sized with maximum 0.10 inch W.C. pressure drop Pressure drop in main exhaust shaft is only limited by fan’s total pressure capability Cleanouts must be provided in the common horizontal as well as the main exhaust shaft for removal of lint The BESB fan can be located anywhere down-stream of the last dryer

89 Common Exhausting of Multiple Dryers
By definition only Type 2 dryers should be used for this application Connector from dryer outlet to common horizontal is metal duct with smooth interior finish Connector diameter = dryer outlet diameter Max connector length = 15 equivalent feet Connector to be attached to common horizontal at no greater than 45°

90 Use an MDVS for Multiple Dryer Exhausting
Multistory exhausting of dryers Common exhausting of multiple dryers

91 Multistory Exhausting of Dryers
Type 1 or Type 2 dryers If main exhaust shaft does not need to be fire rated – attach connector to main shaft at 45° as previously shown If main exhaust shaft does need to be fire rated – attach connector via a 22 inch subduct riser as shown Main exhaust shaft and subduct riser must be made of appropriate materials to meet local codes In order to offset the subducts, a square or rectangular main exhaust shaft should be considered

92 Main Issues when Common Exhausting Dryers
For multistory dryer systems where the 22 inch subduct is used to maintain fire rating, a fan MUST BE USED and it must be in operation at all times to comply with code requirements IBC 2006 Penetrations of shaft enclosures. Shaft enclosures that are permitted to be penetrated by ducts and air transfer openings shall be protected with approved fire and smoke dampers installed in accordance with their listing. Exceptions: 1. Fire dampers are not required at penetrations of shafts where: 1.1 Steel exhaust subducts extend at least 22 inches (559 mm) vertically in exhaust shafts pro-vided there is a continuous airflow upward to the outside. 2. In Group B and R occupancies, equipped throughout with and automatic sprinkler system in accordance with Section smoke dampers are not required at penetrations of shafts where: 2.1. Kitchen, clothes dryer, bathroom and toilet room exhaust are installed with steel exhaust subducts, having a wall thickness of 0.019(0.48 mm); and 2.2 That extend at least 22 inches vertically; and 2.3 An exhaust fan is installed at the upper terminus of the shaft, that is powered continuously in accordance with Section , so as to maintain a continuous upward airflow to the outside.

93 Multistory Exhausting of Dryers
Dryer is connected to subduct riser using a transition duct Type 1 dryers - total equivalent feet of subduct riser plus transition duct = 25 feet Type 1 dryers can use an approved flexible metal duct of max 8 feet Type 2 dryers – total equivalent feet of subduct riser plus transition duct = 15 feet

94 Multistory Exhausting of Dryers
Main exhaust shaft is made of smooth (fire-rated) material Main exhaust shaft sized to max 0.10 inch W.C. pressure drop Access door or cleanout to be located at bottom of main exhaust shaft for lint removal BESB fan can be located anywhere above top most dryer

95 Main Issues when Common Exhausting Dryers
No dampers (back-draft dampers, fire dampers) or baffles can be used IN the duct system unless approved by the dryer manufacturer. An approved back-draft damper can be used at the termination of the exhaust duct. Exhaust system must be able to unload so that off dryers will not be drawn into a deep negative The pressure drop between dryers must be maintained less than 0.10 in W.C.

96 MDVS versus Single Speed
ETL Listed mechanical dryer exhaust system Usually runs at low rpm = low power Uses little to no conditioned air = low additional building heat or A/C Single Speed No listing for lint-laden air Runs at full rpm 24 hr/day X 365 days/yr = high power Uses a large quantity of conditioned air = large additional building heat and A/C

97 Recommended Diversity Factors
Application Number of Dryers per Exhaust Shaft Diversity Factor Common Exhausting 1 - 7 100 % 8 - 14 90 % 15 - up 80 % Multistory Exhausting (One dryer per apartment) 1 - 5 6 - 10 70 % 60 % 20 - up 50 %

98 MDVS versus Single Speed
20 Dryer Multistory Apartment 200 cfm X 20 X 50% = 2000 cfm MDVS Single Speed Savings Fan Power 41 KW/yr $4 /yr 4368 KW/yr $437 /yr $434 /yr Loss of heated air 1,454,200 (BTU/yr) $15 /yr 155,520,000 $1,555 /yr $1540 /yr Loss of A/C air (sensible only) 824,100 $5 /yr 88,128,000 $557 /yr $552 /yr Location = Atlanta, GA (3000 DDH, 1700 DDC) Power = $0.10 per KW/h Heating = $1.00 per therm A/C = .75 KW/ton X $0.10 per KW/h Total Annual Savings = $2526

99 MDVS – Mechanical Dryer Venting System

100 MDVS Components - BESB Fan
Four Models 1200 – 5500 cfm Cast aluminum, backward curved impeller reduces lint build-up. Statically and dynamically balanced with permanently attached balancing weights. Insulated hinged fan housing easily opens to provide easy access to duct and impeller Direct drive with variable speed TEFC motor located outside housing for easy access. Frequency drive should be located inside the building. ETL Listed to UL705 with special consideration for operation with lint-laden air

101 Mechanical Dryer Venting Systems

102 ABC’s of the MDVS A Aesthetics B Back Pressure C Cost reduction
Exhaust your dryers out a less visible wall Locate dryers where you want B Back Pressure Maintain the back pressure required by the manufacture to keep drying time down and reduce the risk of fires C Cost reduction Reduce the size of the exhaust vent Reduce operating costs by keeping drying times down

103 MCAS Modulating Combustion Air Supply for Dryers

104 Why MCAS for Dryers? Make-Up Air. Z223.1-2002 9.4 Clothes Dryers.
Provisions for Make-Up Air. Provisions for make-up air shall be provided for Type 2 clothes dryers, with a minimum free area of 1 sq.in. for each 1000 Btu per hr total input rating of the dryer(s) installed.

105 Manufacturer’s Requirement
National Fuel Gas Code requires a minimum free area opening of 1 sq.in./1000 Btuh Most manufacturers require even larger – approximately 1 sq.in / 700 Btuh. Ex. A twin 30# tumbler dryer with a total input of 204,000 Btuh (1100 cfm) requires a minimum 2 sq.ft. free area opening. Most laundry facilities have problems with make-up air. The industry believes it is one of their biggest problems.

106 MCAS Components – SFTA Fan
Seven Models 1,500 – 30,000 cfm Fan can be mounted indoors Impeller – cast allunimum. Housing in steel Direct drive, variable speed, TEFC motor located outside housing for easy access. Variable Frequency Drive is used on three phase models (VFD should be located inside the building).

107 Marriott Waterfront – Annapolis, MD
One 24 inch ducted combustion air inlet Instead of One 90 ft.² louver

108 Simulators CASV / MCAS MDVS

109 Thank You!


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