100208043_2000004587_Rev Y
Installation & Operation Manual
Models: 751 - 6001
Series: 100 - 101 & 110 - 111
WARNING This manual must only be used by a qualified heating installer / service
technician. Read all instructions, including this manual and the Crest Service Manual, before installing.
Perform steps in the order given. Failure to comply could result in severe personal injury, death, or substantial property damage.
Save this manual for future reference.
Contents
HAZARD DEFINITIONS .................................................. |
2 |
PLEASE READ BEFORE PROCEEDING..................... |
3 |
THE CREST -- HOW IT WORKS................................. |
4-5 |
RATINGS .......................................................................... |
6 |
1. DETERMINE BOILER LOCATION |
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Clearances......................................................................... |
7 |
Provide Air Openings to Room .......................................... |
8 |
Flooring and Foundation................................................... |
8 |
Vent and Air Piping ............................................................ |
8 |
Prevent Combustion Air Contamination............................. |
8 |
Using an Existing Vent System to Install a New Boiler |
..... 9 |
Corrosive Contaminants and Sources ............................... |
9 |
Removing a Boiler from Existing Common Vent.............. |
10 |
Remove Boiler from Wood Pallet..................................... |
11 |
Combustion and Ventilation Air Requirements........... |
12-13 |
2. GENERAL VENTING |
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Direct Venting Options - Sidewall Vent............................ |
14 |
Direct Venting Options - Vertical Vent .............................. |
14 |
Direct Venting Options - Vert. Vent, Opt. Rm Air............. |
14 |
Direct Venting Options - Vert. Vent, Sidewall Air............. |
14 |
Install Vent and Combustion Air Piping ........................... |
15 |
Air Inlet Pipe Materials................................................ |
15 |
Vent and Air Piping .......................................................... |
16 |
Air Intake / Vent Connections .......................................... |
16 |
Min./Max. Combustion Air & Vent Piping Lengths........... |
18 |
Vent and Air Piping .......................................................... |
19 |
Common Venting ............................................................. |
20 |
PVC/CPVC.................................................................. |
20-21 |
Polypropylene................................................................... |
22 |
3. VERTICAL DIRECT VENTING |
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Vent/Air Termination - Vertical......................................... |
23 |
Determine Location..................................................... |
23 |
Prepare Roof Penetrations......................................... |
23 |
Termination and Fittings........................................ |
23-24 |
Multiple Vent/Air Terminations.................................... |
24 |
4. SIDEWALL DIRECT VENTING |
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Vent/Air Termination - Sidewall................................... |
25-27 |
Determine Location................................................ |
25-27 |
Prepare Wall Penetrations.......................................... |
27 |
Termination and Fittings............................................. |
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27 |
Multiple Vent/Air Terminations............................... |
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27-28 |
Room Air..................................................................... |
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28 |
5. HYDRONIC PIPING |
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System Water Piping Methods......................................... |
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29 |
Low Water Cutoff Device ................................................. |
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29 |
Chilled Water System....................................................... |
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29 |
Freeze Protection............................................................. |
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29 |
General Piping Information .............................................. |
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29 |
Circulator Sizing............................................................... |
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30 |
Near Boiler Piping Components....................................... |
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32 |
6. GAS CONNECTIONS |
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Connecting Gas Supply Piping ........................................ |
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37 |
Natural Gas...................................................................... |
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38 |
Pipe Sizing for Natural Gas........................................ |
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38 |
Natural Gas Supply Pressure Requirements |
............. 38 |
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Propane Gas.................................................................... |
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38 |
Pipe Sizing for Propane Gas...................................... |
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38 |
Propane Supply Pressure Requirements................... |
38 |
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Check Inlet Gas Supply .............................................. |
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39-40 |
Gas Valve Replacement .................................................. |
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40 |
7. FIELD WIRING |
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Line Voltage Connections................................................ |
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41 |
Low Voltage Connections ................................................ |
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42 |
Wiring of the Cascade...................................................... |
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43 |
8. CONDENSATE DISPOSAL |
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Condensate Drain ............................................................ |
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45 |
9. STARTUP ............................................................... |
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46-54 |
10. OPERATING INFORMATION |
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General........................................................................ |
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55-57 |
Cascade........................................................................... |
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58 |
Sequence of Operation.................................................... |
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59 |
Home Screen ................................................................... |
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60 |
11. MAINTENANCE |
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Maintenance & Annual Startup.............................. |
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61-65 |
12. DIAGRAMS |
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Ladder Diagrams................................. |
66,68,70, and 72 |
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Wiring Diagrams.................................. |
67,69,71, and 73 |
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Revision Notes.................................................. |
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Back Cover |
Hazard definitions
The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product.
DANGER
WARNING
CAUTION
CAUTION
NOTICE
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.
NOTICE indicates special instructions on installation, operation, or maintenance that are important but not related to personal injury or property damage.
2
Installation & Operation Manual
Please read before proceeding
WARNING |
Installer – Read all instructions, including |
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this manual and the Crest Service Manual, |
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before installing. Perform steps in the |
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order given. |
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User |
– This manual is for use only |
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by a |
qualified |
heating installer/ |
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service technician. Refer to the User’s |
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Information Manual for your reference. |
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Have |
this boiler |
serviced/inspected by |
a qualified service technician, at least annually.
Failure to comply with the above could result in severe personal injury, death or substantial property damage.
WARNING The California Safe Drinking Water and Toxic Enforcement Act requires the
Governor of California to publish a list of substances known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires businesses to warn of potential exposure to such substances.
This product contains a chemical known to the State of California to cause cancer, birth defects, or other reproductive harm. This boiler can cause low level exposure to some of the substances listed in the Act.
When servicing boiler –
NOTICE |
When calling or writing about the boiler |
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– Please have the boiler model and serial |
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number from the boiler rating plate. |
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Consider piping and installation when |
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determining boiler location. |
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Any claims for damage or shortage in |
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shipment must be filed immediately |
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against the transportation company by |
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the consignee. |
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Factory warranty (shipped with unit) does |
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not apply to units improperly installed or |
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improperly operated. |
WARNING
WARNING
WARNING
Failure to adhere to the guidelines on this page can result in severe personal injury, death, or substantial property damage.
If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.
This appliance MUST NOT be installed in any location where gasoline or flammable vapors are likely to be present.
WHAT TO DO IF YOU SMELL GAS
•Do not try to light any appliance.
•Do not touch any electric switch; do not use any phone in your building.
•Immediately call your gas supplier from a near by phone. Follow the gas supplier’s instructions.
•If you cannot reach your gas supplier, call the fire department.
•Installation and service must be performed by a qualified installer, service agency, or the gas supplier.
DO NOT install units in rooms or environments that contain corrosive contaminants (see Table 1A on page 9). Failure to comply could result in severe personal injury, death, or substantial property damage.
•To avoid electric shock, disconnect electrical supply before performing maintenance.
•To avoid severe burns, allow boiler to cool before performing maintenance.
Boiler operation –
•Do not block flow of combustion or ventilation air to the boiler.
•Should overheating occur or gas supply fail to shut off, do not turn off or disconnect electrical supply to circulator. Instead, shut off the gas supply at a location external to the appliance.
•Do not use this boiler if any part has been under water. The possible damage to a flooded appliance can be extensive and present numerous safety hazards. Any appliance that has been under water must be replaced.
Boiler water –
•Thoroughly flush the system to remove debris. Use an approved pre-commissioning cleaner (see Start-Up Section), without the boiler connected, to clean the system and remove sediment. The high-efficiency heat exchanger can be damaged by build-up or corrosion due to sediment.
NOTE: Cleaners are designed for either new systems or pre-existing systems. Choose accordingly.
Freeze protection fluids –
•NEVER use automotive antifreeze. Use only inhibited propylene glycol solutions, which are specifically formulated for hydronic systems. Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems.
3
The Crest - How it works...
1.Front access panels
Provides access to the controls compartment.
2.Top access panel
Provides access to the burner compartment.
3.Air pressure switch
The air pressure switch detects blocked flue/vent conditions.
4.Blower
The blower pulls in air and gas through the venturi (item 34). Air and gas mix inside the blower and is pushed into the burner, where they burn inside the combustion chamber.
5.Boiler drain connection
Location from which the heat exchanger can be drained.
6.Boiler inlet temperature sensor
The boiler inlet temperature sensor monitors system return water temperature. If selected as the controlling sensor, the control module will adjust the boiler firing rate so the inlet temperature matches the set point.
7.Boiler outlet temperature sensor
The boiler outlet temperature sensor monitors boiler outlet water temperature. If selected as the controlling sensor, the control module will adjust the boiler firing rate so the outlet temperature matches the set point.
8.Burner (not shown)
Single chamber design with a stress free metal fiber outer mesh and durable stainless steel structure. Provides firing rates up to 15:1 turndown (Model 751), 20:1 turndown (Models 1001 - 1251 and 2501 - 3501), 25:1 turndown (Models 1501 - 2001), 12:1 turndown (Model 4001) and 10:1 turndown (Models 5001 - 6001).
9.Condensate drain connection
The condensate drain connection provides a connection point to install a condensate drain line using flexible hose provided.
10.Control module (on control panel assembly)
The control module responds to internal and external signals and controls the blower, gas valves, and pump(s), depending on the application, to meet the heating demand.
11.Electronic display
Digital controls with SMART TOUCH screen technology, full color display, and an 8" user interface screen.
12.Flame inspection window
Two large high temperature quartz observation windows provide views of the burner surface during firing.
13.Dual flame sensors (not shown)
Two flame sensors are provided to monitor the main burner and transition flame.
14.Flue temperature sensor
The flue sensor monitors flue gas temperature. The control module will modulate or shut the boiler down if the flue gas temperature gets too high.
15.Gas connection pipe
The gas connection pipe is a threaded black iron pipe connection (see Gas Connections Section for specific model pipe size requirements). This pipe should be connected to the incoming gas supply to deliver gas to the boiler.
16.Gas shutoff valve (inside unit)
The manual gas shutoff valve is used to isolate the boiler gas train from the gas supply.
17.Gas valves
The gas valves sense the negative pressure created by the blower, allowing gas to flow only if the gas valves are powered and combustion air is flowing.
18.Condensate trap
The condensate trap is sized for a 1" PVC outlet connection pipe.
19.High limit devices (primary and backup)
The high limit devices are used to monitor the outlet water temperature - if either device senses the water temperature exceeding the predetermined setting, the boiler will shut down.
Installation & Operation Manual
20.Ignition electrode
An electrical spark across the electrodes will ignite the burner.
21.Line voltage junction box
The line voltage junction box contains the connection points for the line voltage power to the boiler (and pumps if used).
22.Line voltage wiring connections (knockouts)
Conduit connection points for the high voltage junction box.
23.Low gas pressure switch
Monitors gas supply pressure to the boiler and shuts the boiler down in the event a low gas pressure condition occurs.
24.High gas pressure switch
Monitors gas supply pressure to the boiler and shuts the boiler down in the event a high gas pressure condition occurs.
25.Low voltage connection board(s)
Connection boards used to connect external low voltage devices.
26.Low voltage wiring connections (knockouts)
Conduit connection points for the low voltage connection boards.
27.Low water cutoff probe (LWCO) (not shown)
Ensures adequate water is supplied to the boiler. In the event of inadequate water levels, the boiler will shut down.
28.Power switch
The On/Off power switch provides the ability to turn line voltage power to the boiler on and off.
29.Relief valve
The safety relief valve protects the heat exchanger from an over pressure condition. The boiler comes with a 50 PSI relief valve as standard equipment. Optional settings are available.
30.Reset switch
Reset switch for the low water cutoff. Hold the switch for 10 seconds to reset.
31.Test switch
The test switch permits manual triggering of the LWCO safety circuit to test the contacts and evaluate the integrity of the circuit. Hold the switch for 10 seconds to test.
32.Firetube heat exchanger
High grade stainless steel WAVETM firetube design that extracts heat from flue gases and transfers it directly into boiler water.
33.Temperature and pressure gauge
Monitors the outlet temperature of the boiler as well as the system water pressure.
34.Venturi
The venturi controls air and gas flow into the burner.
35.Water inlet
An ANSI flange connects the return water from the system to the heat exchanger.
36.Water outlet
An ANSI flange connects the hot water supply from the boiler to the system.
37.Ignition transformer
The transformer provides voltage to the ignition electrode (item 20).
38.Air arm temperature sensor (not shown)
Monitors fuel-air delivery temperature to the burner.
39.Air inlet cover (shipped loose)
Used with room air for combustion and to prevent debris from entering the boiler.
40.Fuses
A low resistance resistor that acts as a sacrificial device to provide over current protection, of either the load or source circuit.
41.Air metering valve
The air metering valve is used to control the amount of air used when firing.
42.Air metering valve air pressure switch
The air metering valve air pressure switch is used to ensure the air metering valve is open when firing gas valve 2.
43.Proof of closure valve (not shown)
An additional safety shutoff valve with proof of closure contacts is used on the Crest 6.0 model only.
4
Installation & Operation Manual
The Crest - How it works... (continued)
NOTICE |
FBN1000 Series 100 model shown for illustration purposes only. |
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IMG01128 |
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IMG01025 |
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Front View |
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Rear View |
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IMG01130 |
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IMG01129 |
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Left Side (inside unit) |
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Right Side (inside unit) |
5 |
Installation & Operation Manual
Ratings
Crest
AHRI Rating
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Net |
Model Number |
Input |
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Gross |
AHRI |
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MBH |
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Output |
Ratings |
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Note: Change “N” to |
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MBH |
Water, |
(Notes 4 - 6) |
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MBH |
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“L” for L.P. gas models. |
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(Note 1) |
(Note 2) |
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Min |
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Max |
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FB(N,L)0751 |
50 |
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750 |
720 |
626 |
FB(N,L)1001 |
50 |
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999 |
960 |
835 |
FB(N,L)1251 |
62 |
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1250 |
1200 |
1043 |
FB(N,L)1501 |
60 |
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1500 |
1440 |
1252 |
FB(N,L)1751 |
70 |
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1750 |
1680 |
1460 |
FB(N,L)2001 |
80 |
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1999 |
1920 |
1670 |
FB(N,L)2501 |
125 |
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2500 |
2403 |
2089 |
FB(N,L)3001 |
150 |
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3000 |
2880 |
2504 |
FB(N,L)3501 |
175 |
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3500 |
3360 |
2922 |
FB(N,L)4001 |
333 |
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3999 |
3840 |
3339 |
FB(N,L)5001 |
500 |
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4999 |
4800 |
4174 |
FB(N,L)6001 |
600 |
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6000 |
5760 |
5009 |
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Other Specifications |
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Appliance |
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Vent |
Weight |
Pipe |
Pipe |
Gas Inlet |
Air |
Size |
w/Water |
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Water |
Size |
Size |
Size |
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(lbs.) |
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Content |
Size |
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Gallons |
Outlet |
Inlet |
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(Note 3) |
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73 |
3" |
3" |
1 1/4" |
6" |
6" |
1768 |
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77 |
3" |
3" |
1 1/4" |
6" |
6" |
1838 |
87 |
3" |
3" |
1 1/2" |
6" |
8" |
1975 |
94 |
4" |
4" |
1 1/2" |
8" |
8" |
2307 |
106 |
4" |
4" |
1 1/2" |
8" |
8" |
2458 |
111 |
4" |
4" |
1 1/2" |
8" |
8" |
2570 |
157 |
4" |
4" |
2" |
8" |
9" |
3600 |
156 |
4" |
4" |
2" |
10" |
10" |
3900 |
202 |
4" |
4" |
2" |
10" |
10" |
4600 |
201 |
4" |
4" |
2 1/2" |
12" |
12" |
5200 |
254 |
6" |
6" |
2 1/2" |
14" |
14" |
5900 |
304 |
6" |
6" |
2 1/2" |
14" |
14" |
6900 |
NOTICE Maximum allowed working pressure is located on the rating plate.
Notes:
1.The ratings are based on standard test procedures prescribed by the United States Department of Energy.
2.Net AHRI ratings are based on net installed radiation of sufficient quantity for the requirements of the building and nothing need be added for normal piping and pickup. Ratings are based on a piping and pickup allowance of 1.15.
3.Crest boilers require special gas venting. Use only the vent materials and methods specified in the Crest Installation and Operation Manual.
4.Standard Crest boilers are equipped to operate from sea level to 4,500 feet only. The boiler will de-rate by 1.4% for each 1,000 feet above sea level up to 4,500 feet.
5.High altitude Crest Models are equipped to operate from
3,000 to 12,000 feet only. The boiler will not de-rate up to 5,500 feet and will de-rate by 1.6% for each 1,000 feet above 5,500 feet. The operation given in this manual remains the same as the standard boilers. A high altitude label (as shown in FIG A.) is also affixed to the unit.
De-rate values are based on proper combustion
calibration and CO2’s adjusted to the recommended levels.
6.High altitude Crest Models 4.0 and 5.0 will not de-rate up to 5,500 feet.
7.The high altitude Crest 6.0 model will de-rate by 2.0% for each 1000 feet above sea level up to 5,500 feet.
8.For Crest Models 4.0, 5.0 and 6.0, installations above 5,500 feet contact the factory.
9.Ratings have been confirmed by the Hydronics Section of AHRI.
UNIT EQUIPPED FOR
HIGH ALTITUDE
3,000 FT. TO 12,000 FT.
IMG01026
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Figure A High Altitude Label Location |
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Installation & Operation Manual
1 Determine boiler location
Installation must comply with: |
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8. |
Check around the boiler for any potential air contaminants |
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Local, state, provincial, and national |
codes, laws, |
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that could risk corrosion to the boiler or the boiler combustion |
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regulations, and ordinances. |
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air supply |
(see Table 1A on |
page 9). Prevent combustion air |
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• National Fuel Gas Code, NFPA 54 / ANSI Z223.1 – |
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contamination. Remove any of these contaminants from the boiler |
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latest edition. |
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area. |
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• |
Standard for Controls and Safety |
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Devices |
for |
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DO NOT install units in rooms or environments that |
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Automatically Fired Boilers, ANSI/ASME CSD-1 - |
WARNING |
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latest edition, when required. |
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contain corrosive contaminants (see Table 1A on page |
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9). Failure to comply could result in severe personal |
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• National Electrical Code, NFPA 70 - latest edition. |
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injury, death, or substantial property damage. |
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• |
For Canada only: |
CSA B149.1 Installation Code, |
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CSA C22.1 Canadian Electrical Code Part 1 and any |
WARNING |
This appliance is certified as an indoor appliance. Do |
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local codes. |
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not install the appliance outdoors or locate where the |
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NOTICE |
The |
Crest |
gas manifold and |
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appliance will be exposed to freezing temperatures or |
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controls met safe lighting and other |
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to temperatures that exceed 100°F (37.8°C). |
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performance criteria when the boiler |
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Do not install the appliance where the relative humidity |
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underwent tests specified in ANSI |
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may exceed 93%. |
Do not install the appliance where |
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Z21.13/CSA 4.9 – latest edition. |
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condensation may form on the inside or outside of |
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Before locating the boiler, check: |
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the appliance, or where condensation may fall onto |
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1. Check for nearby connection to: |
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the appliance. |
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Failure to install the appliance indoors could result in |
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• System water piping |
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• Venting connections |
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severe personal injury, death, or substantial property |
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• Gas supply piping |
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damage. |
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• Electrical power |
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WARNING |
This appliance requires a special venting system. |
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2. Locate the appliance so that if water connections |
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Use only the vent materials specified in this manual. |
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should leak, water damage will not occur. |
When |
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Failure to follow all instructions can result in flue gas |
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such locations cannot be avoided, it is |
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spillage and carbon monoxide emissions, causing |
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recommended that a suitable drain pan, adequately |
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severe personal injury or death. |
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drained, be installed under the appliance. |
The |
Provide clearances: |
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pan must not restrict combustion air flow. Under no |
Clearances from combustible materials |
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circumstances is |
the |
manufacturer |
to be |
held |
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Hot water pipes |
1/4" |
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responsible for water damage in connection with |
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this appliance, or any of its components. |
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Remove |
any |
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combustible |
materials, |
gasoline |
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other |
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- Vent pipe - Follow special vent system manufacturer’s instructions |
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WARNING |
Failure to keep boiler area clear |
Figure 1-1 Clearances |
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and free of combustible materials, |
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gasoline, |
and other |
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1" (25 MM) MINIMUM CLEARANCE |
VENT PIPE: |
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liquids and |
vapors |
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AROUND HOT WATER PIPES |
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FOLLOW SPECIAL VENT SYSTEM |
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severe personal injury, death, or |
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MANUFACTURER'S INSTRUCTIONS |
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substantial property damage. |
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The Crest must be installed so that |
gas |
control |
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system components are protected from dripping or |
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spraying water or rain during operation or service. |
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VENTILATING* |
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AIR OPENING |
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5. If a new boiler will replace an existing boiler, check |
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exchanger cracks from hard water deposits. |
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VENTILATING* |
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• Lack of freeze protection in boiler water causing |
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cleaned with an appropriate cleaner. |
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6. The appliance must be installed on a level floor, |
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FLOOR: COMBUSTIBLE |
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both front to back and side to side, for proper |
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condensate drainage. |
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IMG01027 |
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FRONT |
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7. If the optional neutralizing kit is to be used, elevate |
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the boiler at least 3" above the floor. |
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Installation & Operation Manual
1 Determine boiler location
NOTICE |
If you do not provide the recommended |
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service clearances shown, it may not be |
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possible to service the boiler without |
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removing it from the space. |
Recommended clearances for service access
- |
Sides .............................................................................. |
24" |
- |
Rear............................................................................... |
24" |
- |
Front ............................................................................. |
30" |
- |
Top................................................................................ |
24" |
Maintain minimum specified clearances for adequate operation. All installations must allow sufficient space for servicing the vent connections, water pipe connections, piping and other auxiliary equipment, as well as the appliance. The clearance labels on each appliance note the same service and combustible clearance requirements as shown in this manual.
Multiple boilers may be installed side by side with no clearance between adjacent boilers because this boiler is approved for zero clearance from combustible surfaces; however, service access will be limited from the sides.
Consult the Venting section of this manual for specific installation instructions for the appropriate type of venting system that you will be using.
Provide air openings to room:
The Crest alone in boiler room
1.No air ventilation openings into the boiler room are needed when clearances around the Crest are at least equal to the SERVICE clearances shown in FIG. 1-1. For spaces that do NOT supply this clearance, provide two openings as shown in FIG. 1-1. Each opening must provide one square inch free area per 1,000 Btu/hr of boiler input.
2.Combustion air openings are required when using the Room Air Option on page 28 of this manual.
The Crest in same space with other gas or oil-fired appliances
1.Follow the National Fuel Gas Code (U.S.) or CSA B149.1 (Canada) to size/verify size of the combustion/ventilation air openings into the space.
WARNING The space must be provided with combustion/ventilation air openings
correctly sized for all other appliances located in the same space as the Crest.
Failure to comply with the above warnings could result in severe personal injury, death, or substantial property damage.
2.Size openings only on the basis of the other appliances in the space. No additional air opening free area is needed for the Crest when it takes its combustion air from outside (direct vent installation).
8
Flooring and foundation
Flooring
The Crest is approved for installation on combustible flooring, but must never be installed on carpeting.
WARNING |
Do not install the boiler on carpeting even if |
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foundation is used. Fire can result, causing |
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severe personal injury, death, or substantial |
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property damage. |
If flooding is possible, elevate the boiler sufficiently to prevent water from reaching the boiler.
WARNING Assure that the floor and structure is sufficient to support the installed weight
of the boiler, including the water content in the heat exchanger. If not, structural building failure will result, causing severe personal injury, death, or substantial property damage.
Vent and air piping
The Crest requires a special gas vent system, designed for pressurized venting.
The boiler is to be used for either direct vent installation or for installation using indoor combustion air. When room air is considered, see page 28 of this manual. Note prevention of combustion air contamination below when considering vent/ air termination.
Vent and air must terminate near one another and may be vented vertically through the roof or out a side wall, unless otherwise specified. You may use any of the vent/air piping methods covered in this manual. Do not attempt to install the Crest using any other means.
Be sure to locate the boiler such that the vent and air piping can be routed through the building and properly terminated. The vent/air piping lengths, routing and termination method must all comply with the methods and limits given in this manual.
Prevent combustion air contamination
Install air inlet piping for the Crest as described in this manual. Do not terminate vent/air in locations that can allow contamination of combustion air. Refer to Table 1A, page 9 for products and areas which may cause contaminated combustion air.
WARNING Ensure that the combustion air will not contain any of the contaminants in Table
1A, page 9. Contaminated combustion air will damage the boiler, resulting in possible severe personal injury, death or substantial property damage. Do not pipe combustion air near a swimming pool, for example. Also, avoid areas subject to exhaust fumes from laundry facilities. These areas will always contain contaminants.
Installation & Operation Manual
1 Determine boiler location (continued)
When using an existing vent system to install a new boiler:
WARNING Failure to follow all instructions can result in flue gas spillage and carbon monoxide
emissions, causing severe personal injury or death.
Check the following venting components before installing:
•Material - For materials listed for use with this appliance, see Section 2 - General Venting, Table 2A-1. For stainless steel venting, an adapter of the same manufacturer (Table 2B) may be used at the flue collar connection.
•Size - To ensure proper pipe size is in place, see Table 2C. Check to see that this size is used throughout the vent system.
•Manufacturer - Only use the listed manufacturers and their type product listed in Table 2A-1 for CAT IV positive pressure venting with flue producing condensate.
•Supports - Non-combustible supports must be in place allowing a minimum 1/4" rise per foot. The supports should adequately prevent sagging and vertical slippage, by distributing the vent system weight. For additional information, consult the vent manufacturer’s instructions for installation.
•Terminations - Carefully review Sections 2 through 4 to ensure requirements for the location of the vent and air terminations are met and orientation of these fit the appropriate image from the Sidewall or Vertical options listed in the General Venting Section.
•Seal - With prior requirements met, the system should be tested to the procedure listed in parts (c) through (f) of the Removal of an Existing Boiler Section on page 10.
With stainless steel vent, seal and connect all pipe and components as specified by the vent manufacturer used.
If any of these conditions are not met,WARNING the existing system must be updated or
replaced for that concern. Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.
Table 1A Corrosive Contaminants and Sources
Products to avoid:
Spray cans containing chloro/fluorocarbons
Permanent wave solutions
Chlorinated waxes/cleaners
Chlorine-based swimming pool chemicals
Calcium chloride used for thawing
Sodium chloride used for water softening
Refrigerant leaks
Paint or varnish removers
Hydrochloric acid/muriatic acid
Cements and glues
Antistatic fabric softeners used in clothes dryers
Chlorine-type bleaches, detergents, and cleaning solvents found in household laundry rooms
Adhesives used to fasten building products and other similar products
Areas likely to have contaminants
Dry cleaning/laundry areas and establishments
Swimming pools
Metal fabrication plants
Beauty shops
Refrigeration repair shops
Photo processing plants
Auto body shops
Plastic manufacturing plants
Furniture refinishing areas and establishments
New building construction
Remodeling areas
Garages with workshops
9
Installation & Operation Manual
1 Determine boiler location
When removing a boiler from existing common vent system:
DANGER |
Do not install the Crest into a common |
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vent with any other appliance except |
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as noted in Section 2 on page 20. |
|
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This will cause flue gas spillage or |
|
|
appliance malfunction, resulting in |
|
|
possible severe personal injury, death, |
|
|
or substantial property damage. |
|
|
Failure to follow all instructions can |
WARNING |
|
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result in flue gas spillage and carbon |
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monoxide emissions, causing severe |
|
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personal injury or death. |
At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.
a.Seal any unused openings in the common venting system.
b.Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion, or other deficiencies, which could cause an unsafe condition.
c.Test vent system – Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.
d.Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliance will operate continuously.
e.Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar, or pipe.
f.After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined herein, return doors, windows, exhaust fans, fireplace dampers, and any other gas-burning appliance to their previous conditions of use.
g.Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CAN/CSA B149.1, Natural Gas and Propane Installation Code. When re-sizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part 11 of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CAN/CSA B149.1, Natural Gas and Propane Installation Code.
Remove boiler from wood pallet
1.After removing the outer shipping crate and plastic from the boiler, remove the parts package (packaged parts inside the controls compartment of the boiler inside the lower front access panel).
2.To remove the boiler from the pallet:
a.Remove the three (3) shipping bolts located inside the controls compartment securing the boiler to the front of the pallet (see FIG. 1-2).
b.Remove the three (3) shipping bolts that fasten the tie-down brackets securing the legs to the rear of the pallet (FIG. 1-2).
c.The boiler can now be removed from the pallet using a lift truck lifting from the front or rear of the boiler. If lifting from the front, the lift truck forks must extend at least half way under the boiler heat exchanger to assure proper lifting technique with no damage to the boiler.
WARNING Failure to assure the truck forks are long enough to extend at least halfway
under the boiler heat exchanger will result in the boiler tipping off the lift truck, and potentially falling. This will result in severe personal injury, death, or substantial property damage.
d.If lifting by crane is desired, remove the top access panels to gain access to the lifting lugs located on the boiler (see FIG. 1-3). It is also recommended that the upper and lower front panels along with both front side panels be removed (no tools required).
Do not drop the boiler or bump the jacket NOTICE on the floor or pallet. Damage to the
boiler can result.
10
Installation & Operation Manual
1 Determine boiler location
Figure 1-2 Boiler Mounted on Shipping Pallet
(continued)
Combustion and ventilation air requirements for appliances drawing air from the equipment room
BOLT, WASHERS & LOCKNUT (3X)
FRONT |
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LAG BOLTS & TABS |
REAR |
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(3X) |
Figure 1-3 Boiler Removed from Shipping Pallet
REMOVE MIDDLE
TOP COVER
LIFTING
LUGS
LIFTING
LUGS
IMG01028
Provisions for combustion and ventilation air must be in accordance with Air for Combustion and Ventilation, of the latest edition of the National Fuel Gas Code, NFPA 54 / ANSI
Z223.1, in Canada, the latest edition of CGA Standard B149
Installation Code for Gas Burning Appliances and Equipment, or applicable provisions of the local building codes.
The equipment room MUST be provided with properly sized openings and/or be of sufficient volume to assure adequate combustion air and proper ventilation for all gas fired appliances in the equipment room to assure adequate combustion air and proper ventilation.
The requirements shown are for the appliance only; additional gas fired appliances in the equipment room will require an increase in the net free area and/or volume to supply adequate combustion air for all appliances.
No combustion air openings are needed when the appliance is installed in a space with a volume NO LESS than 50 cubic feet per 1,000 Btu/hr of all installed gas fired appliances and the building MUST NOT be of “Tight Construction”3.
A combination of indoor and outdoor combustion air may be utilized by applying a ratio of available volume to required volume times the required outdoor air opening(s) size(s). This must be done in accordance with the National Fuel Gas Code, NFPA 54 / ANSI Z223.1.
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IMG01029 |
Figure 1-4_Combustion Air Direct from Outside |
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1. If air |
is |
taken |
directly |
from outside |
the building |
with |
no |
duct, |
provide |
two permanent |
openings to |
the equipment room each with a net free area of one square inch per 4000 Btu/hr input (5.5 cm2 per kW) (see FIG. 1-4).
11
Installation & Operation Manual
1 Determine boiler location
IMG01030 |
Figure 1-5_Combustion Air Through Ducts
2.If combustion and ventilation air is taken from the outdoors using a duct to deliver the air to the equipment room, each of the two openings should be sized based on a minimum free area of one square inch per 2000 Btu/hr (11 cm2 per kW) of input (see FIG. 1-5).
IMG01031
Figure 1-6_Combustion Air from Interior Space
3.If air is taken from another interior space combined with the equipment room:
(a)Two spaces on same story: Each of the two openings specified above should have a net free area of one square inch for each 1000 Btu/hr (22 cm2 per kW) of input, but not less than 100 square inches (645 cm2) (see FIG. 1-6).
(b)Two spaces on different stories: One or more openings should have a net free area of two square inches per 1000 Btu/hr (44 cm2 per kW).
IMG01032
Figure 1-7_Combustion Air from Outside - Single Opening
4.If a single combustion air opening is provided to bring combustion air in directly from the outdoors, the opening must be sized based on a minimum free area of one square inch per 3000 Btu/hr (7 cm2 per kW). This opening must be located within 12” (30 cm) of the top of the enclosure (see FIG. 1-7).
Combustion air requirements are based on the latest edition of the National Fuel Gas Code, NFPA 54 / ANSI Z223.1; in Canada refer to the latest edition of CGA Standard CAN/CSA B149.1. Check all local code requirements for combustion air. All dimensions based on net free area in square inches. Metal louvers or screens reduce the free area of a combustion air opening a minimum of approximately 25%. Check with louver manufacturers for exact net free area of louvers.
Where two openings are provided, one must be within 12"
(30 cm) of the ceiling and one must be within 12" (30 cm) of the floor of the equipment room. Each opening must have a net free area as specified in Table 1B. Single openings shall commence within 12" (30 cm) of the ceiling. The minimum dimension of air openings shall not be less than 3" (80 mm).
Under no circumstances should theCAUTION equipment room ever be under negative
pressure. Particular care should be taken where exhaust fans, attic fans, clothes dryers, compressors, air handling units, etc., may take away air from the unit.
The combustion air supply must be completely free of any flammable vapors that may ignite or chemical fumes which may be corrosive to the appliance. Common corrosive chemical fumes which must be avoided are fluorocarbons and other halogenated compounds, most commonly present as refrigerants or solvents, such as Freon, trichlorethylene, perchlorethylene, chlorine, etc. These chemicals, when burned, form acids which quickly attack the stainless steel heat exchanger, headers, flue collectors, and the vent system.
The result is improper combustion and a non-warrantable, premature appliance failure.
EXHAUST FANS: Any fan or equipment which exhausts air from the equipment room may deplete the combustion air supply and/or cause a downdraft in the venting system. Spillage of flue products from the venting system into an occupied living space can cause a very hazardous condition that must be corrected immediately.
12
Installation & Operation Manual
1 Determine boiler location (continued)
TABLE - 1B
MINIMUM RECOMMENDED COMBUSTION
AIR SUPPLY TO EQUIPMENT ROOM
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FIG. 1-4 |
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FIG. 1-5 |
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FIG. 1-6 |
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FIG. 1-7 |
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*Outside Air from |
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*Outside Air from |
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Inside Air from |
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2 Ducts Delivered from Interior Space2 |
*Outside Air from |
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Model |
2 Openings Directly from |
2 Ducts Delivered from |
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1 Opening Directly |
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Number |
Outdoors1 |
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Outdoors1 |
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Same Story |
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Different |
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from Outdoors, in2 |
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(cm2)1 |
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Top |
Bottom |
Top |
Bottom |
Top |
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Bottom |
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Total |
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Opening, in2 |
Opening, in2 |
Opening, in2 |
Opening, in2 |
Opening, in2 |
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Opening, in2 |
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Openings, in2 |
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(cm2) |
(cm2) |
(cm2) |
(cm2) |
(cm2) |
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(cm2) |
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(cm2) |
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|||||
FB 0751 |
188 (1213) |
188 (1213) |
375 |
(2420) |
375 |
(2420) |
750 |
(4839) |
|
750 |
(4839) |
|
1500 (9678) |
250 |
(1613) |
|
FB 1001 |
250 (1613) |
250 (1613) |
500 |
(3226) |
500 |
(3226) |
1000 (6452) |
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1000 (6452) |
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2000 (12904) |
333 |
(2149) |
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FB 1251 |
313 (2020) |
313 (2020) |
625 |
(4033) |
625 |
(4033) |
1250 (8065) |
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1250 (8065) |
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2500 (16129) |
417 |
(2691) |
|||
FB 1501 |
375 (2420) |
375 (2420) |
750 |
(4839) |
750 |
(4839) |
1500 (9678) |
|
1500 (9678) |
|
3000 (19355) |
500 |
(3226) |
|||
FB 1751 |
438 (2826) |
438 (2826) |
875 |
(5646) |
875 |
(5646) |
1750 |
(11291) |
|
1750 |
(11291) |
|
3500 (22581) |
583 |
(3762) |
|
FB 2001 |
500 (3226) |
500 (3226) |
1000 (6452) |
1000 (6452) |
2000 |
(12904) |
|
2000 |
(12904) |
|
4000 (25807) |
667 |
(4304) |
|||
FB 2501 |
625 (4033) |
625 (4033) |
1250 (8065) |
1250 (8065) |
2500 |
(16129) |
|
2500 |
(16129) |
|
5000 (32258) |
833 |
(5381) |
|||
FB 3001 |
750 (4839) |
750 (4839) |
1500 (9678) |
1500 (9678) |
3000 |
(19355) |
|
3000 |
(19355) |
|
6000 (38710) |
1000 (6452) |
||||
FB 3501 |
875 (5646) |
875 (5646) |
1750 |
(11291) |
1750 |
(11291) |
3500 |
(22581) |
|
3500 |
(22581) |
|
7000 (45162) |
1167 (7530) |
||
FB 4001 |
1000 (6450) |
1000 (6450) |
2000 |
(12900) |
2000 |
(12900) |
4000 |
(25800) |
|
4000 |
(25800) |
|
8000 (51600) |
1333 (8600) |
||
FB 5001 |
1250 (8062) |
1250 (8062) |
2500 |
(16129) |
2500 |
(16129) |
5000 |
(32250) |
|
5000 |
(32250) |
10000 (64500) |
1667 |
(10750) |
||
FB 6001 |
1500 (9677) |
1500 (9677) |
3000 |
(19355) |
3000 |
(19355) |
6000 |
(38710) |
|
6000 |
(38710) |
12000 (77419) |
2000 |
(12903) |
The above requirements are for the appliance only; additional gas fired appliances in the equipment room will require an increase in the net free area and/or volume to supply adequate combustion air for all appliances.
No combustion air openings are needed when the appliance is installed in a space with a volume NO LESS than 50 cubic feet per 1,000 Btu/hr of all installed gas fired appliances. Buildings MUST NOT be of *“Tight Construction”3.
1Outside air openings shall directly communicate with the outdoors.
2Combined interior space must be 50 cubic feet per 1,000 Btu/hr input. Buildings MUST NOT be of *“Tight Construction”. 3”Tight Construction” is defined as a building with less than 0.40 ACH (air changes per hour). For buildings of “Tight Construction”, provide air openings into the building from outside.
Combustion air filter
This unit has a standard air filter located at the combustion air inlet. This air filter is provided to help ensure clean air is used for the combustion process. Check this filter every month and replace when it becomes dirty. You can find these commercially available filters at any home center or HVAC supply store. Follow the steps below when replacing the combustion air filter:
1.Locate the combustion air filter box.
2.Lift and remove the air filter box cover to gain access to the air filter.
3.Slide the air filter out the top of the air filter box.
4.Inspect the air filter for dirt and debris, replace if necessary.
5.Replace the air filter and the air filter box cover.
NOTICE
CAUTION
During construction the air filter should be checked more frequently to ensure it does not become clogged with combustion dirt and debris.
Sustained operation of an appliance with a clogged burner may result in nuisance operational problems, bad combustion, and non-warrantable component failures.
13
Installation & Operation Manual
2 General venting
Direct venting
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IMG01033 |
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IMG01057 |
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IMG01056 |
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Sidewall |
Vertical Vent, Sidewall Air |
Vertical |
Optional room air
IMG01059
IMG01058
Sidewall |
Vertical |
14
Installation & Operation Manual
2 General venting (continued)
Install vent and combustion air piping
DANGER The Crest must be vented and supplied with combustion and ventilation air as
described in this section. Ensure the vent and air piping and the combustion air supply comply with these instructions regarding vent system, air system, and combustion air quality. See also Section 1 of this manual.
Inspect finished vent and air piping thoroughly to ensure all are airtight and comply with the instructions provided and with all requirements of applicable codes.
Failure to provide a properly installed vent and air system will cause severe personal injury or death.
Air inlet pipe materials:
The air inlet pipe(s) must be sealed. Choose acceptable combustion air inlet pipe materials from the following list:
ABS, PVC, or CPVC
Dryer Vent or Sealed Flexible Duct (not recommended for rooftop air inlet)
Galvanized steel vent pipe with joints and seams sealed as specified in this section.
Type “B” double-wall vent with joints and seams sealed as specified in this section.
AL29-4C, stainless steel material to be sealed to specification of its manufacturer.
*Plastic pipe may require an adapter (not provided) to transition between the air inlet connection on the appliance and the plastic air inlet pipe.
Sealing of Type “B” double-wall vent material or galvanized vent pipe material used for air inlet piping on a sidewall or vertical rooftop Combustion Air Supply System:
a.Seal all joints and seams of the air inlet pipe using either Aluminum Foil Duct Tape meeting UL Standard 723 or 181A-P or a high quality UL Listed silicone sealant such as those manufactured by Dow Corning or General Electric.
b.Do not install seams of vent pipe on the bottom of horizontal runs.
c.Secure all joints with a minimum of three sheet metal screws or pop rivets. Apply Aluminum Foil Duct Tape or silicone sealant to all screws or rivets installed in the vent pipe.
d.Ensure that the air inlet pipes are properly supported.
The PVC, CPVC, or ABS air inlet pipe should be cleaned and sealed with the pipe manufacturer’s recommended solvents and standard commercial pipe cement for the material used. The ABS, PVC, CPVC, Dryer Vent or Flex Duct air inlet pipe should use a silicone sealant to ensure a proper seal at the appliance connection and the air inlet cap connection. Dryer vent or flex duct should use a screw type clamp to seal the vent to the appliance air inlet and the air inlet cap. Proper sealing of the air inlet pipe ensures that combustion air will be free of contaminants and supplied in proper volume.
WARNING Using vent or air intake materials other than those specified, failure to properly
seal all seams and joints or failure to follow vent pipe manufacturer’s instructions can result in personal injury, death or property damage. Mixing of venting materials will void the warranty and certification of the appliance.
The use of double-wall vent or insulated NOTICE material for the combustion air inlet
pipe is recommended in cold climates to prevent the condensation of airborne moisture in the incoming combustion air.
15
Installation & Operation Manual
2 General venting
When a sidewall or vertical rooftop combustion air supply system is disconnected for any reason, the air inlet pipe must be resealed to ensure that combustion air will be free of contaminants and supplied in proper volume.
DANGER |
Failure to properly seal all joints and seams |
|
as required in the air inlet piping may |
|
result in flue gas recirculation, spillage |
|
of flue products and carbon monoxide |
|
emissions causing severe personal injury |
|
or death. |
Vent and air piping
The Crest is certified as a Category II/IV boiler. This product has been approved for use with stainless steel vent systems.
All venting systems used with a Crest boiler must be suitable for Category IV operation except for factory approved common vent systems operating as allowed in the Common Venting Section on page 20.
WARNING
NOTICE
Use only the materials, vent systems, and terminations listed in Table 2A-1. DO NOT mix vent systems of different types or manufacturers, unless listed in this manual. Failure to comply could result in severe personal injury, death, or substantial property damage.
Installations must comply with applicable national, state, and local codes. Stainless steel vent systems must be listed as a UL-1738 approved system for the United States and a ULC-S636 approved system for Canada.
NOTICE |
Installation of a stainless steel vent system |
|
should adhere to the stainless steel vent |
||
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||
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manufacturer’s installation instructions |
|
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supplied with the vent system. |
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NOTICE |
The Crest is supplied with an integral |
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FasNSeal vent connector (FIG. 2-1). The |
||
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||
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installer must use a specific vent starter |
|
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adapter supplied by the vent manufacturer |
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to adapt to different vent systems. |
Air intake/vent connections
1.Combustion Air Intake Connector (FIG. 2-1) - Used to provide combustion air directly to the unit from outdoors. A fitting is provided with the unit for final connection. Combustion air piping must be supported per guidelines listed in the National Mechanical Code, Section 305, Table 305.4 or as local codes dictate.
2.Vent Connector (FIG. 2-1) - Used to provide a passageway for conveying combustion gases to the outside. A transition fitting is provided on the unit for final connection. Vent piping must be supported per the National Building Code, Section 305, Table 305.4 or as local codes dictate.
Figure 2-1 Combustion Air Adapter
AIR PIPE (FIELD SUPPLIED)
ROOM AIR BOX
SHIPPED WITH
UNIT
VENT PIPE (FIELD SUPPLIED)
IMG01034
CONNECTOR SIZED FOR STAINLESS STEEL
FLUE PIPE
The Crest uses model specific combustion air intake and vent piping sizes as detailed in Tables 2B and 2C on page 18.
NOTICE |
Increasing or decreasing combustion air |
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or vent piping to sizes not specified in this |
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||
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manual is not authorized. |
Table 2A-1 Approved Stainless Steel Vent Manufacturers
Approved Stainless Steel Vent Manufacturers
Make |
Model |
ProTech Systems (Dura-Vent Co.) |
FasNSeal Vent |
Z-Flex (Nova Flex Group) |
Z-Vent |
Heat Fab (Selkirk Corporation) |
Saf-T Vent |
Metal Fab |
Corr/Guard |
Securities Chimneys International |
Secure Seal SS |
Schebler Chimney Systems |
eVent |
ICC |
VIC |
Jeremias |
-- |
16
Installation & Operation Manual
2 General venting (continued)
Table 2A-2 Approved Stainless Steel Terminations and Adapters - Category IV
Model |
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ProTech |
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Z Flex |
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Heat Fab |
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Adapter |
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Intake |
Adapter |
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Intake |
Adapter |
Flue |
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Intake |
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751-1001 |
|
Not Required |
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810003269 |
2SVDSA06 |
2SVEE0690 |
9601MAD |
CCK06TM |
|
|
9690 / 9692 |
||||
1251 |
|
*See note |
|
810003281 |
2SVDSA06 |
2SVEE0690 |
9801MAD |
CCK08TM |
|
|
9690 / 9692 |
||||
1501-2001 |
|
*See note |
|
810003357 / 810003369 |
2SVDSA08 |
2SVEE0890 |
9801MAD |
CCK08TM |
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9890 / 9892 |
||||
Model |
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Metal-Fab |
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Security Chimney |
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ICC |
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Adapter |
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Flue |
Intake |
Adapter |
Flue |
|
Intake |
Adapter |
Flue |
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Intake |
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751-1001 |
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MC |
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SS0MCU |
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SS6ST90AU |
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HE-6MC-F |
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HE-6E90-F |
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6FCGPVCA |
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6FCGSW90L |
SS6PVCU |
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SSD0STAUK |
HE-6DSA-F |
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6-36" |
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4" - 24" |
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HE-6RC-F |
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HE-6SCR-F |
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4" - 24" |
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1251 |
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8FCGLCA |
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MC |
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SS0MCU |
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SS6ST90AU |
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HE-8SCR-F |
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HE-6E90-F |
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6FCGSW90L |
SS8CRESTU |
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SSD0STAUK |
HE-8DSA-F |
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6-36" |
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4" - 24" |
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HE-8MC-F |
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HE-6SCR-F |
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4" - 24" |
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1501-2001 |
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MC |
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SS0MCU |
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SSE8E9OU |
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HE-8SCR-F |
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HE-8E90-F |
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8FCGLCA |
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8FCGSW90 |
SS8CRESTU |
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SD0STAUK |
HE-8DSA-F |
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6-36" |
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4" - 24" |
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HE-8MC-F |
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HE-8SCR-F |
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4" - 24" |
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Model |
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Jeremias |
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*No adapter needed when using 8" FasNSeal vent length. |
|
|||||||||
Adapter |
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Flue |
Intake |
|
|||||||||||
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*Models 1251 - 1501: For installations using 6" vent, install a FasNSeal |
||||||||||||
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|||||||||
751-1001 |
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SWKL6-KLC |
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SWKL6-WRC |
SWKL6-90ET |
reducing adapter, available from the factory with kit #100295900. Reference |
|||||||||
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the manufacturer's part number provided for Models 751 - 1001 when |
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1251 |
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SWKL8-KLC |
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SWKL8-WRC |
SWKL6-90ET |
||||||||||
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adapting to different vent systems. |
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|||
1501-2001 |
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SWKL8-KLC |
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SWKL8-WRC |
SWKL8-90ET |
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Model |
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ProTech |
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Z Flex |
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Heat Fab |
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|||||
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Adapter |
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Intake |
Adapter |
|
Intake |
Adapter |
Flue |
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Intake |
|||||
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|||||||||||
2501 |
|
*See note |
|
810003397 / 810003409 |
2SVDSA09 |
2SVEE990 |
9901MAD |
CCK09TM |
|
9890 / 9992 |
|||||
3001 - 3501 |
|
*See note |
|
810003435 / 810003447 |
2SVDSA10 |
2SVEE1090 |
91001MAD |
CCK10TM |
|
91090 / 91092 |
|||||
4001 |
|
*See note |
|
810003476 / 810003488 |
2SVDSA12 |
2SVEE1290 |
91201MAD |
CCK12TM |
|
91290 / 91292 |
|||||
5001 - 6001 |
|
*See note |
|
810003516 / 810003528 |
2SVDSA14 |
2SVEE1490 |
91401MAD |
CCK14TM |
|
91490 / 91492 |
|||||
Model |
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Metal-Fab |
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Security Chimney |
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ICC |
|
||||||
|
Adapter |
|
Flue |
|
Intake |
Adapter |
Flue |
|
Intake |
Adapter |
Flue |
|
Intake |
||
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|
||||||||||
2501 |
|
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MC |
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SS0MCU |
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SSE9E9OU |
|
HE-9SCR-F |
|
HE-8E90-F |
|
|
8FCGLCA |
|
|
8FCGSW90 |
SS9CRESTU |
|
SDOST90AUK |
HE-9DSA-F |
|
||||||
|
|
6-36" |
|
4" - 24" |
|
HE-9MC-F |
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HE-9SCR-F |
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4" - 10" |
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3001 - 3501 |
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MC |
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SS0MCU |
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SSE10E9OU |
|
HE-10SCR-F |
HE-10E90-F |
||
|
10FCGLCA |
|
|
10FCGSW90 |
SS10CRESTU |
|
SDOST90AUK |
HE-10DSA-F |
|||||||
|
|
6-36" |
|
4" - 24" |
|
HE-10MC-F |
|
HE-10SCR-F |
|||||||
|
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4" - 10" |
|
|
|||||
|
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|
4001 |
|
12FCGLCA |
|
MC |
|
12FCGSW90 |
SS12CRESTU |
SS0MCU |
|
SSE12E9OU |
HE-12DSA-F |
HE-12SCR-F |
HE-12E90-F |
||
|
|
6-36" |
|
4" - 24" |
|
HE-12MC-F |
HE-12SCR-F |
||||||||
|
|
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|
||||||
5001 - 6001 |
|
14FCGLCA |
|
MC |
|
14FCGSW90 |
SS14CRESTU |
SS0MCU |
|
SSE14E9OU |
HE-14DSA-F |
HE-14SCR-F |
HE-14E90-F |
||
|
|
6-36" |
|
4" - 24" |
|
HE-14MC-F |
|
HE-14SCR-F |
|||||||
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|||||
Model |
|
|
Jeremias |
|
*No adapter needed when using Standard FNS Vent Length. |
|
|||||||||
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|
|||||||||
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Adapter |
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Flue |
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Intake |
|
|||||||||
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2501 |
|
SWKL9-KLC |
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SWKL9-WRC |
SWKL9-90ET |
|
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3001 - 3501 |
|
SWKL10-KLC |
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SWKL10-WRC |
SWKL10-90ET |
|
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4001 |
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SWKL12-KLC |
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SWKL12-WRC |
SWKL12-90ET |
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5001 - 6001 |
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SWKL14-KLC |
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SWKL14-WRC |
SWKL14-90ET |
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17
Installation & Operation Manual
2 General venting
Table 2B Direct Vent Minimum / Maximum Allowable Air / Vent Lengths
|
|
AIR INLET |
|
|
VENT |
|
Input |
Model |
Air Intake |
Air Intake |
Air Intake |
Vent |
Vent |
Vent |
De-Rate per |
|
Diameter |
Min. Length |
Max. Length |
Diameter |
Min. Length |
Max. Length |
25 feet of Vent |
0751-1001 |
6" |
12' |
100' |
6" |
18' |
100' |
0% |
1251* |
6" |
12' |
75' |
6" |
18' |
75' |
1% |
1251 |
6" |
12' |
100' |
8" |
18' |
100' |
0% |
1501* |
8" |
12' |
75' |
6" |
18' |
75' |
1% |
1501 |
8" |
12' |
100' |
8" |
18' |
100' |
0% |
1751-2001 |
8" |
12' |
100' |
8" |
18' |
100' |
0% |
2501 |
8" |
12' |
100' |
9" |
18' |
100' |
0% |
3001 |
10" |
12' |
100' |
10" |
18' |
100' |
0% |
3501 |
10" |
12' |
100' |
10" |
18' |
100' |
0% |
|
|
|
|
|
|
|
|
4001 |
12" |
12' |
100' |
12" |
18' |
100' |
0% |
5001/6001 |
14" |
12' |
100' |
14" |
18' |
100' |
0% |
*FB 1251 - 1501 models using 6" vent require the installation of a field supplied reducing adapter (see Table 2A-2 on page 17). *FB 1251 - 1501 LP models using 6" diameter vent will de-rate 2.5% per 25 feet of vent.
Table 2C Room Air Minimum / Maximum Allowable Air / Vent Lengths
Model |
Vent |
Vent |
Vent |
Input De-Rate per |
|
Diameter |
Min. Length |
Max. Length |
25 feet of Vent |
||
|
|||||
0751-1001 |
6" |
18' |
100' |
0% |
|
1251-1501* |
6" |
18' |
100' |
0% |
|
1251-1501 |
8" |
18' |
100' |
0% |
|
1751-2001 |
8" |
18' |
100' |
0% |
|
2501 |
9" |
18' |
150' |
0% |
|
3001 |
10" |
18' |
150' |
0% |
|
3501 |
10" |
18' |
150' |
0% |
|
4001 |
12" |
18' |
150' |
0% |
|
5001/6001 |
14" |
18' |
150' |
0% |
*FB 1251 - 1501 models using 6" vent require the installation of a field supplied reducing adapter (see Table 2A-2 on page 17). *FB 1251 - 1501 LP models using 6" diameter vent will de-rate 2.5% per 25 feet of vent.
18
Installation & Operation Manual
2 General venting (continued)
When determining equivalent combustion air and vent length, add 5 feet (1.5m) for each 90° elbow and 3 feet (.9 m) for each 45° elbow.
EXAMPLE: 20 feet (6 m) of pipe + (4) 90° elbows + (3) 45° elbows = 49 equivalent feet (15 m) of piping.
Removing from existing vent
Follow the instructions in Section 1, page 10 of this manual when removing a boiler from an existing vent system.
Vent and air piping
Vent and air system:
Installation must comply with local NOTICE requirements and with the National Fuel
Gas Code, NFPA 54 / ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations.
You must also install air piping from outside to the boiler air intake adapter. The resultant installation is direct vent (sealed combustion).
You may use any of the vent/air piping methods covered in this manual. Do not attempt to install the Crest using any other means.
WARNING DO NOT mix components from different systems. The vent system could fail,
causing leakage of flue products into the living space. Use only approved stainless steel pipe and fittings.
When installing outdoor models OF(N,L), NOTICE reference the Outdoor Crest Supplemental
Manual for further information.
Vent, air piping and termination:
The Crest vent and air piping can be installed through the roof or through a sidewall. Follow the procedures in this manual for the method chosen. Refer to the information in this manual to determine acceptable vent and air piping length.
Air contamination
Pool and laundry products and common household and hobby products often contain fluorine or chlorine compounds. When these chemicals pass through the boiler, they can form strong acids. The acid can eat through the boiler wall, causing serious damage and presenting a possible threat of flue gas spillage or boiler water leakage into the building.
Please read the information given in Table 1A, page 9, listing contaminants and areas likely to contain them. If contaminating chemicals will be present near the location of the boiler combustion air inlet, have your installer pipe the boiler combustion air and vent to another location, per this manual.
If the boiler combustion air inlet is locatedWARNING in a laundry room or pool facility, for
example, these areas will always contain hazardous contaminants.
To prevent the potential of severe personalWARNING injury or death, check for areas and products
listed in Table 1A, page 9 before installing the boiler or air inlet piping.
If contaminants are found, you MUST:
•Remove products permanently. —OR—
•Relocate air inlet and vent terminations to other areas.
19
Installation & Operation Manual
2 General venting
Common venting
Crest boilers may be common vented; however, the following criteria MUST BE followed:
1.Only Crest boilers may be connected to common flue applications. DO NOT mix other manufacturer’s appliances or other Lochinvar models. Common air intake is not allowed.
2.Crest boilers connected to the common vent must all be of the same size.
3.Each Crest boiler must have a Lochinvar supplied flue damper installed (see Table 2D).
4.A condensate drain must be installed above the flue damper.
5.Only vertical direct vent, positive pressure, Category IV or vertical/chimney vent, negative pressure, Category II may be used when common venting Crest boilers. Sidewall venting is not allowed.
6.Crest boilers in a common vent must be connected and controlled with the integral Crest SMART TOUCH Cascade.
a.The Leader may be controlled through the Crest SMART TOUCH control through BMS (external 0 - 10V signal), ModBus or its own internally calculated set point.
b.The Cascade (Members) must be controlled by the Crest Leader boiler using the Lead/Lag Cascade option.
For approved common vent sizing, contact the factory.
WARNING When Crest boilers are common vented, the criteria above MUST BE followed.
Failure to follow all these requirements will result in severe personal injury, death, or substantial property damage.
NOTICE |
When Crest boilers are common vented, |
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hot water generators MUST BE piped |
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to the primary heating loop and tank |
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thermostats must not be connected to the |
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Crest. |
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NOTICE |
A field supplied inline condensate |
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collection section MUST BE installed |
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directly above the backflow preventer. |
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NOTICE |
When using polypropylene common vent |
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on Models 751 - 3501, a field supplied |
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polypropylene to stainless steel adapter |
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MUST BE installed between the backflow |
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preventer and the unit connection. |
Table 2D Flue Damper Kits
Flue Damper Kits
Model |
Damper Size |
Kit Number |
FB0751 |
6" |
100056142 |
FB1001 |
6" |
100056142 |
FB1251 |
8" |
100141561 |
FB1501 |
8" |
100141561 |
FB1751 |
8" |
100141561 |
FB2001 |
8" |
100141561 |
FB2501 |
9" |
100141562 |
FB3001 |
10" |
100141563 |
FB3501 |
10" |
100141563 |
FB4001 |
12" |
100141564 |
FB5001/6001 |
14" |
100141565 |
PVC/CPVC (Models 751 - 3501 only)
This product has been approved for use with the PVC/CPVC vent materials listed in Table 2E on page 21.
NOTICE |
Factory installed vent connections are sized |
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for stainless steel venting. |
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Installing vent and air piping |
WARNING
NOTICE
The vent connection to the appliance must be made with a minimum of 10 equivalent feet of CPVC pipe (field provided). The field provided vent fittings must be cemented to the CPVC pipe section using an “All Purpose Cement” suitable for PVC and CPVC pipe. Use only the vent materials, primer, and cement specified in Table 2E to make the vent connections. Failure to follow this warning could result in fire, personal injury, or death.
Use only cleaners, primers, and solvents that are approved for the materials which are joined together.
NOTICE |
All PVC vent pipes must be glued, properly |
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supported, and the exhaust must be |
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pitched a minimum of a 1/4 inch per foot |
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back to the boiler (to allow drainage of |
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condensate). |
WARNING
NOTICE
Insulation should not be used on PVC or CPVC venting materials. The use of insulation will cause increased vent wall temperatures, which could result in vent pipe failure.
CPVC vent or stainless steel pipe and vent fittings must be used in closet and alcove installations.
20
2 General venting (continued)
Table 2E PVC/CPVC Vent Pipe and Fittings
Approved PVC/CPVC Vent Pipe and Fittings
Item |
Material |
Standard |
|
PVC Schedule 40, 80 |
ANSI/ASTM D1785 |
Vent pipe |
PVC - DWV |
ANSI/ASTM D2665 |
|
CPVC Schedule 40, 80 |
ANSI/ASTM F441 |
|
PVC Schedule 40 |
ANSI/ASTM D2466 |
Vent fittings |
PVC Schedule 80 |
ANSI/ASTM D2467 |
CPVC Schedule 80 |
ANSI/ASTM F439 |
|
|
PVC - DWV |
ANSI/ASTM D2665 |
Pipe Cement / |
PVC |
ANSI/ASTM D2564 |
Primer |
CPVC |
ANSI/ASTM F493 |
NOTICE: DO NOT USE CELLULAR (FOAM) CORE PIPE
NOTE: In Canada, CPVC and PVC vent pipe, fittings and cement/ primer must be ULC-S636 certified.
1.Work from the boiler to vent or air termination. Do not exceed the lengths given in this manual for the air or vent piping.
2. |
Cut pipe to the required lengths |
and |
deburr the |
inside |
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and outside of the pipe ends. |
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3. |
Chamfer outside of each pipe |
end |
to ensure |
even |
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cement distribution when joining. |
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4.Clean all pipe ends and fittings using a clean dry rag. (Moisture will retard curing and dirt or grease will prevent adhesion.)
Figure 2-2 Near Boiler PVC/CPVC Venting (Flue connections from the factory are sized for stainless steel venting.)
Installation & Operation Manual
5.Dry fit vent or air piping to ensure proper fit up before assembling any joint. The pipe should go a third to two-thirds into the fitting to ensure proper sealing after cement is applied.
6.Priming and Cementing:
a.Handle fittings and pipes carefully to prevent contamination of surfaces.
b.Apply a liberal even coat of primer to the fitting socket and to the pipe end to approximately 1/2" beyond the socket depth.
c.Apply a second primer coat to the fitting socket.
d.While primer is still wet, apply an even coat of approved cement to the pipe equal to the depth of the fitting socket along with an even coat of approved cement to the fitting socket.
e.Apply a second coat of cement to the pipe.
f.While the cement is still wet, insert the pipe into the fitting, if possible twist the pipe a 1/4 turn as you insert it. NOTE: If voids are present, sufficientcementwasnotappliedandjointcould be defective.
g.Wipe excess cement from the joint removing ring or beads as it will needlessly soften the pipe.
PVC PIPE
(FIELD SUPPLIED)
PVC COUPLING (FIELD SUPPLIED)
MINIMUM OF 10 EQUIVALENT FEET OF CPVC
(FIELD SUPPLIED)
STAINLESS ADAPTER (FIELD SUPPLIED)
DIR #2000557608 00
NOTE: CPVC VENT OR STAINLESS STEEL
PIPE AND VENT FITTINGS MUST BE USED
IN CLOSET AND ALCOVE INSTALLATIONS.
21
Installation & Operation Manual
2 General venting
Polypropylene (Models 751 - 3501 only)
This product has been approved for use with polypropylene vent with the manufacturers listed in Table 2F.
NOTICE |
Factory installed vent connections are sized |
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for stainless steel venting. |
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All terminations must comply with listed options in this manual and be a single-wall vent offering.
For support and special connections required, see the manufacturer's instructions. All vent is to conform to standard diameter and equivalent length requirements established.
When determining equivalent combustion air and vent length for polypropylene single-wall piping contact the manufacturer.
Table 2F Polypropylene Vent Pipe and Fittings
Approved Polypropylene Vent Manufacturers
Make |
Model |
Centrotherm Eco Systems |
InnoFlue SW/Flex |
Duravent (M & G Group) |
PolyPro Single-Wall / PolyPro Flex |
WARNING |
Use only the adapters and vent system listed |
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in Tables 2F and 2G. DO NOT mix vent |
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systems of different types or manufacturers. |
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Failure to comply could result in severe |
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personal injury, death, or substantial |
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property damage. |
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NOTICE |
Installations must comply with applicable |
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national, state, and local codes. For |
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Canadian installation, polypropylene vent |
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must be listed as a ULC-S636 approved |
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system. |
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NOTICE |
Installation of a polypropylene vent system |
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should adhere to the vent manufacturer’s |
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installation instructions supplied with the |
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vent system. |
Figure 2-3 Near Boiler Polypropylene Venting
NOTICE |
The installer must use a specific vent starter |
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adapter at the flue collar connection. The |
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adapter is supplied by the vent manufacturer |
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to adapt to its vent system. See Table 2F for |
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approved vent adapters. |
POLYPROPYLENE PIPE (FIELD SUPPLIED)
POLYPROPYLENE ADAPTER (FIELD SUPPLIED)
NOTICE |
All vent connections MUST be secured by |
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the vent manufacturer's joint connector |
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(FIG. 2-3). |
WARNING Insulation should not be used on polypropylene venting materials. The use
of insulation will cause increased vent wall temperatures, which could result in vent pipe failure.
Table 2G Approved Polypropylene Terminations
IMG01148
MODELS 751 - 1001
POLYPROPYLENE
PIPE (FIELD SUPPLIED)
POLYPROPYLENE
ADAPTER (FIELD
SUPPLIED)
IMG01149
MODELS 1251 - 3501
Model |
Manufacturer |
Vent Model |
Vent Type |
Adapter Number |
Joint Connector |
Sidewall Kit* |
Retaining Bracket / |
|
Adapter* |
||||||||
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Centrotherm |
Innoflue |
Single-Wall |
ISSA0606 |
-- |
-- |
IATP0606 / |
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751-1001 |
Eco Systems |
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Flex |
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ISTAGL0606 |
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DuraVent |
PolyPro |
Single-Wall |
FSA-06M-6PPF |
-- |
6PPS-HLKL |
-- |
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(M & G) |
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Flex |
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|
Centrotherm |
Innoflue |
Single-Wall |
ISSA0808 |
-- |
-- |
-- |
|
1251-2001 |
Eco Systems |
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|
DuraVent |
PolyPro |
Single-Wall |
FSA-08M-8PPF |
-- |
8PPS-HSTL |
-- |
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(M & G) |
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2501 |
-- |
-- |
-- |
-- |
-- |
-- |
-- |
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3001-3501 |
Centrotherm |
Innoflue |
Single-Wall |
ISSA1010 |
-- |
-- |
-- |
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Eco Systems |
||||||||
4001 |
N/A |
N/A |
N/A |
N/A |
N/A |
N/A |
N/A |
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5001-6001 |
N/A |
N/A |
N/A |
N/A |
N/A |
N/A |
N/A |
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* These parts |
are only needed |
if the sidewall |
termination assembly is used (see FIG. 4-1C on page 26). |
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22
3 Vertical direct venting
Vent/air termination – vertical
WARNING Follow instructions below when determining vent location to avoid possibility of severe
personal injury, death or substantial property damage.
WARNING Do not connect any other appliance to the vent pipe or multiple boilers to a common
vent pipe except as noted in Section 2 on page 20. Failure to comply could result in severe personal injury, death, or substantial property damage.
NOTICE Installation must comply with local requirements and with the National Fuel
Gas Code, NFPA 54 / ANSI Z223.1 - latest edition for U.S. installations or CSA B149.1
Installation Code for Canadian installations.
Determine location
Locate the vent/air terminations using the following guidelines:
1.The total length of piping for vent or air must not exceed the limits given in the General Venting Section on page 18 of this manual.
2.The vent must terminate at least 3 feet above the highest place in which the vent penetrates the roof and at least 2 feet above any part of a building within 10 horizontal feet.
3.The air piping must terminate in a down-turned 180° return pipe no further than 2 feet (.6 m) from the center of the vent pipe. This placement avoids recirculation of flue products into the combustion air stream.
4.The vent piping must terminate in an up-turned coupling as shown in FIG. 3-1. The top of the coupling or the rain cap must be at least 36" (914 mm) above the air intake. The air inlet pipe and vent pipe can be located in any desired position on the roof, but must always be no further than 2 feet (.6 m) apart and with the vent termination at least 36" (914 mm) above the air intake.
WARNING Rooftop vent and air inlet terminations must terminate in the same pressure zone,
unless vertical vent sidewall air is set up as shown in the General Venting - Vertical Vent, Sidewall Air Section.
Figure 3-1 Vertical Termination of Air and Vent
|
BIRD SCREEN |
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[TYPICAL] |
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VENT OUTLET |
VENT |
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36" MINIMUM |
12" [305 MM] MINIMUM |
|
ABOVE AIR INLET |
||
ABOVE ROOF / |
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SNOW LINE |
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COMBUSTION AIR |
Installation & Operation Manual
Figure 3-2 Vertical Termination of Air and Vent w/Rain Cap
5.Locate terminations so they are not likely to be damaged by foreign objects, such as stones or balls, or subject to buildup of leaves or sediment.
Prepare roof penetrations
1.Air pipe penetration:
a.Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter.
2.Vent pipe penetration:
a.Cut a hole for the vent pipe. For either combustible or noncombustible construction, size the vent pipe hole per the vent manufacturer’s instructions.
b.Insert a galvanized metal thimble in the vent pipe hole (when required by local codes).
3.Space the air and vent holes to provide the minimum spacing shown in FIG. 3-1.
4.Follow all local codes for isolation of vent pipe when passing through floors, ceilings, and roofs.
5.Provide flashing and sealing boots sized for the vent pipe and air pipe.
Termination and fittings
1.Prepare the vent termination coupling and the air termination elbow (FIG. 3-1) by inserting bird screens. Bird screens should be obtained locally.
2.The air piping must terminate in a down-turned 180° return bend as shown in FIG. 3-1. Locate the air inlet pipe no further than 2 feet (.6 m) from the center of the vent pipe. This placement avoids recirculation of flue products into the combustion air stream.
23