Lochinvar FBN0751, FBN1001, FBN1251, FBN1501, FBN1751 Installation Manual

...

100208043_2000004587_Rev Y

Installation & Operation Manual

Models: 751 - 6001

Series: 100 - 101 & 110 - 111

⚠WARNING

Save this manual for future reference.

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.

Contents

HAZARD DEFINITIONS .................................................. 2

PLEASE READ BEFORE PROCEEDING ..................... 3

THE CREST -- HOW IT WORKS ................................. 4-5

RATINGS .......................................................................... 6

1. DETERMINE BOILER LOCATION

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

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

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

Vent/Air Termination - Sidewall ................................... 25-27

Determine Location ................................................ 25-27

Prepare Wall Penetrations .......................................... 27

Termination and Fittings ............................................. 27

Multiple Vent/Air Terminations ............................... 27-28

Room Air ..................................................................... 28

5. HYDRONIC PIPING

System Water Piping Methods ......................................... 29

Low Water Cutoff Device ................................................. 29

Chilled Water System ....................................................... 29

Freeze Protection ............................................................. 29

General Piping Information .............................................. 29

Circulator Sizing ............................................................... 30

Near Boiler Piping Components ....................................... 32

6. GAS CONNECTIONS

Connecting Gas Supply Piping ........................................ 37

Natural Gas ...................................................................... 38

Pipe Sizing for Natural Gas ........................................ 38

Natural Gas Supply Pressure Requirements ............. 38

Propane Gas .................................................................... 38

Pipe Sizing for Propane Gas ...................................... 38

Propane Supply Pressure Requirements ................... 38

Check Inlet Gas Supply .............................................. 39-40

Gas Valve Replacement .................................................. 40

7. FIELD WIRING

Line Voltage Connections ................................................ 41

Low Voltage Connections ................................................ 42

Wiring of the Cascade ...................................................... 43

8. CONDENSATE DISPOSAL

Condensate Drain ............................................................ 45

9. STARTUP ............................................................... 46-54

10. OPERATING INFORMATION

General ........................................................................ 55-57

Cascade ........................................................................... 58

Sequence of Operation .................................................... 59

Home Screen ................................................................... 60

11. MAINTENANCE

Maintenance & Annual Startup .............................. 61-65

12. DIAGRAMS

Ladder Diagrams ................................. 66,68,70, and 72

Wiring Diagrams .................................. 67,69,71, and 73

Revision Notes .................................................. 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.

Please read before proceeding

⚠WARNING

NOTICE

⚠WARNING

Installer – Read all instructions, including this manual and the Crest Service Manual, before installing. Perform steps in the order given.

User – This manual is for use only by a qualified heating installer/ service technician. Refer to the User’s Information Manual for your reference.

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.

When calling or writing about the boiler – Please have the boiler model and serial number from the boiler rating plate.

Consider piping and installation when determining boiler location.

Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.

Factory warranty (shipped with unit) does not apply to units improperly installed or improperly operated.

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.

When servicing boiler –

Boiler operation –

Boiler water –

Freeze protection fluids –

Installation & Operation Manual

⚠WARNING

• To avoid electric shock, disconnect electrical supply before performing maintenance.

• To avoid severe burns, allow boiler to cool before performing maintenance.

• 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.

• 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.

• 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.

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.

⚠WARNING

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.

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.

The Crest - How it works... (continued)

Installation & Operation Manual

NOTICE

Front View

FBN1000 Series 100 model shown for illustration purposes only.

IMG01025

Rear View

IMG01128

10 40

21 22

25 26

24 23

30 31

IMG01130

Left Side (inside unit)

IMG01129

Right Side (inside unit)

Ratings

Installation & Operation Manual

Crest

AHRI Rating

Model Number

Note: Change “N” to

“L” for L.P. gas models.

Min Max

FB(N,L)0751 50 750 720 626

FB(N,L)1001 50 999 960 835

FB(N,L)1251 62 1250 1200 1043

FB(N,L)1501 60 1500 1440 1252

FB(N,L)1751 70 1750 1680 1460

FB(N,L)2001 80 1999 1920 1670

FB(N,L)2501 125 2500 2403 2089

FB(N,L)3001 150 3000 2880 2504

FB(N,L)3501 175 3500 3360 2922

FB(N,L)4001 333 3999 3840 3339

FB(N,L)5001 500 4999 4800 4174

FB(N,L)6001 600 6000 5760 5009

Input MBH

(Notes 4 - 6)

Gross

Output

MBH

(Note 1)

Net

AHRI

Ratings

Water,

MBH

(Note 2)

Other Specifications

Appliance

Water Content Gallons

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

Pipe

Pipe Size Inlet

Gas Inlet

Size

Outlet

73 3" 3" 1 1/4" 6" 6" 1768

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

Air

Size

Vent Size

(Note 3)

Weight

w/Water

(lbs.)

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.  e 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.  e operation given in this manual remains the same as the standard boilers. A high altitude label (as shown in FIG A.) is also a xed 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.  e 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 con rmed by the Hydronics Section of AHRI.

UNIT EQUIPPED FOR

HIGH ALTITUDE

3,000 FT. TO 12,000 FT.

IMG01026

Figure A High Altitude Label Location

Installation & Operation Manual

1 Determine boiler location

Installation must comply with:

• Local, state, provincial, and national codes, laws, regulations, and ordinances.

• National Fuel Gas Code, NFPA 54 / ANSI Z223.1 – latest edition.

• Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1 latest edition, when required.

• National Electrical Code, NFPA 70 - latest edition.

• For Canada only: CSA B149.1 Installation Code, CSA C22.1 Canadian Electrical Code Part 1 and any local codes.

NOTICE

The Crest gas manifold and controls met safe lighting and other performance criteria when the boiler underwent tests specified in ANSI Z21.13/CSA 4.9 – latest edition.

Before locating the boiler, check:

1. Check for nearby connection to:

• System water piping

• Venting connections

• Gas supply piping

• Electrical power

2. Locate the appliance so that if water connections

should leak, water damage will not occur. When such locations cannot be avoided, it is recommended that a suitable drain pan, adequately drained, be installed under the appliance. The pan must not restrict combustion air flow. Under no circumstances is the manufacturer to be held responsible for water damage in connection with this appliance, or any of its components.

3. Check area around the boiler. Remove any

combustible materials, gasoline and other flammable liquids.

⚠WARNING

4. The Crest must be installed so that gas control

system components are protected from dripping or spraying water or rain during operation or service.

5. If a new boiler will replace an existing boiler, check

for and correct system problems, such as:

• System leaks causing oxygen corrosion or heat exchanger cracks from hard water deposits.

• Incorrectly-sized expansion tank.

• Lack of freeze protection in boiler water causing system and boiler to freeze and leak.

• Debris left from existing piping, if not flushed and cleaned with an appropriate cleaner.

6. The appliance must be installed on a level floor, both front to back and side to side, for proper condensate drainage.

7. If the optional neutralizing kit is to be used, elevate the boiler at least 3" above the floor.

Failure to keep boiler area clear and free of combustible materials, gasoline, and other flammable liquids and vapors can result in severe personal injury, death, or substantial property damage.

8. Check around the boiler for any potential air contaminants that could risk corrosion to the boiler or the boiler combustion air supply (see Table 1A on page 9). Prevent combustion air contamination. Remove any of these contaminants from the boiler area.

⚠WARNING

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.

⚠WARNING

This appliance is certified as an indoor appliance. Do not install the appliance outdoors or locate where the appliance will be exposed to freezing temperatures or to temperatures that exceed 100°F (37.8°C).

Do not install the appliance where the relative humidity may exceed 93%. Do not install the appliance where condensation may form on the inside or outside of the appliance, or where condensation may fall onto the appliance.

Failure to install the appliance indoors could result in severe personal injury, death, or substantial property damage.

⚠WARNING

This appliance requires a special venting system. Use only the vent materials specified in this manual. Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

Provide clearances:

Clearances from combustible materials

- Hot water pipes ........................................................... 1/4"

- Sides .............................................................................. 0"

- Rear ............................................................................... 0"

- Front ............................................................................. 0"

- Top ................................................................................ 0"

- Floor ........................................................... Combustible

- Vent pipe - Follow special vent system manufacturer’s instructions

Figure 1-1 Clearances

1" (25 MM) MINIMUM CLEARANCE

ROUND HOT WATER P IPES

0" LEFT

FLOOR: COMBUSTIBLE

0" REAR

VENT PIPE: FOLLOW SPECIAL VENT SYSTEM MANUFACTURER'S INSTRUCTIONS

0" TOP

VENTILATING* AIR OPENING

CLOSED DOOR

VENTILATING*

RIGHT

FRONT

IMG01027

1 Determine boiler location

Installation & Operation Manual

NOTICE

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.

If you do not provide the recommended service clearances shown, it may not be possible to service the boiler without removing it from the space.

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

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).

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.

Flooring and foundation

Flooring

The Crest is approved for installation on combustible flooring, but must never be installed on carpeting.

⚠WARNING

If flooding is possible, elevate the boiler sufficiently to prevent water from reaching the boiler.

⚠WARNING

Do not install the boiler on carpeting even if foundation is used. Fire can result, causing severe personal injury, death, or substantial property damage.

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.

1 Determine boiler location (continued)

When using an existing vent system to install a new boiler:

Table 1A Corrosive Contaminants and Sources

Installation & Operation Manual

⚠WARNING

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.

⚠WARNING

Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

If any of these conditions are not met, 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.

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

1 Determine boiler location

Installation & Operation Manual

When removing a boiler from existing common vent system:

⚠ DANGER

⚠WARNING

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.

Do not install the Crest into a common vent with any other appliance except as noted in Section 2 on page 20. 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 result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

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

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).

NOTICE

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.

Do not drop the boiler or bump the jacket on the floor or pallet. Damage to the boiler can result.

1 Determine boiler location (continued)

Installation & Operation Manual

Figure 1-2 Boiler Mounted on Shipping Pallet

BOLT, WASHERS & LOCKNUT (3X)

FRONT

REAR

LAG BOLTS & TABS (3X)

Figure 1-3 Boiler Removed from Shipping Pallet

REMOVE MIDDLE TOP COVER

LIFTING LUGS

Combustion and ventilation air requirements for appliances drawing air from the equipment room

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”

IMG01028

LIFTING LUGS

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.

IMG01029

Figure 1-4_Combustion Air Direct from Outside

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 cm

per kW) (see FIG. 1-4).

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 cm

per kW) of input (see FIG. 1-5).

Installation & Operation Manual

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 cm 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).

per kW). This

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 cm

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 cm

per kW).

⚠CAUTION

Under no circumstances should the 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.

IMG01032

Figure 1-7_Combustion Air from Outside - Single Opening

Installation & Operation Manual

1 Determine boiler location (continued)

TABLE - 1B

MINIMUM RECOMMENDED COMBUSTION

AIR SUPPLY TO EQUIPMENT ROOM

FIG. 1-4 FIG. 1-5 FIG. 1-6 FIG. 1-7

Inside Air from

Same Story

Opening, in

Bottom

(cm2)

Different

Stories

Openings, in

Total

(cm2)

*Outside Air from 1 Opening Directly from Outdoors, in

(cm2)

Model

Number

*Outside Air from

2 Openings Directly from

Bottom

Opening, in

(cm2)

Outdoors

Top

Opening, in

(cm2)

*Outside Air from

2 Ducts Delivered from

Bottom

Opening, in

(cm2)

Outdoors

Top

Opening, in

(cm2)

2 Ducts Delivered from Interior Space

Top

Opening, in

(cm2)

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) 1000 (6452) 2000 (12904) 333 (2149)

FB 1251 313 (2020) 313 (2020) 625 (4033) 625 (4033) 1250 (8065) 1250 (8065) 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.

Outside air openings shall directly communicate with the outdoors.

Combined interior space must be 50 cubic feet per 1,000 Btu/hr input. Buildings MUST NOT be of *“Tight Construction”.

”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.

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.

5. Replace the air filter and the air filter box cover.

2 General venting

Installation & Operation Manual

Direct venting

Sidewall

IMG01033

Vertical Vent, Sidewall Air

Optional room air

IMG01056

IMG01057

Vertical

Sidewall

IMG01058

IMG01059

Vertical

2 General venting (continued)

Install vent and combustion air piping

Installation & Operation Manual

⚠ 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.

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.

*Plastic pipe may require an adapter (not provided) to transition between the air inlet connection on the appliance and the plastic air inlet pipe.

⚠WARNING

NOTICE

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 material for the combustion air inlet pipe is recommended in cold climates to prevent the condensation of airborne moisture in the incoming combustion air.

2 General venting

Installation & Operation Manual

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.

Installation of a stainless steel vent system should adhere to the stainless steel vent manufacturer’s installation instructions supplied with the vent system.

The Crest is supplied with an integral FasNSeal vent connector (FIG. 2-1). The installer must use a specific vent starter adapter supplied by the vent manufacturer 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 or vent piping to sizes not specified in this 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 --

Installation & Operation Manual

2 General venting (continued)

Table 2A-2 Approved Stainless Steel Terminations and Adapters - Category IV

Model

751-1001

1251

1501-2001

Model

751-1001

1251

1501-2001

Model

751-1001

1251

1501-2001

ProTech Z Flex Heat Fab

Adapter Intake Adapter Intake Adapter Flue Intake

Not Required 810003269 2SVDSA06 2SVEE0690 9601MAD CCK06TM 9690 / 9692

*See note 810003281 2SVDSA06 2SVEE0690 9801MAD CCK08TM 9690 / 9692

*See note 810003357 / 810003369 2SVDSA08 2SVEE0890 9801MAD CCK08TM 9890 / 9892

Metal-Fab Security Chimney ICC

Adapter Flue Intake Adapter Flue Intake Adapter Flue Intake

6FCGPVCA

8FCGLCA

6-36"

6FCGSW90L SS6PVCU

6FCGSW90L SS8CRESTU

8FCGSW90 SS8CRESTU

Jeremias

Adapter Flue Intake

SWKL6-KLC SWKL6-WRC SWKL6-90ET

SWKL8-KLC SWKL8-WRC SWKL6-90ET

SWKL8-KLC SWKL8-WRC SWKL8-90ET

SS0MCU

4" - 24"

SS0MCU

4" - 24"

SS0MCU

4" - 24"

*No adapter needed when using 8" FasNSeal vent length.

*Models 1251 - 1501: For installations using 6" vent, install a FasNSeal reducing adapter, available from the factory with kit #100295900. Reference the manufacturer's part number provided for Models 751 - 1001 when adapting to different vent systems.

SS6ST90AU

SSD0STAUK

4" - 24"

SS6ST90AU

SSD0STAUK

4" - 24"

SSE8E9OU SD0STAUK

4" - 24"

HE-6DSA-F

HE-8DSA-F

HE-6MC-F HE-6RC-F

HE-8SCR-F

HE-8MC-F

HE-8SCR-F

HE-8MC-F

HE-6E90-F

HE-6SCR-F

HE-6E90-F

HE-6SCR-F

HE-8E90-F

HE-8SCR-F

Model

2501

3001 - 3501

4001

5001 - 6001

Model

2501

3001 - 3501

4001

5001 - 6001

Model

2501

3001 - 3501

4001

5001 - 6001

ProTech Z Flex Heat Fab

Adapter Intake Adapter Intake Adapter Flue Intake

*See note 810003397 / 810003409 2SVDSA09 2SVEE990 9901MAD CCK09TM 9890 / 9992

*See note 810003435 / 810003447 2SVDSA10 2SVEE1090 91001MAD CCK10TM 91090 / 91092

*See note 810003476 / 810003488 2SVDSA12 2SVEE1290 91201MAD CCK12TM 91290 / 91292

*See note 810003516 / 810003528 2SVDSA14 2SVEE1490 91401MAD CCK14TM 91490 / 91492

Metal-Fab Security Chimney ICC

Adapter Flue Intake Adapter Flue Intake Adapter Flue Intake

8FCGLCA

10FCGLCA

12FCGLCA

14FCGLCA

6-36"

8FCGSW90 SS9CRESTU

10FCGSW90 SS10CRESTU

12FCGSW90 SS12CRESTU

14FCGSW90 SS14CRESTU

Jeremias

Adapter Flue Intake

SWKL9-KLC SWKL9-WRC SWKL9-90ET

SWKL10-KLC SWKL10-WRC SWKL10-90ET

SWKL12-KLC SWKL12-WRC SWKL12-90ET

SWKL14-KLC SWKL14-WRC SWKL14-90ET

SS0MCU

4" - 24"

SS0MCU

4" - 24"

SS0MCU

4" - 24"

SS0MCU

4" - 24"

*No adapter needed when using Standard FNS Vent Length.

SSE9E9OU

SDOST90AUK

4" - 10"

SSE10E9OU

SDOST90AUK

4" - 10"

SSE12E9OU HE-12DSA-F

SSE14E9OU HE-14DSA-F

HE-9DSA-F

HE-10DSA-F

HE-9SCR-F

HE-9MC-F

HE-10SCR-F

HE-10MC-F

HE-12SCR-F

HE-12MC-F

HE-14SCR-F

HE-14MC-F

HE-8E90-F

HE-9SCR-F

HE-10E90-F

HE-10SCR-F

HE-12E90-F

HE-12SCR-F

HE-14E90-F

HE-14SCR-F

2 General venting

Table 2B Direct Vent Minimum / Maximum Allowable Air / Vent Lengths

Installation & Operation Manual

AIR INLET VENT

Model

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%

Air Intake

Diameter

Air Intake

Min. Length

Air Intake

Max. Length

Vent

Diameter

Vent

Min. Length

Vent

Max. Length

Input

De-Rate per

25 feet of Vent

*FB 1251 - 1501 models using 6" vent require the installation of a  eld 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

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%

Vent

Diameter

Vent

Min. Length

Vent

Max. Length

Input De-Rate per

25 feet of Vent

2 General venting (continued)

Installation & Operation Manual

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:

NOTICE

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

NOTICE

Installation must comply with local requirements and with the National Fuel Gas Code, NFPA 54 / ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations.

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), 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.

⚠WARNING

If the boiler combustion air inlet is located in a laundry room or pool facility, for example, these areas will always contain hazardous contaminants.

To prevent the potential of severe personal 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.

2 General venting

Installation & Operation Manual

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

NOTICE

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.

When Crest boilers are common vented, hot water generators MUST BE piped to the primary heating loop and tank thermostats must not be connected to the Crest.

A field supplied inline condensate collection section MUST BE installed directly above the backflow preventer.

When using polypropylene common vent on Models 751 - 3501, a field supplied polypropylene to stainless steel adapter MUST BE installed between the backflow 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

Installing vent and air piping

⚠WARNING

NOTICE

⚠WARNING

NOTICE

Factory installed vent connections are sized for stainless steel venting.

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.

All PVC vent pipes must be glued, properly supported, and the exhaust must be pitched a minimum of a 1/4 inch per foot back to the boiler (to allow drainage of condensate).

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.

2 General venting (continued)

Installation & Operation Manual

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

Vent fittings

Pipe Cement /

Primer

NOTICE: DO NOT USE CELLULAR (FOAM) CORE PIPE

NOTE: In Canada, CPVC and PVC vent pipe,  ttings and cement/ primer must be ULC-S636 certi ed.

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 and outside of the pipe ends.

3. Chamfer outside of each pipe end to ensure even cement distribution when joining.

4. Clean all pipe ends and fittings using a clean dry rag. (Moisture will retard curing and dirt or grease will prevent adhesion.)

PVC - DWV ANSI/ASTM D2665

CPVC Schedule 40, 80 ANSI/ASTM F441

PVC Schedule 40 ANSI/ASTM D2466

PVC Schedule 80 ANSI/ASTM D2467

CPVC Schedule 80 ANSI/ASTM F439

PVC - DWV ANSI/ASTM D2665

PVC ANSI/ASTM D2564

CPVC ANSI/ASTM F493

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, sufficient cement was not applied and joint could be defective.

g. Wipe excess cement from the joint removing ring or beads as it will needlessly soften the pipe.

Figure 2-2 Near Boiler PVC/CPVC Venting (Flue connections from the factory are sized for stainless steel venting.)

PVC PIPE (FIELD SUPPLIED)

PVC COUPLING (FIELD SUPPLIED)

MINIMUM OF 10 EQUIVALENT FEET OF CPVC (FIELD SUPPLIED)

STAINLESS ADAPTER (FIELD SUPPLIED)

NOTE: CPVC VENT OR STAINLESS STEEL PIPE AND VENT FITTINGS MUST BE USED IN CLOSET AND ALCOVE INSTALLATIONS.

DIR #2000557608 00

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 for stainless steel venting.

Installation & Operation Manual

⚠WARNING

Use only the adapters and vent system listed in Tables 2F and 2G. DO NOT mix vent systems of different types or manufacturers. Failure to comply could result in severe personal injury, death, or substantial property damage.

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

Duravent (M & G Group)

NOTICE

The installer must use a specific vent starter adapter at the flue collar connection. The

PolyPro Single-Wall / PolyPro Flex

InnoFlue SW/Flex

adapter is supplied by the vent manufacturer to adapt to its vent system. See Table 2F for approved vent adapters.

NOTICE

All vent connections MUST be secured by the vent manufacturer's joint connector (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.

NOTICE

Installations must comply with applicable national, state, and local codes. For Canadian installation, polypropylene vent must be listed as a ULC-S636 approved system.

NOTICE

Installation of a polypropylene vent system should adhere to the vent manufacturer’s installation instructions supplied with the vent system.

Figure 2-3 Near Boiler Polypropylene Venting

POLYPROPYLENE PIPE (FIELD SUPPLIED)

POLYPROPYLENE

DAPTER (FIELD

SUPPLIED)

IMG01148

MODELS 751 - 1001

POLYPROPYLENE PIPE (FIELD SUPPLIED)

POLYPROPYLENE ADAPTER (FIELD SUPPLIED)

Table 2G Approved Polypropylene Terminations

Model Manufacturer Vent Model Vent Type Adapter Number Joint Connector Sidewall Kit*

Centrotherm

751-1001

1251-2001

2501

3001-3501

4001

5001-6001

* These parts are only needed if the sidewall termination assembly is used (see FIG. 4-1C on page 26).

Eco Systems

DuraVent

(M & G)

Centrotherm

Eco Systems

DuraVent

(M & G)

-- -- -- -- -- -- --

Centrotherm

Eco Systems

N/A N/A N/A N/A N/A N/A N/A

Innoflue

PolyPro

Innoflue Single-Wall ISSA0808 -- -- --

PolyPro Single-Wall FSA-08M-8PPF -- 8PPS-HSTL --

Innoflue Single-Wall ISSA1010 -- -- --

Single-Wall

Flex

Single-Wall

Flex

ISSA0606 -- --

FSA-06M-6PPF -- 6PPS-HLKL --

MODELS 1251 - 3501

Retaining Bracket /

IATP0606 /

ISTAGL0606

IMG01149

Adapter*

3 Vertical direct venting

Vent/air termination – vertical

Installation & Operation Manual

⚠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 3-2 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

Figure 3-1 Vertical Termination of Air and Vent

BIRD SCREEN [TYPICAL]

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

VENT OUTLET

36" MINIMUM

BOVE AIR INLET

VENT

COMBUSTION AIR

12" [305 MM] MINIMUM ABOVE ROOF / SNOW LINE

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.

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