O and M Manual for Boiler.pdf

Operations and Maintenance Manual

Specification:

23.52.16

CONDENSING BOILERS

Project:

Fort Yuma Health Care Center

401 Picacho Road Winterhaven, CA 92283

Prepared for

IHS Engineering Services 701 5th Ave, Suite 1600

Seattle, WA 98121

Architect Dekker/Perich/Sabatini, Ltd.

7601 Jefferson St., N.E. Suite 100 Albuquerque, NM 87109

Contractor:

Pilkington Commercial Co., Inc.

Women-Owned Small Business 2975 South Avenue B

Yuma, Az. 85364

STREAMLINE

Enterprises Incorporated www.streamlineenterprisesinc. com

P.O. Box 25326 Yuma, AZ 85367 Phone (928) 314-0906 Fax (928)314-0920

Warranty /Guarantee

Project: ________ ~Fo,rt'""--"Y-"u""'m"""a"-'H'-'-""ea"-!lt""'"h'-'C""a""r-"'e_,C"""e""'n"'te"'"r ___________ _

Project Address: ____ -'4'-"0-"-1-"P...!.ic=a=c=h=o~R=d'-'-. ___,Wc.:...=in=te=r=ha=v::....:e=n~Cc:...A"""'9~2=2=8=3 ________ _

Streamline Enterprises Incorporated hereby warrants and guarantees its work and all equipment, structure, and facilities furnished, installed or constructed by or under the direction of the Subcontractor or material supplier, to be free from improper or defective materials or workmanship.

Provided in the Contract Documents, this warranty and guarantee shall continue for a period of (1) year from the date of certificate of acceptance of the entire construction project.

The obligation under this warranty and guarantee shall include all cost and expenses whatsoever to repair and correct such defects. Upon notice by the Owner or Pilkington Commercial Co., Inc. of any such defects, Subcontractor, at his own expense and with due diligence, shall immediately repair and replace any defective materials or perform any labor necessary to correct any such defect in the work. Should the Subcontractor fail to repair, replace, or connect any such defect as provided above, the Owner or Pilkington Commercial Co., Inc. at Subcontractor's expense, may furnish all materials and labor performed to correct of repair any such defects will have the same warranty and guarantee as Subcontractor's original warranty and guarantee and shall as to the repaired or replaced item commence on the date of completion of such repair of correction.

It is the Subcontractor's responsibility to enforce all warranties or guarantees of all suppliers, vendors and second tier Subcontractors, shall not apply to work which has been abused, neglected, or altered by others or to work for which the owner has previously given the contractor a written acceptance of the defect.

By: 03/28/2018 President www.streamlineenterprisesinc.com

P.O. Box 25326 Yuma, AZ 85367 Phone (928) 314-0906 Fax (928)314-0920

FORT YUMA HEALTH CARE CENTER

Operation and Maintenance Data

Condensing Boilers

Spec Section: 23 52 16

Sub Paragraph: 1.3, E www.streamlineenterprisesinc.com

P.O. Box 25326 Yuma, AZ 85367 Phone (928) 314-0906 Fax (928)314-0920

Name of Item: CREST Condensing Boilers

Model: FBL-1501

Name & Phone Numbers of Manufacturers or

Supplier: Mechanical Products South West 2620 East Rose Garden Lane, Suite 1 Phoenix, AZ 85050 (602) 288-

Names, Addresses and Telephone Numbers of

Sources of Spare Parts: Mechanical Products South West 2620 East Rose Garden Lane, Suite 1 Phoenix, AZ 85050 (602) 288-4920

Manufacturer’s Representative Name &

Phone Number: Bo Yeager (602) 288-4920 http://www.streamlineenterprisesinc.com/

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.

� WARNING

Save this manual for future reference.

FBII-I-O_100208043_2000004587_Rev R

Installation & Operation Manual Models: 751 - 2001

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Contents

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.

HAZARD DEFINITIONS

PLEASE READ BEFORE PROCEEDING

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

RATINGS

1. DETERMINE BOILER LOCATION

Clearances Provide Air Openings to Room Flooring and Foundation Vent and Air Piping Prevent Combustion Air Contamination Using an Existing Vent System to Install a New Boiler Corrosive Contaminants and Sources Removing a Boiler from Existing Common Vent Remove Boiler from Wood Pallet Combustion and Ventilation Air Requirements ........... 12-13

2. GENERAL VENTING

Direct Venting Options - Sidewall Vent Direct Venting Options - Vertical Vent Direct Venting Options - Vert. Vent, Opt. Rm Air Direct Venting Options - Vert. Vent, Sidewall Air Install Vent and Combustion Air Piping Air Inlet Pipe Materials Vent and Air Piping Air Intake / Vent Connections Min./Max. Combustion Air & Vent Piping Lengths Vent and Air Piping Common Venting PVC/CPVC .................................................................. 19-20 Polypropylene

3. VERTICAL DIRECT VENTING

Vent/Air Termination - Vertical Determine Location Prepare Roof Penetrations Termination and Fittings ........................................ 22-23 Multiple Vent/Air Terminations

4. SIDEWALL DIRECT VENTING

Vent/Air Termination - Sidewall ................................... 24-26 Determine Location ................................................ 24-26 Prepare Wall Penetrations

Termination and Fittings Multiple Vent/Air Terminations ............................... 26-27 Room Air

5. HYDRONIC PIPING

System Water Piping Methods Low Water Cutoff Device Chilled Water System Freeze Protection General Piping Information Circulator Sizing Near Boiler Piping Components .................................. 30-34

6. GAS CONNECTIONS

Connecting Gas Supply Piping Natural Gas Pipe Sizing for Natural Gas Natural Gas Supply Pressure Requirements Propane Gas Pipe Sizing for Propane Gas Propane Supply Pressure Requirements Check Inlet Gas Supply .............................................. 37-38 Gas Valve Replacement

7. FIELD WIRING

Line Voltage Connections Low Voltage Connections Wiring of the Cascade

8. CONDENSATE DISPOSAL

Condensate Drain

9. STARTUP ............................................................... 44-52

10. OPERATING INFORMATION

General ........................................................................ 53-55 Cascade Sequence of Operation Home Screen

11. MAINTENANCE

Maintenance & Annual Startup .............................. 59-63

12. DIAGRAMS

Ladder Diagram Wiring Diagram Revision Notes .................................................. Back Cover

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Installation & Operation Manual

Please read before proceeding 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.

Failure to adhere to the guidelines on this page can result in severe personal injury, death, or substantial property damage.

When servicing boiler –

• 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.

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.

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.

� WARNING

NOTICE

� WARNING

� 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 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.

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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 25:1 turndown (Models 1501 - 2001).

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.

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 A 3" (Models 751 - 1251) or 4” (Models 1501 - 2001) ANSI flange connects the return water from the system to the heat exchanger.

36. Water outlet A 3" (Models 751 - 1251) or 4" (Models 1501 - 2001)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.

Right Side (inside unit)

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

Installation & Operation Manual

IMG01025

Front View

IMG01128

Rear View

IMG01130

IMG01129

Left Side (inside unit)

Ratings

Crest AHRI Rating

Model Number

Note: Change “N” to “L” for L.P. gas models.

Input

MBH

(Notes 4 - 6)

Min Max

Gross Output

MBH

(Note 1)

Net

AHRI

Ratings Water, MBH

(Note 2)

FB(N,L)0751 50 750 720 626

FB(N,L)1001 50 1000 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 2000 1920 1670

Other Specifications

Appliance Water

Content Gallons

Pipe Size

Outlet

Pipe Size Inlet

Gas Inlet Size

Air Size

Vent Size

(Note 3)

Weight w/Water

(lbs.)

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

106 4" 4" 1 1/2" 8" 8" 2458

111 4" 4" 1 1/2" 8" 8" 2570

Maximum allowed working pressure is located on the rating plate. NOTICE

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. Th 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. Th e operation given in this manual remains the same as the standard boilers. A high altitude label (as shown in FIG A.) is also affi xed to the unit.

De-rate values are based on proper combustion calibration and CO2’s adjusted to the recommended levels.

UNIT EQUIPPED FOR

HIGH ALTITUDE

3,000 FT. TO 12,000 FT.

IMG01026

Figure A High Altitude Label 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. � 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.

1 Determine boiler location

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.

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.

NOTICE

� WARNING

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.

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.

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

� WARNING

VENTILATING*

AIR OPENING

VENTILATING*

CLOSED DOOR

FLOOR: COMBUSTIBLE

IMG01027 0"

FRONT

0"

RIGHT

0"

TOP

VENT PIPE:

FOLLOW SPECIAL VENT SYSTEM

MANUFACTURER'S INSTRUCTIONS

1" (25 MM) MINIMUM CLEARANCE

AROUND HOT WATER PIPES

0"

REAR

0"

LEFT

Figure 1-1 Clearances

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.

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

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1 Determine boiler location

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 27 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.

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).

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

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

Flooring and foundation Flooring

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

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 27 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.

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.

� 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.

� WARNING

Recommended clearances for service access

- Sides .............................................................................. 24"

- Rear ............................................................................... 24"

- Front ............................................................................. 30"

- Top ................................................................................ 24"

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.

NOTICE

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.

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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

Table 1A Corrosive Contaminants and Sources

1 Determine boiler location (continued)

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

� WARNING

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

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

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.

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1 Determine boiler location

When removing a boiler from existing common vent system:

Do not install the Crest into a common vent with any other appliance except as noted in Section 2 on page 19.

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.

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.

� 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.

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.

AlecSullivan Highlight

1 Determine boiler location (continued)

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.

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 on the floor or pallet. Damage to the boiler can result.

REAR

FRONT

BOLT, WASHERS

& LOCKNUT (3X)

LAG BOLTS & TABS

(3X)

Figure 1-2 Boiler Mounted on Shipping Pallet

NOTICE

IMG01028

LIFTING

LUGS

LIFTING

LUGS

REMOVE MIDDLE

TOP COVER

Figure 1-3 Boiler Removed from Shipping Pallet

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.

� WARNING

1 Determine boiler location

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”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.

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).

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 cm2 per kW) (see FIG. 1-4).

IMG01032

Figure 1-7_Combustion Air from Outside - Single Opening12

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).

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.

� 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 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.

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.

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.

1 Determine boiler location (continued)

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.

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).

TABLE - 1B

MINIMUM RECOMMENDED COMBUSTION

AIR SUPPLY TO EQUIPMENT ROOM

Model Number

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

*Outside Air from 2 Openings Directly from

Outdoors1

*Outside Air from 2 Ducts Delivered from

Outdoors1

Inside Air from 2 Ducts Delivered from Interior Space2 *Outside Air from

1 Opening Directly from Outdoors, in2

(cm2)1

Same Story Different Stories

Top Opening, in2

(cm2)

Bottom Opening, in2

(cm2)

Top Opening, in2

(cm2)

Bottom Opening, in2

(cm2)

Top Opening, in2

(cm2)

Bottom Opening, in2

(cm2)

Total Openings, in2

(cm2)

FB 0751 188

(1213)

(1213)

(2420)

(2420)

(4839)

(4839)

(9678)

(1613)

FB 1001

(1613)

(1613)

(3226)

(3226)

(6452)

(6452)

(12904)

(2149)

FB 1251 313

(2020)

(2020)

(4033)

(4033)

(8065)

(8065)

(16129)

(2691)

FB 1501 375

(2420)

(2420)

(4839)

(4839)

(9678)

(9678)

(19355)

(3226)

FB 1751 438

(2826)

(2826)

(5646)

(5646)

(11291)

(11291)

(22581)

(3762)

FB 2001 500

(3226)

(3226)

(6452)

(6452)

(12904)

(12904)

(25807)

(4304)

Vertical

IMG01033

2 General venting

IMG01059

IMG01056

Sidewall

Direct venting

Vertical Vent, Sidewall AirSidewall

IMG01057

Vertical

IMG01058

Optional room air

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.

� 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.

NOTICE 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.

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.

AlecSullivan Highlight

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.

IMG01034

ROOM AIR BOX

SHIPPED WITH

UNIT

AIR PIPE

(FIELD SUPPLIED)

VENT PIPE

(FIELD SUPPLIED)

CONNECTOR SIZED FOR STAINLESS STEEL

FLUE PIPE

Figure 2-1 Combustion Air Adapter

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 19.

� WARNING

NOTICE

NOTICE

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.

The Crest uses model specific combustion air intake and vent piping sizes as detailed in Tables 2B and 2C on page 17.

Increasing or decreasing combustion air or vent piping to sizes not specified in this manual is not authorized.

NOTICE

2 General venting

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.

NOTICE 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.

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 --

AlecSullivan Highlight

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

Table 2C Room Air Minimum / Maximum Allowable Air / Vent Lengths

Model AIR INLET VENT Input

De-Rate per 25 feet of Vent

Air Intake Diameter

Air Intake Min. Length

Air Intake Max. Length

Vent Diameter

Vent Min. Length

Vent Max. Length

FB 0751 6" 12' 100' 6" 18' 100' 0%

FB 1001 6" 12' 100' 6" 18' 100' 0%

FB 1251 6" 12' 100' 8" 18' 100' 0%

FB 1501 8" 12' 100' 8" 18' 100' 0%

FB 1751 8" 12' 100' 8" 18' 100' 0%

FB 2001 8" 12' 100' 8" 18' 100' 0%

Model Vent Diameter

Vent Min. Length

Vent Max. Length

Input De-Rate per 25 feet of Vent

FB 0751 6" 18' 100' 0%

FB 1001 6" 18' 100' 0%

FB 1251 8" 18' 100' 0%

FB 1501 8" 18' 100' 0%

FB 1751 8" 18' 100' 0%

FB 2001 8" 18' 100' 0%

Installation & Operation Manual

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

Model ProTech Z Flex Heat Fab Adapter Intake Adapter Intake Adapter Flue Intake

751-1001 *See note 810003269 2SVDSA06 2SVEE0690 9601MAD CCK06TM 9690

1251 *See note 810003281 2SVDSA06 2SVEE0690 9801MAD CCK08TM 9690

1501-2001 *See note 810003357

810003369 2SVDSA08 2SVEE0890 9801MAD CCK08TM 9890

Model Metal-Fab Security Chimney ICC Adapter Flue Intake Adapter Flue Intake Adapter Flue Intake

751-1001 6FCGPVCA MC

6-36" 6FCGSW90L SS6PVCU SS0MCU

4" - 24"

SS6ST90AU

SSD0STAUK

4…