CWD Series Gas-Fired Direct Vent Hot Water Boilers INSTALLATION INSTRUCTIONS These instructions must be affixed on or adjacent to the boiler Models: WARNING: Improper installation, CWD060 • adjustment, alteration, service or CWD083 maintenance can cause property • damage, injury, or loss of life. For CWD110 •...
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WARNINGS FOR THE HOMEOWNER FOLLOW ALL INSTRUCTIONS and warnings unless alarms or other safeguards are in place to printed in this manual and posted on the boiler. prevent such damage INSPECT THE BOILER ANNUALLY. To keep your DO NOT BLOCK AIR FLOW into or around the boiler safe and efficient, have a service technician boiler.
TABLE OF CONTENTS Product Description Specifications Before Installing Locating the Boiler Air for Combustion and Ventilation Venting Vent System Design Vent System Assembly Gas Piping VIII System Piping Wiring Start-up and Checkout Operation Service and Maintenance XIII Troubleshooting Parts Appendix A:Special Requirements for Side-Wall Vented Appliances in the Commonwealth of Massachusetts...
III Before Installing 1) Safe, reliable operation of this boiler depends upon installation by a professional heating contractor in strict accordance with this manual and the authority having jurisdiction. • In the absence of an authority having jurisdiction, installation must be in accordance with this manual and the National Fuel Gas Code, ANSI Z223.1.
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FIGURE 4.1a: CLEARANCES WHEN BOILER IS DIRECT VENTED (OUTDOOR COMBUSTION AIR IS USED) FIGURE 4.1b: CLEARANCES WHEN COMBUSTION AIR IS OBTAINED FROM BOILER ROOM...
TABLE 4.2: CLEARANCES FROM VENT PIPING TO COMBUSTIBLE CONSTRUCTION MINIMUM CLEARANCE TO COMBUSTIBLE TYPE OF VENT PIPE PIPE DIRECTION ENCLOSURE MATERIAL HEAT FAB SAF-T VENT AT LEAST ONE SIDE OPEN, PROTECH FASNSEAL VERTICAL OR 1” COMBUSTIBLE MATERIAL ON A PROTECH FASNSEAL W2 HORIZONTAL MAXIMUM OF THREE SIDES METAL-FAB CORR/GUARD...
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Step 1: Determine whether the boiler is to be installed in a building of unusually tight construction A good definition of “unusually tight construction” is construction having all of the following features: • Walls and ceilings exposed to outside atmosphere have a continuous water vapor retarder with a rating of 1 perm or less with openings gasketed and sealed.
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floor (Fig 3). The minimum opening dimension is 3 inches. • If the CWD boiler is the only gas-burning appliance in the boiler room, these openings must each have a free area of 100 square inches. • If other gas-burning appliances are in the boiler room, size the openings in accordance with the appliance manufacturer’s instructions or the National Fuel Gas Code.
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FIGURE 5.1: BOILER INSTALLED IN A CONFINED SPACE - VENTILATION OR COMBUSTION / VENTILATION AIR FROM INSIDE FIGURE 5.2: ALL AIR FROM OUTSIDE USING VENTILATED CRAWL SPACE AND ATTIC...
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FIGURE 5.3: ALL AIR FROM OUTSIDE USING VENTILATED ATTIC FIGURE 5.4: ALL AIR FROM OUTSIDE USING OPENINGS INTO BOILER ROOM...
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FIGURE 5.5: ALL AIR FROM OUTSIDE USING HORIZONTAL DUCTS INTO BOILER ROOM...
VI Venting WARNING • FAILURE TO VENT THIS BOILER IN ACCORDANCE WITH THESE INSTRUCTIONS MAY RESULT IN UNRELIABLE BOILER OPERATION, PROPERTY DAMAGE AND/OR THE RELEASE OF FLUE GASES, WHICH CONTAIN DEADLY CARBON MONOXIDE (CO), INTO THE HOME, WHICH CAN CAUSE SEVERE PERSONAL INJURY OR DEATH. •...
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N.A. PENETRATION VENT PIPE SIZE 3” 4” 3” 4” AIR INTAKE PIPE SIZE 4” 4” N.A. N.A. CWD060 - CWD138 55 FT 55 FT 55 FT 55 FT CWD165 35 FT 55 FT 35 FT 55 FT CWD193 25 FT...
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FIGURE 6.2a: HORIZONTAL DIRECT VENTING USING SEPARATE TERMINALS (VENT OPTIONS 1-2) FIGURE 6.2b: HORIZONTAL DIRECT VENTING USING COAXIAL TERMINAL (VENT OPTIONS 1-2)
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FIGURE 6.3: HORIZONTAL DIRECT EXHAUST VENT SYSTEM (VENT OPTIONS 4,5) 2) Maximum Vent and Air Intake Lengths - The maximum length of the vent air intake piping depends upon the vent option selected, the vent pipe size, and the boiler size. See Table 6.1 for the maximum vent length. In addition to the maximum length of piping shown in Table 6.1, the following fittings may also be used: •...
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3) Permitted Terminals for Horizontal Venting (Vent Options 1 - 5) - Table 6.1a shows permitted types of terminals for both the vent and air inlet systems. On horizontal direct vent systems using 4” air inlet pipe (Vent Options 1 and 2), the following Crown co-axial terminals may be used.
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N.A. PENETRATION VENT PIPE SIZE 3” 4” 3” 4” AIR INTAKE PIPE SIZE 4” 4” N.A. N.A. CWD060 - CWD138 47 FT 47 FT 47 FT 47 FT CWD165 27 FT 47 FT 27 FT 47 FT CWD193 17 FT...
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FIGURE 6.4: VERTICAL NON-COAXIAL DIRECT VENT SYSTEM (VENT OPTIONS 6, 7) FIGURE 6.5: VERTICAL DIRECT EXHAUST SYSTEM (VENT OPTIONS 9, 10)
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3” 4” AIR INTAKE PIPE SIZE 4” 4” 4” (NON-COAXIAL SECTION) AIR INTAKE PIPE SIZE 5” 5” 7” (COAXIAL SECTION) CWD060 - CWD138 47 FT 47 FT 47 FT CWD165 27 FT 27 FT CWD193 N.R. N.R. CONSULT FACTORY CWD220 N.R.
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FIGURE 6.6: VERTICAL COAXIAL DIRECT VENT USING CROWN #500005 VENT KIT (VENT OPTION 11) FIGURE 6.7: VERTICAL COAXIAL DIRECT VENT USING HEAT FAB SAF-T VENT SC (VENT OPTIONS 12, 13)
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TABLE 6.8: PERMISSIBLE VENT SYSTEMS AND PRINCIPLE VENT COMPONENTS CONDENSATE WALL HORIZONTAL VERTICAL MANUFACTURER VENT SYSTEM SIZE TRAP THIMBLES TERMINATION TERMINATION 7393GC ELBOW: 7314TERM 9321 7393GCS TEE: 7390TEE 5300CI (NOTE 3) SAF-T VENT 5391CI EZ SEAL 7493GC 9421 ELBOW: 7414TERM 7493GCS 5400CI (NOTE 3)
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12) Vertical and horizontal sections of piping must be properly supported. See vent system manufacturer’s instructions for more information. 13) Non-coaxial vent piping must be accessible for periodic inspection. 14) Fire stops and wall thimbles – Use fire stops where required by code or by the vent system manufacturer. Consult vent system manufacturer’s literature for information on suitable fire stops.
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FIGURE 6.10: HORIZONTAL TERMINAL OFFSETS FIGURE 6.11a: LOCATION OF DIRECT VENT TERMINAL RELATIVE TO WINDOWS, DOORS, GRADE...
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FIGURE 6.11b: LOCATION OF DIRECT EXHAUST TERMINAL RELATIVE TO WINDOWS, DOORS, GRADE FIGURE 6.11c: LOCATION OF VENT TERMINAL RELATIVE TO METERS AND FORCED AIR INLETS FIGURE 6.11d: POSITIONING VENT TERMINAL UNDER OVERHANGS...
FIGURE 6.12: USE OF CONDENSATE TRAPS C. Vent / Intake System Assembly 1) General Assembly Notes: a) Where the use of “silicone” is called for in the following instructions, use GE RTV 106 for the vent collar and coaxial terminal. Air inlet piping sections are sealed with any general-purpose silicone sealant such as GE RTV102. PVC air inlet piping sections are connected with PVC cement.
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FIGURE 6.13: INSTALLATION OF FAN OUTLET ORIFICE 3) Optional Coaxial Terminal Installation – If the optional coaxial terminal is used, it should be installed in the wall before vent assembly is started. Install the terminal in accordance with the following procedure (Figures 6.14a & 6.14b): NOTE •...
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j) Attach the intake tee to the end of the straight section protruding from the inside wall. Use the procedure described in (d) to clean and assemble these parts. k) If the inside terminal section is not supported by the wall through which it passes, install additional supports or bracing to support the terminal.
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5) Assembly of Z-Flex Z-Vent III: a) General Notes: • Non-expanded ends of SVE Series III piping sections may be cut using aviation snips or a 24 thread per inch hacksaw. File or sand the cut end smooth before assembling. Expanded ends may be cut to adapt the SVE series III to the vent collar or Crown coaxial terminal.
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6) Assembly of Heat Fab Saf-T Vent EZ Seal: a) Saf-T Vent General Notes: These instructions cover the installation of Saf-T Vent EZ Seal. Saf-T Vent EZ Seal piping has integral gaskets installed in the female ends of the pipe which seal the joints. •...
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7) Assembly of Heat Fab Saf-T Vent SC - On CWD Boiler installations where Saf-T Vent SC is used, some Saf-T Vent EZ Seal (single wall pipe) will always be required between the boiler and the Saf-T Vent SC. Install this pipe as described above.
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8) Assembly of Protech FasNSeal a) FasNSeal General Notes: • Do not cut 4” FasNSeal pipe. Consult FasNSeal instructions for method of cutting other 3” pipe. • Orient FasNSeal vent components so that the arrows on the piping labels are in the direction of flue gas flow. •...
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FIGURE 6.19: INSTALLATION OF BLADE BAFFLE ON HORIZONTAL DIRECT VENT INLET TERMINAL 11) Assembly of Vertical Coaxial Vent System Using Crown #500005 Coaxial Vent Kit (Vent Option #11) a) Start by installing the “B” vent piping. Install and assemble this piping in accordance with the “B” vent manufacturer’s instructions.
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FIGURE 6.20: INSTALLATION OF VENT SUPPORT PROVIDED IN CROWN #500005 VERT. COAXIAL VENT KIT FIGURE 6.21: CONDENSATE TRAP/DRAIN DETAIL...
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13) Rodent Screens: a) A rodent screen is provided with the CWD boiler. On direct exhaust boilers, this screen is installed in the air inlet collar on the boiler and held in place with screws or RTV sealant. b) The Crown coaxial terminal has integral inlet and exhaust rodent screens. The rodent screen supplied with the boiler is not used when the boiler is installed with the coaxial terminal.
VII Gas Piping WARNING • SHUT OFF GAS SUPPLY BEFORE SERVICING THE BOILER. • ALL GAS PIPING MUST BE GAS TIGHT. USE GAS RATED THREAD COMPOUND ON ALL THREADED JOINTS TO AVOID LEAKS, WHICH MAY RESULT IN FIRE OR EXPLOSION. •...
VIII System Piping WARNING • INSTALL BOILER SO THAT THE GAS IGNITION SYSTEM COMPONENTS ARE PROTECTED FROM WATER (DRIPPING, SPRAYING, RAIN, ETC.) DURING APPLIANCE OPERATION AND SERVICE (CIRCULATOR REPLACEMENT, ETC.). • OPERATION OF THIS BOILER WITH CONTINUOUS RETURN TEMPERATURES BELOW 120°F CAN CAUSE SEVERE HEAT EXCHANGER CORROSION DAMAGE. •...
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7) Manual Reset High Limit (Required by some codes) – This control is required by ASME CSD-1 and some other codes. Install the high limit in the boiler supply piping just beyond the boiler with no intervening valves. Set manual reset high limit as far above the operating limit setting as possible, but not over 240F.
Section IX Wiring WARNING • All wiring and grounding must be done in accordance with the authority having jurisdiction or, in the absence of such requirements, with the national electrical code (ansi/nfpa 70) . • Disconnect electrical power to the boiler and heating system before servicing. Positively assure that no voltage is present.
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• Do not attempt to use EnviraCom connections for any purpose not explicitly permitted by Crown Boiler Company. Attempting to do so may result in unreliable operation and/or damage to controls. •...
X Start-up and Checkout WARNING DO NOT LEAVE THE BOILER IN SERVICE IF IT FAILS ANY OF THE FOLLOWING START-UP CHECKS. DOING SO MAY RESULT IN FIRE, EXPLOSION, OR CARBON MONOXOIDE (CO) POISONING. WARNING • GAS LEAKS MAY RESULT IN FIRE OR EXPLOSION. •...
FOR YOUR SAFETY READ BEFORE OPERATING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance is equipped with an ignition If you cannot reach your gas supplier, call device which automatically lights the pilot.
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WARNING Failure to follow the following procedure exactly could result in over-firing of the boiler and a carbon monoxide hazard. 12) Check the manifold pressure and adjust if necessary. To do this, use the following procedure: a) Connect a manometer to the line pressure tap on the gas valve (see Figure 10.3). b) Check the line pressure with all gas appliances on and off.
XI Operation A. General Information This boiler uses a proprietary version of the Honeywell S9361A “integrated boiler control” to manage all boiler functions including flame supervision, temperature control, and circulator operation. This control can operate one or two circulator zones without the use of additional relays.
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FIGURE 11.2: BOILER CONTROL MENU STATUS MODE: =Current Status (Table 11.3) Press and Hold I, ↑, and ↓ for at least 3 Press I to enter OPERATING MODE sec to enter ADJUSTMENT MODE = Current Boiler Temp. = High Limit Setting = Limit Differential = Current Set Point = High Limit Setting =Circulator Overrun = Limit Differential =Thermal Purge Time =Call for Heat? (On/Off) =Thermal Purge Temp =DHW Priority (ON/OFF) =Call for DHW? (On/Off) Zone =Flame Signal (uA) =Use of 2 =Total Run Time (hrs) =Reset =Temperature Units =total burner Cycles =Return to Status Mode Boiler in ...
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TABLE 11.3: STATUS CODES Status # Description Meaning No call for heat or DHW Standby Call for heat present , but boiler is in thermal purge (See on page 54) Call for heat/DHW present but boiler temperature is above high limit (HL) setting. Waiting for Pressure Control is confirming that air pressure switch contacts are open before starting fan.
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TABLE 11.5: OPERATING MODE PARAMETERS Parameter # Description Meaning Boiler Temperature Current boiler water temperature measured by the control’s sensor. Current target temperature (always the same as the high limit setting unless Boiler water set point Crown outdoor reset card option is installed). Boiler will stop firing if boiler water temperature exceeds this value (Circulator/s High Limit Set point will continue to operate)
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C. Using Adjustment Mode WARNING Improper adjustments to control parameters could result in unreliable boiler operation, property damage, personal injury, or loss of life. Adjustments should only be made by a qualified heating technician. A list of parameters which can be changed on this control are shown in Table 11.6. To enter Adjustment mode and change parameters: 1) Press and hold I, ↑, ↓...
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TABLE 11.7: EXAMPLES OF THERMAL PURGE OPERATION Thermal Purge Settings Boiler Call for Temp at Example Heat Use of Start Temp Begin From DHW Zone Time (Pt) (St) Call Boiler Behavior • Heating Circulator starts 2 min. 140F immediately • Burner fires immediately •...
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F-C (Temperature Units ) - Determines whether temperature units on the S9361A are displayed in F or C. Note that this selection only applies to the temperature displayed on the LED shown in Figure 11.1. Temperature units must be selected independently on the displays of any control options plugged into Option Plugs 1 or 2.
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1) If the water temperature climbs above the high limit setting during the call for heat, the burner and blower will shut down while the Heating Circulator continues to operate. The ignition sequence will restart (from Step 3) when the water tempera- ture falls to the high limit setting (HL) minus the high limit differential (HdF).
XII Service and Maintenance WARNING • THE BOILER CONTAINS REFRACTORY CERAMIC FIBER, A POSSIBLE HUMAN CARCINOGEN. USE A NIOSH APPROVED RESPIRATOR WHEN SERVICING HIGH-TEMPERATURE INSULATION AND GASKET MATERIALS. WASH EXPOSED SKIN GENTLY WITH SOAP AND WATER AFTER CONTACT. WASH EXPOSED CLOTHING SEPERATE FROM NORMAL LAUNDRY.
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WARNING SOOT DEPOSITS IN THE FLUE PASSAGES ARE A SIGN THAT THE BOILER MAY BE OPERATING AT HIGH CARBON MONOXIDE (CO) LEVELS. AFTER CLEANING THE BOILER OF SOOT DEPOSITS, CHECK THE CO LEVEL IN THE FLUE GAS TO INSURE THAT THE BOILER IS OPERATING PROPERLY. If it is necessary to check CO, use a combustion analyzer, or other instrument which is designed to measure CO in flue gas.
6) Disconnect the pressure switch hoses. 7) Loosen the two ¼-20 nuts and washers in the flue collector lugs. Slide the flue collector lugs off of each flue collector flange. 8) Score the silicone seal around the flue collector with a utility knife or similar tool. 9) Pry the flue collector off of the heat exchanger, being careful not to damage the flue collector or fan.
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TABLE 12.1: PRESSURE SWITCH SETTINGS APPROX. MAKE BREAK SETTING* MODEL CROWN PN SETTING (inches w.c.) (inches w.c.) CWD060 - CWD110 620039 1.21 1.16 CWD138 - CWD220 620040 1.40 1.35 CWD245 620041 1.45 1.40 *Settings shown are based on “plus tolerance” - actual setting may be lower.
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FIGURE 12.2b: MEASURING PRESSURE ACROSS PRESSURE SWITCH...
XIII Troubleshooting A. Before Troubleshooting The following pages contain trouble shooting tables for use in diagnosing control problems. When using these tables the following should be kept in mind: 1) This information is only meant to be used by a professional heating technician as an aid in diagnosing boiler problems. 2) Where applicable, follow all precautions outlined in the Section X (Start-up and Checkout) of the boiler installation manual.
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TABLE 13.0: ERROR CODES Error Code Meaning Possible Cause • Jumped air pressure switch Pressure Switch failed to open • Condensate in air pressure switch or switch tubing • Defective air pressure switch • Low gas pressure at gas valve inlet •...
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TABLE 13.1: FAULTS WITHOUT ERROR CODE PRESENT Displayed Codes Problem Possible Cause • Thermostat/s not calling for heat StA 1 Burners and • Loose connection in thermostat, zone valve end switch, or zone panel wiring. tt OFF Circulator Off • Thermostat, zone valve, or zone panel miswired dh OFF •...
XIV PARTS The following parts may be obtained from any Crown distributor. To find the closest Crown distributor, consult the area Crown representative or the factory at: Crown Boiler Co. Customer Service P.O. Box 14818 Philadelphia Pa. 19134 www.crownboiler.com Main burner orifice shown are for sea level configured boilers. For boilers installed at elevations above 2000 ft, consult the...
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BLOCK, BASE, FLUE COLLECTOR COMPONENTS PART PART # OR QTY. KEY DESCRIPTION # OR CWD060 CWD083 CWD110 CWD138 CWD165 CWD193 CWD220 CWD245 QTY. BASE 620113 620114 620115 620116 620117 620118 620119 620120 NYLON FEET (GLIDES) 700111 INTAKE BOX 620233 620234...
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BURNER TRAY COMPONENTS PART# PART # OR QTY. DESCRIPTION CWD060 CWD083 CWD110 CWD138 CWD165 CWD193 CWD220 CWD245 QTY. FRONT FIREDOOR 620543 620544 620545 620546 620547 620548 620549 620550 FRONT FIREDOOR INSULATION 620523 620524 620525 620526 620527 620528 620529 620530 INSULATION SUPPORT BRACKET...
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CONTROLS & TRIM PART# PART # OR QTY KEY DESCRIPTION CWD060 CWD083 CWD110 CWD138 CWD165 CWD193 CWD220 CWD245 1/8” SILICONE TUBING 14-008 2.5 FT 2.5 FT 2.5 FT 2.5 FT 2.5 FT 2.5 FT 2.5 FT 2.5 FT TRIDICATOR GAUGE...
Appendix A: Special Requirements For Side-Wall Vented Appliances In The Commonwealth of Massachusetts IMPORTANT The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00 and 5.00 for installation of side-wall vented gas appliances as follows: 1. For direct-vent appliances, mechanical-vent heating appliances or domestic hot water equipment, where the bottom of the vent terminal and the air intake is installed below four feet above grade the following requirements must be satisfied: If there is not already one present, on each floor level where there are bedroom(s), a carbon...
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