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continued - Lochinvar

1. 31 Using an Existing Vent System to Install a New Boiler 9 Natural GaS fm 32 Corrosive Contaminants and Sources 9 Pipe Sizing for Natural 32 Removing a Boiler from Existing Common Vent 10 Natural Gas Supply Pressure Requirements 92 Remove Boiler from Wood Pallet 11 Propane NETT 32 Combustion and Ventilation Air Requirements 12 13 Pipe Sizing for Propane Gas aannnnnnnnnnnennnnennnenenne 32 2 GENERAL VENTING Propane Supply Pressure Requirements 32 Direct Venting Options Sidewall Vent 14 Check Inlet Gas Supply 33 34 Direct Venting Options Vertical Vent 14 Gas TOSS GO eee eee MN tea UNICUM 34 Direct Venting Options Vert Vent Opt Rm Air 14 Gas Valve Replacement n nnnnnnnnennnennnnennnnnrnnnnernnnrnni 34 Direct Venting Options Vert Vent Sidewall Air 14 7T FIELD WIRING Install Vent and Combustion Air Piping 15 Line Voltage Connections 35 Air Inlet Pipe Materials 15 Low Voltage Connections 36 Requirements for Installation
2. 1750 1750 3500 3500 7000 1167 5646 5646 11291 11291 22581 22581 45162 7530 4000 1000 1000 2000 2000 4000 4000 8000 1333 6450 6450 12900 12900 25800 25800 51600 8600 5000 1250 1250 2000 2000 5000 5000 10000 1667 8062 8062 12900 12900 32250 32250 64500 10750 The above requirements 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 IOutside 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 13 CREST Installation amp Operation Manual CAGE Aes TUI RT 2 General venting Direct venting Sidewall Vertical Vent Sidewall Air Vertical Optional room air ec SC a Sidewall Vertical 2 General venting continued
3. 125 12791305 MM 12 305 MM 305 MM EN 20 4 Sidewall direct venting Vent air termination sidewall Follow instructions below when determining vent location to avoid possibility of severe personal injury death or substantial property damage A WARNING A gas vent extending through an exterior wall shall not terminate adjacent to a wall or below building extensions such as eaves parapets balconies or decks Failure to comply could result in severe personal injury death or substantial property damage A WARNING A WARNINGI P 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 18 Failure to comply could result in severe personal injury death or substantial property damage Sidewall venting commercial products will result in large exhaust plumes in cold climates Consideration should be taken when locating in proximity to windows doors walkways etc A CAUTION 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 NOTICE 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 17 of this manual 2 You must consider the surroundings when ter
4. CREST CN IDEAE ie ERBEN Installation amp Operation Manual Install vent and combustion air piping 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 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 A WARNING Using vent or air intake materials other than those specified failure to properly seal all seams and joints
5. STATUS Main Burner On ica Set Point 110 F System Supply j a Flue Temperature 12 45 T When the ON OFF switch is turned to the ON position the first screen visible on the LCD display will be the Home Screen This screen displays the current status of the Crest boiler The following items can be viewed or interacted with on the Home Screen On Off button Pressing this button allows the boiler to be placed in either Manual Shutdown Mode or Standby Mode Status This line shows the current operating status of the Crest boiler and the current set point Outlet Water Temperature This is the boiler outlet temperature Inlet Water Temperature This is the boiler inlet temperature System Supply Temperature This is the water temperature as measured by the system supply sensor located in the downstream piping if connected System Return Temperature This is the water temperature measured by the system return sensor located in the upstream piping if connected Outside Air Temperature This is the outdoor air temperature 1f connected Inlet WaterTemperature System Return Temperature 80 F DHW Temperature TTE DHW Temperature This is the temperature as measured by the tank sensor in the hot water storage tank if connected Flue Temperature Temperature measured by the flue sensor Time The time is displayed in the lower left hand corner of the display Reference th
6. l Visually inspect the entire flue gas venting system and air piping for blockage deterioration or leakage Repair any joints that show signs of leakage Verify that air inlet pipe is connected and properly sealed Verify that boiler vent discharge and air intake are clean and free of obstructions A WARNING Failure to inspect for the above conditions and have them repaired can result in severe personal injury or death Check water system 1 Verify all system components are correctly installed and operational Check the cold fill pressure for the system Verify it is correct must be a minimum of 12 psi 82 7 kPa Watch the system pressure as the boiler heats up during testing to ensure pressure does not rise too high Excessive pressure rise indicates expansion tank sizing or performance problem Inspect automatic air vents and air separators Remove air vent caps and briefly press push valve to flush vent Replace caps Make sure vents do not leak Replace any leaking vents Check expansion tank Expansion tanks provide space for water to move in and out as the heating system water expands due to temperature increase or contracts as the water cools Tanks may be open closed or diaphragm or bladder type See Section 5 Hydronic Piping for suggested best location of expansion tanks and air eliminators Check boiler relief valve Inspect the relief valve and lift the lever to verify flow Before opera
7. ANSI Z223 1 for U S installations or CSA B149 1 for Canadian installations You must also install air piping from outside to the boiler air intake adapter The resultant installation is direct vent sealed combustion You may use any of the vent air piping methods covered in this manual Do not attempt to install the Crest using any other means A WARNING DO NOT mix components from different systems The vent system could fail causing leakage of flue products into the living space Use only approved stainless steel pipe and fittings 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
8. CREST Installation amp Operation Manual COMO RAS TC RAE 5 Hydronic piping oninueo Figure 5 2 Single Boiler Recommended Primary Secondary Piping with a Hot Water Generator FROM SYSTEM N SYSTEM RETURN SENSOR 12 MAX a 4 BALL VALVE TYPICAL RELIEF VALVE HOT WATER GENERATOR AIR SEPERATOR DRAIN PORT TYPICAL SYSTEM SUPPLY SENSOR 4 SYSTEM CIRCULATOR M PRESSURE REDUCING VALVE BAR M MAKE UP WATER PREVENTER WATER GENERATOR EXPANSION PRESSURE CIRCULATOR TANK GAUGE Y STRAINER RECOMMENDED FLOW CHECK VALVE TYPICAL BOILER PUMP System flow should always remain higher than the required flow for the boiler s when the boiler s is in NOTICE operation to prevent short cycling and high limit issues NOTICE Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment and detailing required by local codes 27 CREST Installation amp Operation Manual Chr G if Pre 5 Hydronic piping Table 5C Multiple Boilers Common Header Primary Secondary Flow Number of Units 2 3 4 5 6 7 8 Recommended Common Header Pipe Sizes in Inches FB1500 4 J 4 J 5 5 6 6 27 S CUR RT PR E IE FB 2500 5 5 6 7 7 J 8 o 10 Ese s m qp wg tt FB3500 5 6 7
9. Louver relay If louvers need to operate before the boiler fires they can be controlled by this output Connect these terminals to a 24V relay coil which is wired to operate the louvers FIG 7 3 Louver proving switch Louvers are used to provide combustion air for the room air option A louver proving switch should be connected to the appropriate terminals and are verified prior to operation see FIG 7 3 Boiler pump speed output This 0 10V output is available to control the speed of a variable speed boiler pump The SMART TOUCH control will vary the speed of this pump in order to maintain a minimum AT set by the installer see the Crest Service Manual across the heat exchanger as well as prevent high limit lockouts when the flow in the primary loop is extremely low Connect this output to the 0 10V input on the boiler pump speed control NOTICE A system supply sensor must be installed for this feature to work Rate output This output provides a 0 10V signal that is proportional to the firing rate of the boiler This may be used by a BMS system to monitor the actual rate of the boiler D Field wiring continued Auxiliary switch 1 amp 2 Additional field supplied limit controls may be connected to the auxiliary switch inputs If additional limit controls fail or open it will result in a manual reset lockout System supply sensor 1 By installing the system supply sensor into the supply of the primary loo
10. 24 VAC LOUVER Y RELAY COIL OR HIGH LIMIT SWITCH A L R SOM BL AUX L R a SWITCH 2 LWCO BOARD x2 3 FLAME SENSE 2 E xi d LWCO TEST 1 10 SPARK ROD PROBE SWITCH X6 3 Ek OR BK 1 1 5 FLAME SENSE 1 LWCO RESET eR FRANSPORMER OR 2 TRANSFORMER x2 5 GND ol o OR ofo OR oto BR X6 5 FLUE DAMPER GPS1 GPS2 GPS3 BL D oL o OR x6 15 a Y NC BLOWER PROVING SWITCH LARGE X13 4 OR 9 0 o of o T X6 12 BLOWER PROVING SWITCH SMALL 0 20 X13 1 BLOCKED FLUE SWITCH TRANSFORMER GEN BK X6 6 BLOCKED DRAIN SWITCH BL X11 Y X5 BLOCK WIRING IS MODEL DEPENDANT Notes 1 All wiring must be installed in accordance with local state provincial and national code requirements per either N E C in USA or C S A in Canada 2 If any original equipment wire as supplied with the appliance must be replaced it must be replaced with wire having same wire gauge AWG and rated for a minimum of 105 C Exceptions Replacement high vo spark lead and ribbon cables must be purchased from the factory Use of a non approved spark lead or ribbon cables can lead to operational problems which could result in non repairable damage to the integrated controller or other components 3 Actual connector block locations may vary from those shown on diagrams Refer to actual components for proper connector block locations when using diagrams
11. Failure to use the bubble test or check for gas leaks can cause severe personal injury death or substantial property damage 5 Use pipe sealing compound compatible with propane gases Apply sparingly only to male threads of the pipe joints so that pipe dope does not block gas flow A WARNING Failure to apply pipe sealing compound as detailed in this manual can result in severe personal injury death or substantial property damage Table 6A Gas Inlet Size en omase 31 Installation amp Operation Manual CREST CONDAM es EC 6 Gas connections Use two wrenches when tightening gas piping at boiler FIG 6 2 using one wrench to prevent the boiler gas line connection from turning Failure to support the boiler gas connection pipe to prevent it from turning could damage gas line components WARNING Figure 6 2 Inlet Pipe with Backup Wrench USE BACK UP WRENCH TO PREVENT PIPE FROM ROTATING Maximum inlet gas pressure must not NOTICE due E exceed the value specified Minimum value listed is for the purposes of input adjustment Natural gas Check boiler rating plate to determine which fuel the boiler is set for Crest boilers CANNOT be field converted Failure to comply could result in severe personal injury death or substantial property damage WARNING Pipe sizing for natural gas 1 Refer to Table 6B for pipe length and diameter Based on rated boiler input divide by 1
12. RATE 2139 X4 2 OUT 2248 X4 3 BOILER 2349 PUMP OUT 2449 SYSTEM RETURN 2549 SENSOR 264 SYSTEM SUPPLY 2749 SENSOR 2849 TANK 29 49 SENSOR J 3058 ORW OUTDOOR 3149 SENSOR 325 BMS 3349 IN 3449 SYSTEM 3549 PUMP IN 3619 MEE SHIELD 3739 CASCADE INLET GC B 3959 SHIELD 405 R W GY GY BR BK ll 00941 CN1 CREST CPSP AP Ae P P INTEGRATED CONTROL SMALL CONNECTION BOARD ALARM 1 CONTACTS 2 RUN TIME 3 R CONTACTS 4 R TANK 5 OR THERMOSTAT 6 OR 7 BL ENABLE E i LOUVER BR E PROVING R 24 VAC LOUVER Y He RELAY COIL H P HIGH LIMIT Wi SWITCH 1 Rae E AUX R SWITCH 2 Lwco BOARD LWCO TEST PROBE SWITCH c OR BK aLo ORBK LWCO RESET 520 OR ofo OR oto OR odto BR GPS1 GPS2 GPS3 o oc OR BLOWER PROVING SWITCH LARGE o o T BLOWER PROVING SWITCH SMALL opo PR BLOCKED FLUE SWITCH O BLOCKED DRAIN SWITCH 5 BLOCK WIRING IS MODEL DEPENDANT Notes X6 4 X6 3 X6 5 X6 15 X13 4 X6 12 A i X13 1 X6 6 X5 1 X5 7 X5 2 X5 8 X5 3 X5 9 X5 4 X5 10 X5 5 X5 41 X5 6 X5 12 lt s xt Lil L Lo _ _ _ i I x10 3 i X6 8 L X1 8 Lu X3 3 ad X6 9 1 X6 17 L X3 2 X6 1 X6 11 X24 X6 2 X6 14 X6 10 X6 13 FLUE DAMPER
13. TRANSFORMER Installation amp Operation Manual BoxpePiCTS OPTIONAL ITEMS LOW VOLTAGE 120 VAC emm HIGH VOLTAGE A WARNING DISCONNECT POWER BEFORE SERVICING 208V N L1 L2 L3 1 5A EACH MAX SYSTEM PUMP CONTACTOR bei BOILER PUMP dy DHW PUMP CONTACTOR JUNCTION BOX G GAS VALVE SMALL GAS VALVE LARGE RN BLOWER SMALL BLOWER LARGE FLAME SENSE 2 SPARK ROD FLAME SENSE 1 ies E 2 Q ii cho FLUE DAMPER 24V TRANSFORMER BL 1 All wiring must be installed in accordance with local state provincial and national code requirements per either N E C in USA or C S A in Canada 2 If any original equipment wire as supplied with the appliance must be replaced it must be replaced with wire having same wire gauge AWG and rated for a minimum of 105 Exceptions Replacement high vo spark lead and ribbon cables must be purchased from the factory Use of a non approved spark lead or ribbon cables can lead to operational problems which could result in non repairable damage to the integrated controller or other components 3 Actual connector block locations may vary from those shown on diagrams Refer to actual components for proper connector block locations when using diagrams to troubleshoot unit WIRING DIAGRAM LBL20269 REVA 6
14. a 0 10V signal is available from the pump speed control this signal can be used by the SMART TOUCH control to anticipate changes in the building heat load By connecting this 0 10V signal to the 0 10V SYS PUMP IN terminals the boiler or cascade can modulate up and down as the primary flow increases and decreases 36 CREST PPE A eee Ee Installation amp Operation Manual ModBus The RS 485 ModBus cable is connected to the ModBus terminals Use shielded 2 wire twisted pair cable If desired the shield can be connected to ground by installing a jumper wire between terminals 1 and 3 on connector X5 on the ModBus interface module Hot Water thermostat 1 Connect the HWG tank thermostat to the Tank Thermostat terminals on the connection board FIG 7 3 Hot Water Generator HWG tank sensor 1 By installing a HWG tank sensor the SMART TOUCH control can perform the tank thermostat function The SMART TOUCH control automatically detects the presence of this sensor and generates a HWG call for heat when the tank temperature drops 6 F 3 C below the tank set point and finishes the call for heat when the tank temperature reaches the tank set point 2 TST20015 sensor MUST be used with any indirect tank Failure to use the correct sensor will result in the tank temperature being either above or below the set point Connect the correct sensor to the Tank Sensor terminals see FIG 7 3 Generator HWG
15. 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 without boiler connected to remove sediment The high efficiency heat exchanger can be damaged by build up or corrosion due to sediment e Do not use petroleum based cleaning or sealing compounds in the boiler system Gaskets and seals in the system may be damaged This can result in substantial property damage e Do not use homemade cures or boiler patent medicines Serious damage to the boiler personnel and or property may result Continual fresh make up water will reduce boiler life Mineral buildup in the heat exchanger reduces heat transfer overheats the stainless steel heat exchanger and causes failure Addition of oxygen carried in by makeup water can cause internal corrosion in system components Leaks in boiler or piping must be repaired at once to prevent the need for makeup water Freeze protection fluids NEVER
16. 000 to obtain cubic feet per hour a Table 6B is only for natural gas with specific gravity 0 60 inches with a pressure drop through the gas piping of 0 5 inches w c b For additional gas pipe sizing information refer to the National Fuel Gas Code 54 ANSI Z223 1 latest edition or in Canada CSA B149 1 Installation Code 32 Natural gas supply pressure requirements 1 Pressure required at the gas valve inlet pressure port e Maximum 14 inches w c 3 5 kPa with no flow lockup or with boiler on Minimum 4 inches w c 99 kPa with gas flowing verify during boiler startup 2 Install 10096 lockup gas pressure regulator in supply line if inlet pressure can exceed 14 inches w c 3 5 kPa at any time Adjust lockup regulator for 14 inches w c 3 5 kPa maximum A WARNING Ensure that the high gas pressure regulator is at least 10 feet 3 m upstream of the appliance Propane Gas Check boiler rating plate to determine which fuel the boiler is set for Crest boilers CAN NOT be field converted Failure to comply could result in severe personal injury death or substantial property damage Pipe sizing for propane gas 1 Contact gas supplier to size pipes tanks 100 lockup gas pressure regulator Propane Supply Pressure Requirements 1 Adjust propane supply regulator provided by the gas supplier for 14 inches w c 3 5 kPa maximum pressure 2 Pressure required at gas valve inl
17. 242 PUMP OUT X8 14 CN3 13 X X SYSTEM RETURN 26 SENSOR SYSTEM SUPPLY Ke 28 SENSOR B 30 SENSOR OUTDOOR 32 SENSOR 334 _ BMS EE COON IN 85 SYSTEM 36 __0 10 _ PUMP IN an SHIELD 38 39 40 X8 12 CN3 12 X8 11 CN3 11 X8 5 CN3 10 4C N X8 15 cN34 CN3 9 QO OO OPO OO OP OP YOY VY OYVOO X8 6 CN3 8 X8 16 CN3 1 X8 7 CN3 2 CASCADE SHIELD X8 17 CN3 3 X8 18 CN3 4 X8 3 EDN INLET SENSOR X8 8 X8 2 X8 4 X8 9 X7 1 X7 5 X7 2 X7 6 SMALL BLOWER LARGE BLOWER RIBBON CABLE LCD DISPLAY SMALL DU941 CONNECTION BOARD ALARM CONTACTS RUN TIME CONTACTS TANK THERMOSTAT ENABLE LOUVER PROVING 24 VAC LOUVER RELAY COIL AUX SWITCH 1 AUX SWITCH 2 OPP PV OPVOPY 1 All wiring must be installed in accordance with local state provincial and national code requirements per either N E C in USA or C S A in Canada 2 If any original equipment wire as supplied with the appliance must be replaced it must be replaced with wire having same wire gauge AWG and rated for a minimum of 105 C Exceptions Replacement high voltage spark lead and ribbon cables must be purchased from the factory Use of a non approved spark lead or ribbon cables can lead to
18. blowers allowing gas to flow only if the gas valves are powered and combustion air is flowing 18 Blower proving switches Prove adequate airflow during prepurge 4 CREST Installation amp Operation Manual Chr A Ae Ea EUN 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 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 Ignition electrode An electrical spark across the electrodes will ignite the first burner 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 Line voltage wiring connections knockouts Conduit connection points for the high voltage junction box 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 High gas pressure switch not shown Monitors gas supply pressure to the burner and shuts the boiler down in the event a high gas pressure condition occurs Low voltage connection board s Connection boards used to connect external low voltage devices Low voltage wiring connections knockouts Conduit connection points for the low voltage conne
19. combustion calibration is performed and CO s are adjusted to the recommended levels m p E 6 Figure A High Altitude Label Location C ST Installation amp Operation Manual AOE PIE 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 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
20. fall onto the appliance Failure to install the appliance indoors could result in severe personal injury death or substantial property damage A 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 If you do not provide the recommended service NOTICE clearances shown it may not be possible to service the boiler without removing it from the space Clearances from combustible materials Hot water DID6Suusesennraresdterenancenasunzsascsancnessodesenarares 1 4 Ee TEEN 0 E 0 EN dece 0 o Mc 0 Ze Tm Combustible Vent pipe Follow special vent system manufacturer s instructions Recommended clearances for service access RTT 24 CE cR IEEE 24 TEM DOOR EEN 30 S o A 24 Figure 1 1 Recommended Service Clearances 1 4 6 MM MINIMUM CLEARANCE AROUND HOT WATER PIPES VENTILATING AIR OPENING CLOSED DOOR 24 RIGHT VENTILATING AIR OPENING C Installation amp Operation Manual dk Ady REI D 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 NO
21. flue gas temperature sensor to prevent flue gas spillage into the room Failure to comply could result in severe personal injury death or substantial property damage 44 TEA RIEF 14 2 9 2 5 2 7 5 13 0 9 5 6 3 3 8 1 1 3 0 19 0 15 6 1 2 5 0 19 2 13 3 8 3 4 1 Installation amp Operation Manual Set space heating operation Verify space heat circulator mode The system pump output can be programmed to never run OFF run only when a space heating demand is present ON or run continuously except during warm weather shutdown WWSD If the boiler is not heating an indirect HWG Hot Water Generator tank it also turns on the boiler pump After the space heating call for heat ends and the system pump is programmed as ON the system pump continues to run for a short period of time If the boiler pump was running it continues to run for a short period of time as well These pump delays are factory set to 30 seconds If different delays are desired the appropriate parameters in the control must be changed See the Crest Service Manual for a detailed explanation of this procedure Set space heating set point temperature During normal operation space heating set point temperatures can be adjusted from the Set Points Menu Press the following buttons to navigate to the Set Points Menu from the Home Screen After pressing SETUP the Password Screen will appear Entering the correct pass
22. follow the proper shutdown procedure and to schedule an annual start up at the beginning of the next heating season Shut down boiler Follow the To Turn Off Gas to Appliance instructions for the boiler in Section 9 Startup Do not drain the boiler unless it will be exposed to freezing temperatures If using freeze prevention fluid in system do not drain Allow time for the boiler to cool to room temperature if it has been firing Remove the top access panel to remove the gas air manifold assembly Remove the nuts securing the burner to the burner mounting plate Remove the burner FIG 11 2 Remove the nuts securing the burner mounting plate from the heat exchanger and set aside Remove the entire burner mounting plate assembly A WARNING The boiler contains ceramic fiber materials 10 11 12 13 14 Use care when handling these materials per instructions on this page Failure to comply could result in severe personal injury Use a vacuum cleaner to remove any accumulation on the tube sheet surfaces Do not use any solvent Brush the heat exchanger tube sheet combustion chamber walls and tube entry while dry using a nylon bristle brush Caution DO NOT use a metal brush Re vacuum the heat exchanger Finish cleaning using a clean cloth dampened with warm water Temporarily remove the condensate drain line from the condensate trap and route directly to a drain Rinse out debris with a low p
23. line 15 psi 103 kPa nominal Check temperature and pressure gauge which should read a minimum pressure of 12 psi 83 kPa Install the circulators as shown on the piping diagrams in this section Make sure the circulators are properly sized for the system and friction loss Install check valves with each boiler circulator Install an expansion tank on the system supply Consult the tank manufacturer s instruction for specific information relating to tank installation Size the expansion tank for the required system volume and capacity Install an air elimination device on the system supply This appliance is supplied with a relief valve sized in accordance with ASME Boiler and Pressure Vessel Code Section IV Heating Boilers The safety relief valve is installed at the factory and is located on the rear of the boiler Pipe the discharge of the safety relief valve to prevent injury in the event of pressure relief Pipe the discharge to a drain Provide piping that is the same size as the safety relief valve outlet Never block the outlet of the safety relief valve On any pre existing system it is good practice to install a field supplied strainer to prevent damage to the heat exchanger See the piping illustrations included in this section FIG s 5 2 thru 5 5 for suggested guidelines in piping the Crest NOTICE Please note that these illustrations are meant to show system piping concept only the installer is respon
24. of its components 3 Check area around the boiler Remove any combustible materials gasoline and other flammable liquids Failure to keep boiler area clear A WARNING 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 Ifa new boiler will replace an existing boiler check for and correct system problems such as e 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 6 The appliance must be installed on a level floor both front to back and side to side for proper condensate drainage 7 Ifthe optional neutralizing kit is to be used elevate the boiler at least 3 above the floor This appliance is certified as an indoor appliance 1 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 WARNING 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
25. or existing systems must use glycol that is specially formulated for this purpose This includes inhibitors which prevent the glycol from attacking the metallic system components Make certain to check that the system fluid is correct for the glycol concentration and inhibitor level The system should be tested at least once a year and as recommended by the producer of the glycol solution Allowance should be made for the expansion of the glycol solution in the system piping Use only inhibited propylene glycol ER solutions which are specifically formulated for hydronic systems Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems 24 i I ie d Ree A FP Installation amp Operation Manual General piping information Basic steps are listed below along with illustrations on the following pages which will guide you through the installation of the Crest 5 2 thru 5 5 l 10 Connect the system return to the 4 flanged connection marked Inlet make sure to install with a suitable gasket between flanges Connect the system supply to the 4 flanged connection marked Outlet make sure to install with a suitable gasket between flanges Install purge and balance valve or shutoff valve and drain on system return to purge air out of each zone Install a backflow preventer on the cold feed make up water line Install a pressure reducing valve on the cold feed make up water
26. or failure to follow vent pipe manufacturer s instructions can result in personal injury death or property damage Mixing of venting materials will void the warranty and certification of the appliance The use of double wall vent or insulated NOTICE material for the combustion air inlet pipe is recommended in cold climates to prevent the condensation of airborne moisture in the incoming combustion air Sealing of Type 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 Sealall 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 inl
27. supplied Full port valves are required Failure to use full port valves could result in a restricted flow Table 5B1 Minimum Flow Rate with the Boiler at Full Fire rate through the boiler TEMPERATURE RISE APPLICATIONS 5 Check valves Field supplied Check valves are required for MODEL FLOW RATE temet installation as shown in FIG s 5 2 and 5 3 Failure to install check valves could result in a reverse flow FB N L 1500 condition during pump s off cycle FB N L 2000 6 Domestic indirect hot water isolation valves FB N L 2500 Field supplied Full port valves are required Failure to use full port valves could result in a restricted flow rate through FB N L 5000 the boiler FB N L 3500 7 Anti scald mixing valve FB N L 4000 Field supplied An anti scald mixing valve is FB N L 5000 recommended when storing domestic hot water above 115 F 46 Based on 80 F Temperature Rise 8 Pressure relief valve Factory supplied The pressure relief valve is sized to ASME specifications Table 5B2 Absolute Minimum Flow Rate ABSOLUTE MINIMUM FLOW RATE 9 System temperature sensor MODEL FLOW RATE GPM a system temperature sensor Lochinvar supplies The sensor is to be installed in the heating loop FB N L 1500 Senne downstream from the boiler hot water piping and FB N L 2000 heating loop junction The sensor should be located far enough downstream to sense system diluted FB N L 2500 u 26
28. switch limits louver proving switch optional and damper proving switch optional contacts close The Pre Purge cycle begins The control confirms both blowers come up to the desired speed both blower proving switches close and the air pressure switch is closed Once the Pre Purge cycle is complete the control lowers the blower speeds initiates sparking of the ignition electrode and opens Gas Valve 1 After a short wait the control stops sparking and checks for the presence of flame current through the flame sense electrode If the control does not detect flame current the control will lockout indefinitely until the RESET button on the touch screen LCD is pressed Models FB 1500 2500 will have one retry If the control detects flame current the control will hold the blower speed constant for a few seconds to allow the flame to stabilize then begin modulating the firing rate in order to maintain the controlling sensor to the desired set point temperature If the current call for heat is for space heating and a HWG call for heat becomes active the control will turn on the HWG pump relay output then turn off the boiler pump It will then modulate the blower speed in order to maintain the outlet temperature to the desired HWG outlet set point temperature If the first combustion system in the boiler is unable to maintain the desired set point temperature the second combustion system in the boiler will be started Both blowers wil
29. 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 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 Blowers The blowers pull in air and gas through the venturis item 34 Air and gas mix inside the blowers and are 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 If selected as the controlling sensor the control module will adjust the boiler firing rate so the inlet water temperature temperature matches the set point 7 Boiler outlet temperature sensor The boiler outlet temperature sensor monitors boiler outlet If selected as the controlling sensor the control module will adjust the boiler firing rate so the outlet water temperature temperature matches the set point 8 Burner not shown Integral dual chamber design with a stress free metal fiber outer mesh and durable stainless steel structure Provides two 2 independent firing rates up to 25 1 turndo
30. 00 Btu hr input 5 5 per kW see FIG 1 4 12 CREST Installation amp Operation Manual o ied Pre _ 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 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 cm 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 per kW Figure 1 7 Combustion Air from Outside Single Opening Installation amp Operation Manual CREST Vr tS PE 1 Determine boiler location continued 4 Ifa 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 per kW This opening must be located
31. 1 COANE Ate TUR EFE 12 Dia grams continued Figure 12 5 Ladder Diagram 5 0 Model 62 JUNCTION BOX NEUTRAL INTEGRATED CONTROL ON OFF 1 5A EACH MAX SWITCH TERMINAL STRIP SYSTEM PUMP CONTACTOR BOLIER PUMP CONTACTOR DHW PUMP CONTACTOR O SMALL BLOWER CONTACTOR O LARGE BLOWER CONTACTOR GAS VALVE SMALL SPARK GENERATOR SENSE 1 X11 USB INTERFACE SMALL BLOWER CONTACTOR SMALL BLOWER LL 2 3 LARGE BLOWER Eli MROE BLOWER LARGE BLOWER ee 2 3 E X12 X1 3 FLUE DAMPER TRANSFORMER pea 1 24V TRANSFORMER Jl AY J3 6 J3 5 LWCO TEST PROBE SWITCH J333 J3 2 LWCO RESET J2 1 J3 4 INTEGRATED CONTROL of og oot GPS1 GPS2 GPS3 BLOWER PROVING SWITCH LARGE OA BLOWER PROVING SWITCH SMALL BLOCKED FLUE SWITCH O BLOCKED DRAIN SWITCH 7 x5 BLOCK WIRING HIGH LIMIT IS MODEL SWITCH DEPENDANT Ost Notes Tsoxbericts 1 AWARNING DISCONNECT POWER BEFORE SERVICING OPTIONAL ITEMS LOW VOLTAGE 120 VAC HIGH VOLTAGE GROUND INTEGRATED CONTROL LARGE CONNECTION BOARD CN6 3 CN6 2 CN61 17 SHIELD 18 MODBUS 19 B OPTION 20 SHIELD 21 RATE CN3 6 X7 7 CN3 7 22 OUT X8 13 CN3 14 239 BOILER
32. 2845 Cement and primer must comply with ASME D2564 or F493 For Canada use CSA or ULC certified PVC or CPVC pipe fittings and cement NOTICE To allow for proper drainage on large horizontal runs a second line vent may be required and tubing size may need to increase to 1 inch 25 mm The condensate line must remain unobstructed allowing free flow of condensate If condensate is allowed to freeze in the line or if the line is obstructed in any other manner condensate can exit from the boiler tee resulting in potential water damage to property 10 A condensate removal pump is required if boiler is below the drain When installing a condensate pump select one approved for use with condensing boilers and furnaces The pump should have an overflow switch to prevent property damage from condensate spillage The switch should be wired to the auxiliary device proving switch terminals on the low voltage connection board IMG00174 CONDENSATE TRAP SAME LEVEL OR BELOW BOILER BASE En 39 9 Start up Check control water chemistry A CAUTION Do not use petroleum based cleaning or sealing compounds in the boiler system Damage to elastomer seals and gaskets in the system could occur resulting in substantial property damage Hardness less than 7 grains 1 Consult local water treatment companies for hard water areas above 7 grains hardness Chlorine concentration less than 200 ppm 1 Do not fill boiler o
33. 3 Turn the main power on to the boiler by placing the On Off switch in the ON position CREST Installation amp Operation Manual TRAE Ze f Gre 9 Start u D continued Figure 9 2 Operating Instructions 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 This appliance does not have a pilot It is e Immediately call your gas supplier from a equipped with an ignition device which neighbor s phone Follow the gas suppliers automatically lights the burner Do not try instructions to lightthe burner by hand If you cannot reach your gas supplier call BEFORE OPERATING smell all around the fire department the appliance area for gas Be sure to C Use onl hand to turn th rol knob smell next to the floor because some gas SE EE i Never use tools If the handle will not turn by is heavier than air and will sette on the hand don t try to repair it call a qualified service floor technician Force or attempted repair may WHAT TO DO IF YOU SMELL GAS result in a fire or explosion Do not try to light any appliance Do not use this appliance if any part has been under water Immediately call a qualified Do not touch any electric switch do service technician to inspect the appliance and not use any phone in your building to replace any part of the control system and any gas con
34. ACK button This will return you to the Cascade Screen Note The SAVE button must be pressed to ensure proper programming of the controls Failure to press the SAVE button will require all changes to be reprogrammed 45 10 Operating information General How the boiler operates The Crest uses an advanced stainless steel heat exchanger and electronic control module that allows fully condensing operation The blowers pull in air and push flue products out of the boiler through the heat exchanger and flue piping The control module regulates blower speeds to control the boiler firing rate The gas valves sense the amount of air flowing into the boiler and allow only the right amount of gas to flow How the control modules operate The Crest boiler is equipped with a SMART TOUCH control module The SMART TOUCH control module receives inputs from boiler sensors and external devices The control module activates and controls the blowers and gas valves to regulate heat input and switches the boiler Hot Water Generator HWG and system pumps on and off as needed The user programs the control module to meet system needs by adjusting control parameters These parameters set operating temperatures and boiler operating modes Control inputs and outputs Enable This input tells the boiler to provide water for space heating Hot Water Generator HWG tank thermostat This input tells the boiler to provide water for heating an indirect H
35. Cascade 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 For approved common vent sizing contact the factory When Crest boilers are common vented A WARNING the criteria above MUST BE followed Failure to follow all these requirements will result in severe personal injury death or substantial property damage 18 Vertical direct venting Vent air termination vertical A WARNING Follow instructions below when determining e vent location to avoid possibility of severe personal injury death or substantial property damage A 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 18 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 17 of this manual p The vent must terminate at least 3 feet above the highest place in which the vent penetrates the roof and at l
36. Connect the 3 8 inch 9 8 mm fitting to the 3 8 inch 9 8 mm fitting on the condensate trap shipped loose with the factory supplied silicone hose Secure the hose to the condensate trap and the boiler using the factory supplied hose clamps The condensate trap must be installed at the same level or below the boiler base The condensate trap is sized for a 1 PVC outlet connection pipe Plug the wiring connection from the condensate trap into the connector located on the back of the unit Slope condensate tubing down and away from the boiler into a drain or condensate neutralizing filter Condensate from the Crest will be slightly acidic typically with a pH from 3 to 5 Install a neutralizing filter if required by local codes A neutralizer kit FIG 8 1 is available from the factory KIT30097 The neutralizer kit must be placed on a surface that is a minimum of 3 inches lower than the condensate trap with field supplied piping vacuum break installed between the condensate trap and the neutralizer kit Figure 8 1 Condensate Disposal VACUUM BREAK DETAIL FLOOR DRAIN OR DRAIN PAN NEUTRALIZER KIT OPTIONAL 3 MINIMUM BELOW CONDENSATE TRAP CREST Installation amp Operation Manual AOR A ee 9 Do not expose condensate line to freezing temperatures Use materials approved by the authority having jurisdiction In the absence of other authority PVC and CPVC pipe must comply with ASTM D1785 or D
37. FB I O Rev J EST CONDENSING BOILER Installation amp Operation Manual Models 1 5 5 0 A WARNING This manual must only be used by a qualified heating installer service technician Read all instructions including this manual and the Crest Service Manual before installing Perform steps in the order given Failure to comply could result in severe personal injury death o substantial property damage 34 Lochinvar x ER C ar Save this manual for future reference High Efficiency Water Heaters Boilers and Pool Heaters HAZARD DEFINITIONS 2 5 HYDRONIC PIPING PLEASE READ BEFORE PROCEEDING 3 System Water Piping Methode 24 THE CREST HOW IT WORKS 4 5 Low Water Cutoff Device 24 RATINGS 6 Chilled Water Gvasiem 24 1 DETERMINE BOILER LOCATION Freeze Protection enin hernia 24 Clearances ERR RET T General Piping Information 24 Provide Air Openings to Room 8 e ge Y rz lol ao e E 25 Flooring and Foundation EE 8 Near Boiler Piping Components 26 30 Vent and Air ettet perti eo uso Ero DF 8 6 GAS CONNECTIONS Prevent Combustion Air Contamination 8 Connecting Gas Supply Piping
38. Gas Code ANSI Z223 1 NFPA 54 and or CAN CSA B149 1 Natural Gas and Propane Installation Code CREST Installation amp Operation Manual AA Aes SC EAE 1 Determine boiler location continued Remove boiler from wood pallet l After removing the outer shipping crate and plastic from the boiler removethe parts package packaged parts inside the controls compartment of the boiler inside the lower front access panel 2 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 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 A WARNING Failure to assure the truck forks are long enough to extend at least halfway under the boiler heat exchanger will result in the boiler tipping off the lift truck and potentially falling This will result in severe personal injury death or substantial property damage 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 a
39. ILER DRAIN DRAIN PORT TYPICAL SYSTEM CIRCULATOR Y STRAINER RECOMMENDED EXPANSION TANK ei TO SYSTEM PRESSURE PRESSURE GAUGE REDUCING VALVE BACK FLOW NL WAKE UE PREVENTER WATER NOTICE Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment and detailing required by local codes 29 CREST Installation amp Operation Manual PKR DEN iae 5 Hydronic piping Figure 5 5 Multiple Boilers Alternate Common Header Fixed or Variable Flow Primary RELIEF VALVE TYPICAL BALL VALVE TYPICAL FROM SYSTEM BOILER DRAIN TYPICAL Pune SENSOR AIR SEPERATOR DRAIN PORT TYPICAL SYSTEM SUPPLY SENSOR SYSTEM BES CIRCULATOR Y STRAINER a RECOMMENDED TYPICAL TO SYSTEM EXPANSION TANK PRESSURE BACK FLOW WATER PREVENTER PRESSURE REDUCING VALVE NOTICE Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment and detailing required by local codes When installing multiple Crest boilers in fixed or variable flow primary applications utilize a reverse return NOTICE W or other piping method to ensure balanced flow through each boiler 30 6 Gas connections Connecting gas supply piping NOTICE For dual fuel models reference the Crest Dual Fuel Supplemental Manual 1 Refer to FIG 6 1 to pip
40. IN OR NEUTRALIZER KIT Inspect check condensate lines and fittings 1 PVC CPVC CONNECTION 1 Inspect the condensate drain line condensate PVC fittings and condensate trap 41 9 Start up Final checks before starting the boiler LI Read the Crest Service Manual to familiarize yourself with SMART TOUCH control module operation Read this manual page 43 for proper steps to start boiler LI Verify the boiler and system are full of water and all system components are correctly set for operation LI Verify the preparation procedures of Section 9 pages 40 and 41 have been completed Verify electrical connections are correct and securely attached LI Inspect vent piping and air piping for signs of deterioration from corrosion physical damage or sagging Verify air piping and vent piping are intact and correctly installed per this manual Start the boiler 1 Read and follow the Operating instructions in FIG 9 2 page 43 If boiler does not start correctly 1 Check for loose connections blown fuse or service switch off 2 Is external limit control if used open Is boiler water temperature above 200 F 93 C 3 Isthe boiler receiving a call for heat 4 Is gas turned on at meter and boiler 5 Is incoming gas pressure less than 4 inches w c 99 kPa If none of the above corrects the problem refer to the Troubleshooting Section of the Crest Service Manual Check system and boiler Check water
41. J J 8 10 10 Egg cg Jg gu qq qo qu FB 3000 6 8 J 8 l0 10 2 19 Based on a boiler AT of 30 F NOTICE A system supply sensor factory supplied MUST BE installed for proper boiler operation Figure 5 3 Multiple Boilers Common Header Hecommended Primary Secondary Flow FROM SYSTEM ei SYSTEM RETURN SENSOR BALL VALVE TYPICAL AIR SEPARATOR DRAIN PORT TYPICAL aes SYSTEM SUPPLY SENSOR gt HOT WATER GENERATOR SYSTEM CIRCULATOR i Ss SYSTEM bom MAKE UP WATER BACK FLOW PREVENTER WATER PRESSURE GENERATOR REDUCING VALVE CIRCULATOR BOILER DRAIN TYPICAL PRESSURE GAUGE EXPANSION TANK Y STRAINER RECOMMENDED BOILER PUMP FLOW CHECK TYPICAL VALVE TYPICAL System flow should always remain higher than the required flow for the boiler s when the boiler s is in NOTICE operation to prevent short cycling and high limit issues NOTICE Please note that these illustrations are meant to show system piping concept only the installer is responsible for all equipment and detailing required by local codes 28 CREST Installation amp Operation Manual COMPRA Aes 5 Hydronic piping continueg Figure 5 4 Single Boiler Alternate Fixed or Variable Flow Primary System Piping RELIEF VALVE BALL VALVE TYPICAL FROM SYSTEM Tx AIR SEPERATOR BO
42. MPER TRANSFORMER SS OR ofo OR ofo OR oto BR GPS1 GPS2 GPS3 FLUE DAMPER GND 02 o OR BLOWER PROVING SWITCH LARGE o o T BLOWER PROVING SWITCH SMALL 0 0 PR BLOCKED FLUE SWITCH BK BLOCKED DRAIN SWITCH 24V TRANSFORMER X11 USB INTERFACE X5 BLOCK WIRING IS MODEL DEPENDANT Notes 1 All wiring must be installed in accordance with local state provincial and national code requirements per either N E C in USA or C S A in Canada 2 If any original equipment wire as supplied with the appliance must be replaced it must be replaced with wire having same wire gauge AWG and rated for a minimum of 105 C Exceptions Replacement high vo Itage spark lead and ribbon cables must be purchased from the factory Use of a non approved spark lead or ribbon cables can lead to operational problems which could result in non repairable damage to the integrated controller or other components 3 Actual connector block locations may vary from those shown on diagrams Refer to actual components for proper connector block locations when using WIRING DIAGRAM diagrams to troubleshoot unit LBL20280 REV A 59 Installation amp Operation Manual COANE Ate TUR EFE 12 Dia grams continued Figure 12 3 Ladder Diagram 4 0 Model JUNCTION BOX BOX DEPICTS OPTIONAL ITEMS A WARNING DISCONNECT POWER BEFORE SERVICING INTEG
43. ON BOARD BLOWER PROVING SWITCH LARGE BLOWER PROVING SWITCH SMALL opo ALARM BLOCKED FLUE o CONTACTS SWITCH o RUN TIME ea CONTACTS BLOCKED DRAIN SIE C o THERMOSTAT 2 e LOUVER PROVING 24 VAC LOUVER RELAY COIL AUX SWITCH 1 X5 AUX BLOCK WIRING HIGH LIMIT SWITCH 2 IS MODEL SWITCH DEPENDANT OO Notes 1 All wiring must be installed in accordance with local state provincial and national code requirements per either N E C in USA or C S A in Canada 2 If any original equipment wire as supplied with the appliance must be replaced it must be replaced with wire having same wire gauge AWG and rated for a minimum of 105 C Exceptions Replacement high voltage spark lead and ribbon cables must be purchased from the factory Use of a non approved spark lead or ribbon cables can lead to operational problems which could result in non repairable damage to the integrated controller or other components 3 Actual connector block locations may vary from those shown on diagrams Refer to actual components for proper Nx connector block locations when using diagrams to troubleshoot unit LADDER DIAGRAM LBL20270 REV A 12 Dia grams continued Figure 12 4 Wiring Diagram 4 0 Model MODBUS BOARD X1 1 LARGE CONNECTION BOARD X1 2 X1 3 SHIELD 1749 GY X6 3 MODBUS 1839 R X6 1 OPTION 1949 PR X6 2 SHIELD 2054 X4 1
44. RATED CONTROL ON OFF SWITCH 1 5A EACH MAX TERMINAL STRIP LOW VOLTAGE 120 VAC HIGH VOLTAGE GROUND SYSTEM PUMP CONTACTOR INTEGRATED X CONTROL LARGE CONNECTION BOARD CN6 3 BOLIER PUMP CONTACTOR DHW PUMP CONTACTOR RELAY O SMALL BLOWER LARGE BLOWER CONTACTOR GAS VALVE SMALL X8 13 X8 14 X8 12 X8 11 X8 5 SHIELD MODBUS B OPTION SHIELD RATE OUT BOILER PUMP OUT SYSTEM RETURN SENSOR SYSTEM SUPPLY SENSOR TANK SENSOR OUTDOOR SENSOR X8 15 33 BMS 34 IN A 35 0107 SYSTEM PUMP IN SPARK X8 16 SHIELD GENERATOR X8 7 CASCADE ON SO SHON OS ON OPO ORO OO YO POV OOOO SENSE 1 SHIELD X8 17 X8 18 X11 X8 3 INLET SENSOR X8 8 USB INTERFACE SMALL BLOWER X82 SMALL BLOWER N RELAY 1 Mi X8 4 LARGE BLOWER CONTACTOR LARGE BLOWER 1 2 3 4 X1 2 X8 9 X7 1 X7 5 FLUE DAMPER X7 2 TRANSFORMER X7 6 SMALL BLOWER FLUE DAMPER 7 24 TRANSFORMER J3 6 J3 5 LWCO PROBE LARGE BLOWER TEST SWITCH 93 3 J3 2 LWCO RESET J2 1 J3 4 RIBBON CABLE INTEGRATED CONTROL DISPLAY oL o oT oT GPS1 GPS2 GPS3 SMALL DU941 CONNECTI
45. S LOW VOLTAGE 120 VAC HIGH VOLTAGE AWARNING DISCONNECT POWER BEFORE SERVICING LARGE CONNECTION BOARD X6 1 CN6 2 X6 2 CN6 1 LT SHIELD 7 MODBUS B OPTION SHIELD 4 RATE OUT BOILER PUMP OUT SENSOR _ SYSTEM SUPPLY SENSOR TANK SENSOR OUTDOOR SENSOR BMS IN SYSTEM PUMP IN SHIELD CASCADE SHIELD _ SMALL BLOWER LARGE BLOWER CN CN3 DU941 ALARM 4 TANK THERMOSTAT CONTACTS 4 RUN TIME CONTACTS ENABLE LOUVER PROVING AUX AUX 24 VAC LOUVER RELAY COIL SWITCH 2 SWITCH 1 zc Gel 1 All wiring must be installed in accordance with local state provincial and national code requirements per either N E C in USA or C S A in Canada 2 If any original equipment wire as supplied with the appliance must be replaced it must be replaced with wire having same wire gauge AWG and rated for a minimum of 105 C Exceptions Replacement high voltage spark lead and ribbon cables must be purchased from the factory Use of a non approved spark lead or ribbon cables can lead to operational problems which could result in non repairable damage to the integrated controller or other components 3 Actual connector block locations may vary from those shown on diagrams Refer to actual components for proper connector block locations when using diagrams to troubleshoot un
46. T 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 23 of this manual The Crest in same space with other gas or oil fired appliances 1 Follow the National Fuel Gas Code U S or CSA B149 1 Canada to size verify size of the combustion ventilation air openings into the space WARNING The Spass 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 Flooring and foundation Flooring The Crest is approved for installation on combustible flooring but must never be installed on carpeting A 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 If flooding is possible elevate the boiler sufficiently to prevent water from reaching the boiler Assure that the floor and structure is sufficient to support the installed weight of t
47. WG tank 0 10V BMS input set point or power The Crest can be controlled by a Building Management System BMS using a 0 10 VDC signal The control can be configured by the installer to use this signal to either control set point or firing rate 0 10V System Pump speed input When a variable speed system pump is used and there is a 0 10V signal available from the pump speed control this signal may be connected to the boiler Doing so will allow the boiler to anticipate changes in the BTU s needed by the system as the system flow changes and therefore help the boiler to maintain the desired system temperature Connect the input terminal to the COM or output terminal on the pump speed control and the input terminal to the 0 10V or output terminal on the pump speed control Note that the voltage on these inputs must never go below ground 46 Installation amp Operation Manual CEA EE Ze f Ger HWG priority The SMART TOUCH control allows the connection of a HWG thermostat or tank sensor to the low voltage connection board When a tank sensor is connected the HWG thermostat input is ignored When a boiler is programmed for HWG Normal Mode the maximum firing rate can be limited to match the input rating of the indirect tank coil HWG space heating SH cycling If a HWG call for heat is received while a space heating call is in progress and the HWG is in Normal Mode the control will start the HWG p
48. afety turn off electrical power supply before making any electrical connections to avoid possible electric shock hazard Failure to do so can cause severe personal injury or death NOTICE Wiring must be N E C Class 1 If original wiring as supplied with boiler must be replaced use only type 105 C wire or equivalent Boiler must be electrically grounded as required by National Electrical Code ANSI NFPA 70 latest edition Label all wires prior to disconnection when A CAUTION P servicing controls Wiring errors can cause improper and dangerous operation Installation must comply with 1 National Electrical Code and any other national state provincial or local codes or regulations 2 In Canada CSA C22 1 Canadian Electrical Code Part 1 and any local codes CREST Installation amp Operation Manual OMOEA es Cd RUE Line voltage connections Models 1 5 3 5 1 Connect 120 VAC power wiring to the line voltage terminal strip in the junction box as shown in FIG 7 1 2 Provide and install a fused disconnect or service switch sized per the boiler amp draw shown on the boiler rating plate as required by the code see FIG 7 1 3 When connecting the boiler system and hot water generator pumps connect the wiring to the line voltage terminal strip as shown in FIG 7 1 Maximum current is 1 5 amps Install a field supplied contactor between the pump s and the boiler connections 4 For alternate voltage
49. allation amp Operation Manual Gas Pressure The gas pressure must remain between 4 inches w c 99 kPa minimum and 14 inches w c 3 5 kPa maximum for Natural gas and between 4 inches w c 99 kPa minimum and 14 inches w c 3 5 kPa maximum for LP gas during standby static mode and while in operating dynamic mode If an in line regulator is used it must be a minimum of 10 feet 3 m from the Crest boiler It is very important that the gas line is properly purged by the gas supplier or utility company Failure to properly purge the lines or improper line sizing will result in ignition failure Ignition problems are especially noticeable in NEW LP installations and also in empty tank situations This can also occur when a utility company shuts off service to an area to provide maintenance to their lines Gas valve replacement The gas valve MUST NOT be replaced with a conventional gas valve under any circumstances As an additional safety feature the gas valves have flanged connections to the venturis and blowers A WARNING Failure to follow all precautions could result in fire explosion or death A WARNING DO NOT adjust or attempt to measure gas valve outlet pressure Attempting to alter or measure the gas valve outlet pressure could result in damage to the valve causing potential severe personal injury death or substantial property damage f Field iring A WARNING ELECTRICAL SHOCK HAZARD For your s
50. anon TN 37090 615 889 8900 Fax 615 547 1000 www Lochinvar com FB I O Rev J 11 12
51. 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 Figure 3 4 Alternate Vertical Terminations with Multiple Boilers 4 Maintain the required dimensions of the finished termination piping as shown in FIG 3 1 5 Do not extend exposed vent pipe outside of building more than shown in this document Condensate could freeze and block vent pipe 36 914 MM Multiple vent air terminations 1 When terminating multiple Crest boilers terminate each vent air connection as described in this manual FIG 3 3 waRNiNG Terminate all vent pipes at the same height and all air pipes at the same height to avoid recirculation of flue products and the possibility of severe personal injury death or substantial property damage 2 Place roof penetrations to obtain minimum clearance of 12 inches 305 mm between edge of air intake elbow and adjacent vent pipe of another boiler for U S installations see FIG 3 3 For Canadian installations provide clearances required by CSA B149 1 Installation Code 3 The air inlet of a Crest boiler is part of a direct vent connection It is not classified as a forced air intake with regard to spacing from adjacent boiler vents Figure 3 3 Vertical Terminations with Multiple Boilers 36 914 MM 12 1291305 MM 122305 MM 305 MM 36 914 MM
52. ction boards Low water cutoff probe LWCO Ensures adequate water is supplied to the boiler In the event of inadequate water levels the boiler will shut down Power switch The On Off power switch provides the ability to turn line voltage power to the boiler on and off 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 Reset switch Reset switch for the low water cutoff Hold the switch for 10 seconds to reset 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 Firetube heat exchanger High grade stainless steel WAVE firetube design that extracts heat from flue gases and transfers it directly into boiler water Temperature and pressure gauge Monitors the outlet temperature of the boiler as well as the system water pressure Venturis Separate venturis control air and gas flow into two 2 independent burner sections Water inlet A 4 ANSI flange connects the return water from the system to the heat exchanger Water outlet A 4 ANSI flange connects the hot water supply from the boiler to the system Ignition transformer The transformer provides voltage to the ignition electrode item 20 Air arm temperature sensors not shown Monit
53. d 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 CREST Installation amp Operation Manual CEN IEEE T 1 Determine boiler location continued When using an existing vent system to install a new boiler A WARNING Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions causing severe personal injury or death Check the following venting components before installing e Material For materials listed for use with this appliance see Section 2 General Venting Table 2A 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 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 instruc
54. e Crest Service Manual for Night Setback parameters and more information regarding adjusting the date and time Boiler Status button Pressing this button brings up the Boiler Status Screen This screen shows the status of the various safeties inputs and outputs to the control module Reference the Boiler Status Screen section in the Crest Service Manual for more information regarding this screen Main Menu button Pressing this button brings up the Main Menu Screen From this screen navigation to nine 9 other screens is possible Reference the Main Menu Screen section on page 52 of this manual for more information regarding this screen Modulation button Pressing this button brings up the Modulation Screen This screen shows overall boiler modulation individual fan speeds and flame currents Modulation Percentage Displays the current boiler firing rate pe 51 E 10 Operating information ST Installation amp Operation Manual 28 COA NIENTE SC FF Use the Main Menu Screen FIG 10 2 to access the screens necessary to set temperatures operating conditions and monitor boiler operation The Crest is equipped with a SMART TOUCH control system All menu options are accessed by touching the screen with your finger or a stylus from a PDA Figure 10 2 Main Menu Screen The Main Menu Screen allows navigation to nine 9 additional screens which are used to set temperatures operating conditions and monitor boiler op
55. e gas to the boiler a Install ground joint union for servicing when required b In Canada When using manual main shutoff valves it must be identified by the installer Figure 6 1 Gas Supply Piping GAS SUPPLY UNION FACTORY SUPPLIED MANUAL SHUTOFF VALVE FACTORY SUPPLIED SEDIMENT TRAP DRIP LEG CLEAN OUT FACTORY SUPPLIED 2 Support piping with hangers not by the boiler or its accessories The gas valve and blower will not support the weight of the piping Do not attempt to support the weight of the piping with the boiler or its accessories Failure to comply could result in severe personal injury death or substantial property damage Installation amp Operation Manual CREST OM RAs D Purge all air from the gas supply piping Before placing the boiler in operation check the boiler and its gas connection for leaks a The appliance must be disconnected from the gas supply piping system during any pressure testing of that system at a test pressure in excess of 1 2 PSIG 3 5 kPa b The appliance must be isolated from the gas supply piping system by closing a manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 PSIG 3 5 kPa c The appliance and its gas connection must be leak tested before placing it in operation A WARNING Do not check for gas leaks with an open flame use the bubble test
56. e operating lever check to see that a discharge line is connected to this valve directing the flow of hot water from the valve to a proper place of disposal Otherwise severe personal injury may result If no water flows valve is inoperative Shut down the boiler until a new relief valve has been installed After following the above warning directions if the relief valve weeps or will not seat properly replace the relief valve Ensure that the reason for relief valve weeping is the valve and not over pressurization of the system due to expansion tank waterlogging or undersizing 55 1 1 Maintenance Inspect ignition and flame sense electrodes 1 Remove the ignition and both flame sense electrodes from the burner plate Remove any deposits accumulated on the ignition flame sense electrodes using sandpaper If the electrodes cannot be cleaned satisfactorily replace with new ones Replace ignition flame sense electrodes making sure the gaskets are in good condition and correctly positioned Check ignition ground wiring 1 Inspect boiler ground wire from the heat exchanger access cover to ground terminal strip Verify all wiring is in good condition and securely attached Check ground continuity of wiring using continuity meter Replace ground wires if ground continuity is not satisfactory Check all boiler wiring 1 Inspect all boiler wiring making sure wires are in good condition and securely a
57. east 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 Rooftop vent and air inlet terminations must terminate in the same pressure zone unless vertical vent sidewall air is set up as shown in the General Venting Vertical Vent Sidewall Air Section Figure 3 1 Vertical Termination of Air and Vent BIRD SCREEN TYPICAL VENT OUTLET 36 MINIMUM pd ABOVE AIR INLET 12 305 MM MINIMUM ih E ABOVE ROOF SNOW LINE CREST CAE Ae Rd B Installation amp Operation Manual Figure 3 2 Vertical Termination of Air and Vent w Rain Cap BIRD SCREEN TYPICAL VENT OUTLET 36 914 MM MINIMUM ABOVE AIR INLET 12 305 MM MINIMUM ABOVE ROOF SNOW LINE 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
58. eld wire of the second cable to the other shield terminal If it is desired to ground the cable shield at the heater connect the shield wire to one of the shield terminals and install a jumper across the two 2 terminals in connector X5 on the ModBus interface board 0 10V Rate output A 0 10V signal which indicates the firing rate of the heater is available This output may be connected to a Building Management System BMS to allow it to monitor the actual firing rate Connect the terminal to the COM or terminal on the BMS and connect the terminal to the 0 10V or terminal on the BMS Ramp Delay For systems with lower flow the SMART TOUCH can limit the firing rate when enabled when a space heating call for heat starts or when switching from a DHW call for heat to a space heating call for heat There are six 6 limits that can be programmed as well as six 6 time intervals corresponding to each limit The sixth limit will also limit the firing rate for the rest of the call for heat Protection features Outlet temperature flue temperature and temperature rise limiting The outlet water temperature is monitored by the boiler outlet temperature sensor When the outlet temperature exceeds 185 F the unit will reduce the fan speed If the outlet water temperature exceeds 195 F 90 C the control will shut the unit down until the minimum off time has expired and the outlet drops 10 F 5 5 The control module
59. em supply sensor factory supplied MUST BE installed with Primary Secondary 1 Boiler piping Boiler system piping should be sized per the pipe requirements listed in Tables 5A and 5C 10 Y Strainer Field supplied A Y strainer or equivalent multipurpose strainer is recommended at the inlet of the heat exchanger to remove system particles from older hydronic systems and protect newer systems 3 Hot Water Generator circulating pump The maximum allowable water flow rate Field supplied When installed in a Primary Secondary A CAUTION through a single Crest boiler is 350 GPM arrangement the Crest requires an additional pump for Exceeding this flow rate will result in damage the Hot Water Generator Loop The pump should to the heat exchanger and or piping be sized per Table 5A Consult the indirect water heater operating guide to determine flow characteristics Reference Table 5B1 for the minimum NOTICE for the selected product used The pump s total flow and recommended flow rate through a single systems for proper boiler operation 2 Boiler circulating pump Field supplied When using Primary Secondary piping the boiler circulating pump should be sized per Table 5A heat requirements are the sum of the boiler and the indirect Crest boiler at full fire to maintain a 80 F water heater temperature rise Reference Table 5B2 for the absolute minimum flow rate through a 4 Boiler isolation valves single Crest boiler Field
60. ent Manufacturers ProTech Systems Simpson Dura Vent Co Z Flex Nova Flex Group FasNSeal Vent Z Vent Heat Fab Selkirk Corporation Saf T Vent Metal Fab Corr Guard Securities Chimneys International Secure Seal SS Schebler Chimney Systems 16 Installation amp Operation Manual PE A Ae Ea NO General venting continued Table 2B Direct Vent Minimum Maximum Allowable Air Vent Lengths AIR INLET VENT Input Air Intake Air Intake Air Intake Vent Vent Vent De Rate per Diameter Min Length Max Length Diameter Min Length Max Length 25 feet of Vent FB 150 T NN CNN 7 FB 2000 e 0 8 100 9 10 250 3000 10 FB 3500 Table 2C Room Air Minimum Maximum Allowable Air Vent Lengths Vent Input De Rate per 25 feet of Vent Vent Vent gt x 1500 2000 2500 When determining equivalent combustion air and vent length add 5 feet 1 5m for each 90 elbow and 3 feet 9 m for each 45 elbow EXAMPLE 20 feet 6 m of pipe 4 90 elbows 3 45 elbows 49 equivalent feet 15 m of piping Removing from existing vent Follow the instructions in Section 1 page 10 of this manual when removing a boiler from an existing vent system Vent and air piping Vent and air system Installation must comply with local A requirements and with the National Fuel Gas Code NFPA 54
61. er rate thus more efficient This Cascade is also required when cascading boilers in a common vent application Lead Lag The Lead Lag method is chosen when the application requires firing as few boilers at a time as possible This method will not bring on another boiler until the current number of boilers cannot meet the demand This Cascade is NOT allowed in a common vent application The parameters for both types of Cascade are adjustable Reference the Crest Service Manual for a more detailed description of these adjustments Sequence of the cascade To equalize the run time of all boilers on the Cascade the firing sequence will automatically be changed at set intervals For the first 24 hours after initializing the Cascade the sequence will be changed every hour After that the sequence will be changed once every 24 hours HWG operation with cascade For normal mode HWZG operation any boiler s in the Cascade can be selected to provide heat for a HWG call Select a boiler to be designated as the HWG boiler Connect the HWG thermostat or sensor to the terminals on the Low Voltage Connection Board marked for the corresponding device When the boiler receives a HWG call the Leader control will take that boiler out of the Cascade sequence If another boiler is available the Leader will start it up to take its place The HWG boiler will adjust its set point to the programmed HWG boiler set point and will adjust its firing rate
62. eration These screens are as follows Home Navigates back to the Home Screen Setup Allows access to 12 other screens for the adjustment of the control parameters Cascade Shows the status of multiple boilers connected together in a cascade arrangement Leader only Modulation Shows the status of the two 2 gas train systems used in the boiler BMS Shows the information from a Building Integration System Pumps Allows the installer to configure the boiler system and DHW pumps History Shows the operating and fault history of the control module Graphs Allows the selection of items to be graphed on a chart Service Allows the installer to control the fan speed of the individual combustion systems for the purposes of combustion analysis Service Mode will override all other heat demands however all limits will remain active EH 5 um Reference the Crest Service Manual for more information regarding the nine 9 accessible screens 1 1 Maintenance CPP PS eee ITUBRIB FF Maintenance and annual startup Table 11A Service and Maintenance Schedules Service technician see the following pages for instructions Ti F LC lt F v lt Ka 4 General Address reported problems if any Inspect interior clean and vacuum if necessary Clean condensate trap and fill with fresh water e Check for leaks water gas flue condensate Verify flue and air li
63. esign installation and maintenance practice to prevent freeze potential for the boiler and system 47 water 10 Operating information Monitor external limits Connections are provided on the connection board for external limits such as an additional high limit The SMART TOUCH control will shut off the burner and inhibit relighting whenever any of these external limits open Run time and alarm outputs The boiler provides dry contacts for indicating when the boiler is running and when it is unable to operate Run time and cycle counting The control uses four timers to monitor the total hours of burner operation 75 100 25 5096 50 7596 lt 25 The control uses four 4 ignition counters to monitor the amount of boiler cycles The first counter counts all ignitions of the control The second counter counts only ignition attempts that have failed The third and fourth counters are the same as the first and second respectively but can be reset by the installer Service reminder The control can be programmed for service reminder notification This notification will become active when either a set amount of time has expired or a set amount of running hours or cycles has expired all adjustable by the installer The service reminder notification can be reset by the installer The service company s name and phone number can be programmed to display when service is due Error logging The control will hold i
64. et point if higher The boiler pump will be turned on The system pump may be forced on forced off or not changed depending on the System Pump Mode selected reference the Crest Service Manual for details In this mode any low temperature zones such as radiant heating may need additional controls to limit the water temperature sent to those zones Set HWG boiler target temperature When in the HWG Mode the control will modulate to maintain the boiler outlet temperature or system supply temperature to a set point This set point is set at the factory to 180 F If a different set point is desired the appropriate parameter in the control must be changed See the Crest Service Manual for a detailed explanation of this procedure Set maximum HWG fan speed If the rated input of the indirect tank is less than the maximum output of the boiler change the maximum HWG fan speed setting to limit the boiler output accordingly see the Crest Service Manual for a detailed explanation of this procedure Set clock Press the following buttons to program the clock NS Initial j SS SS Setup After pressing SETUP the Password Screen will appear Entering the correct password will allow access to all Installer Level adjustable parameters Press ENTER without a password to access the User Level parameters The SMART TOUCH control has a built in clock that it uses for its night setback feature and for logging events This clock mus
65. et 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 15 2 General venting When a sidewall or vertical rooftop combustion air supply system is disconnected for any reason the air inlet pipe must be resealed to ensure that combustion air will be free of contaminants and supplied in proper volume 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 A DANGER This product has been approved for use with stainless steel vent systems Use only the materials vent systems and terminations listed in Table 2A DO NOT mix vent systems of different types or manufacturers unless listed in this manual Failure to comply could result in severe personal injury death or substantial property damage Installations must comply with applicable national state and local codes Stainless steel vent systems must be listed as a UL 1738 approved system for the United States and a ULC S636 approved system for Canada NOTICE Installation of a stainless steel vent system should adhere to the stainless steel vent manufacturer s installation instruct
66. et pressure port Maximum 14 inches w c 3 5 kPa with no flow lockup or with boiler on Minimum 4 inches w c 99 kPa with gas flowing verify during boiler startup A WARNING Ensure that the high gas pressure regulator is at least 10 feet 3 m upstream of the appliance FIG 6 3 Figure 6 3 Gas Supply Piping to Regulator GAS PRESSURE REGULATOR FIELD SUPPLIED 10 MINIMUM MANUAL SHUT OFF VALVE FIELD SUPPLIED REQUIRED FOR INSTALLATION IN THE COMMONWEALTH OF MASSACHUSETTS CREST Installation amp Operation Manual TENDA iMr 6 Gas connections continued Table 6B Natural Gas Pipe Size Chart TABLE 6B GAS PIPING SIZE CHART Nominal E Maximum Iron Pipe Length of Pipe in Straight Feet Capacity of Pipe Size s EIE PSIG or less and of 0 5 Inch Water Column Based 21 6 460 4 460 3 610 3 100 2 720 2 460 2 3 on NAT GAS 1025 Btu hr per D 11 200 7 900 6 400 5 400 4 870 4 41 Cubic Foot of 23 500 16 100 13 100 11 100 10 000 9 000 Gas and 0 60 Check inlet gas supply in Thousands of Btu hr for 200 gas pressures of 14 Inches Water Specific Gravity LA C HH amp amp DO NOT adjust or attempt to measure gas 4 Slowly turn on the gas supply at the factory installed A WARNING manual gas valve valve outlet pressure Attempting to alter or measure the gas valve outlet pressure 5 Turn the power switch to the ON
67. ge wires through the knockouts in the rear of the boiler as shown in FIG 7 2 2 Connect low voltage wiring to low voltage connection board as shown in FIG 7 3 on page 38 of this manual and the boiler wiring diagram Figure 7 2 Routing Field Wiring LOW VOLTAGE WIRING KNOCKOUTS LINE VOLTAGE WIRING KNOCKOUTS LOW VOLTAGE J BOX LINE VOLTAGE J BOX Enable 1 Connect the room thermostat or boiler enable contacts isolated contact only to terminals 7 and 8 as shown in FIG 7 3 2 Ifathermostat is used install the thermostat on the inside wall away from influences of drafts hot or cold water pipes lighting fixtures television sunlight or fireplaces 3 Thermostat anticipator if applicable a If connected directly to boiler set for 0 1 amps b If connected to relays or other devices set to match total electrical power requirements of connected devices See device manufacturers specifications and thermostat instructions for details Outdoor temperature sensor 1 Connect the outdoor temperature sensor FIG 7 3 to the Outdoor Sensor terminals on the connection board to enable outdoor reset operation of the Crest 2 Mount the sensor on an exterior wall shielded from direct sunlight or flow of heat or cooling from other sources 3 Route sensor wires through a knockout at the rear of the boiler see FIG 7 2 Variable speed system pump If a variable speed pump is used in the primary loop and
68. he 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 23 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 Contaminate
69. iir Tiii FR 4 Sidewall direct venting continues 2 Place wall penetrations to obtain minimum clearance of 12 inches 305 mm between vent pipe and adjacent air inlet as shown in FIG 4 4 for U S installations For Canadian installations provide clearances required by CSA B149 1 Installation Code 3 The air inlet of a Crest is part of a direct vent connection It is not classified as a forced air intake with regard to spacing from adjacent boiler vents Figure 4 4 Multiple Vent Terminations must also comply with Figure 4 1 VENT AIR 12 Ca Figure 4 5 Direct Vent Terminations DIRECT VENT TERMINATIONS Air Inlet Vent Termination Dryer Inlet 4 Straight n Wa Figure 4 6 Room Air Direct Exhaust Terminations ROOM AIR DIRECT EXHAUST TERMINATIONS 23 Elbow 45 Elbow 90 Elbow Room air The Crest boiler may be installed with a single pipe carrying the flue products to the outside while using combustion air from the equipment room Follow the requirements in the General Venting Sidewall Direct Venting and Vertical Direct Venting sections for vent material specifications vent length requirements and vent termination requirements Install the air inlet cover shipped loose with the boiler per FIG 4 7 Combustion and ventilation air must be supplied to the equipment room per the requirements on pages 12 and 13 of this manual for proper operation of the Crest boiler when utilizing
70. imum cold water fill pressure for a commercial system is 12 psi 82 7 kPa b Pressure will rise when boiler is turned on and system water temperature increases 4 Atinitial fill and during boiler startup and testing check system thoroughly for any leaks Repair all leaks before proceeding further A WARNING Eliminate all system leaks Continual fresh makeup water will reduce boiler life Minerals can build up in the heat exchanger reducing heat transfer overheating the heat exchanger and causing heat exchanger failure Purge air from water system 1 Purge air from system 2 Open automatic air vent diaphragm type or bladder type expansion tank systems only one turn 3 Open other vents a Starting on the lowest floor open air vents one at a time until water squirts out b Repeat with remaining vents 4 Refill to correct pressure CREST Installation amp Operation Manual PE SVEDESE Ea FR 9 Start u D continued Check for gas leaks A WARNING Propane boilers only Your propane supplier mixes an odorant with the propane to make its presence detectable In some A WARNING A WARNING o starting the boiler and during initial operation smell near the floor and around the boiler for gas odorant or any unusual odor Remove the top access panel and smell the interior of the boiler enclosure Do not proceed with startup if there is any indication of a gas leak Use an approved leak detection so
71. in Canada 15 d ee r ET 9f Vent and Air Ping 16 8 CONDENSATE DISPOSAL Air Intake Vent Connections 16 Condensate Drain 39 Min Max Combustion Air amp Vent Piping Lengths 17 9 STARTUP 40 45 Vent and Air Ge e 17 10 OPERATING INFORMATION Common Venting ME 18 ET HUP 46 48 3 VERTICAL DIRECT VENTING Ca CAG RT 49 Vent Air Termination 19 Sequence of Operation 50 Determine Location 19 Status GOEG E 51 Prepare Roof Henetratons 19 Main EE 52 Termination and Fittings 19 20 11 MAINTENANCE Multiple Vent Air Termmmatons 20 Maintenance amp Annual Startup 53 57 4 SIDEWALL DIRECT VENTING 12 DIAGRAMS Vent Air Termination Sidewall 21 23 Ladder Diagrams 58 60 62 Determine 21 23 Wiring Diagrams 59 61 63 Prepare Wall Heneiratons 22 Revision Notes AAA Back Cover Termination and Fittings E 22 Multiple Vent Air Termmmatons 22 23 pie geen eee aero 23 Hazard definitions The following defined terms are
72. in g for leaks listed in Section 1 of this manual If any of these are present in the boiler intake air vicinity they must be A WARNING Eliminate all system or boiler leaks removed If they cannot be removed reinstall the air and Continual fresh makeup water will vent lines per this manual reduce boiler life Minerals can build up reducing heat transfer overheating heat Ins pect boiler interior exchanger and causing heat exchanger failure Leaking water may also cause 1 Remove the front access covers and inspect the interior of severe property damage the boiler 1 Inspect all water and gas piping and verify to be leak free 2 Vacuum any sediment from inside the boiler and 2 Look for signs of leaking lines and correct any problems components Remove any obstructions found Clean condensate tra p 3 Check gas line using the procedure found in Section 6 Gas Connections 1 Inspect the condensate drain line vent line condensate PVC fittings and condensate trap Flush condensate trap with water 1 Remove the four 4 screws securing the top cover to the condensate trap and remove the cover FIG 11 1 2 Locate the plastic ball inside the float tube Verify there is nothing under the ball causing it to not seat properly 3 Fill with fresh water until the water begins to pour out of the drain 4 Replace the top cover and the screws removed in Step 1 54 1 1 Maintenance continued Flue vent system and air piping
73. ions 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 NOTICE Table 2A Approved Stainless Steel Vent Manufacturers Installation amp Operation Manual PPS AP Ae FETUBI FU 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 WITH THE BOILER SHIPPED LOOSE IT GASKET VENT PIPE FIELD SUPPLIED CONNECTOR 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 NOTICE 5 ee ee or vent piping to sizes not specified in this manual is not authorized Approved Stainless Steel V
74. it LADDER DIAGRAM LBL20281 REV A CREST Installation amp Operation Manual PPP N iNi AO PT 12 Dia grams continued Figure 12 2 Wiring Diagram 1 5 3 5 Models AWARNING DISCONNECT POWER MODBUS BOARD LARGE CONNECTION BOARD LOW VOLTAGE o os Sd X INTEGRATED CONTROL 120 VAC OPTION PR emm HIGH VOLTAGE SHIELD RATE OUT BOILER LI PUMP OUT SYSTEM RETURN L SENSOR i SYSTEM SUPPLY SENSOR TANK SENSOR i 1 5 EACH MAX OUTDOOR SYSTEM PUMP SENSOR M CONTACTOR EE 120V BMS SUPPLY BOILER PUMP IN GND CONTACTOR SYSTEM Un DHW PUMP PUMEN CONTACTOR SHIELD JUNCTION BOX T Xj INLET SENSOR A CASCADE o0 9 ds K BK Ill Ww Gen pen SHIELD B SWITCH ON OFF GAS VALVE SMALL GAS VALVE LARGE DU941 CN1 SMALL CONNECTION BOARD ALARM CONTACTS RUN TIME CONTACTS TANK THERMOSTAT Joo Go ENABLE W LOUVER PROVING 24 VAC LOUVER RELAY COIL OR HIGH LIMIT AUX SWITCH SWITCH 1 es ee R CH BL R BLOWER LARGE Jj FLAME SENSE 2 ET i LWCO TEST Bere eae SPARK ROD PROBE SWITCH Ch OR BK 1 FLAME SENSE 1 LWCO RESET FLUE DA
75. l 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 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 4223 1 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 40
76. l modulate to a set speed and the second gas valve will be energized The second combustion system will light from the first combustion system The second flame will be monitored much like the first Once both combustion systems are firing the control will work in synchronization to maintain the desired set point temperature If the heat load should decrease sufficiently the second combustion system will be shut down Once both the space heating and HWG calls for heat are satisfied the control will turn off the gas valve s and begin the Post Purge cycle Any pumps that are running will begin their respective Pump Delay cycles At the end of the Post Purge cycle the louver relay contacts will de energize The control verifies that the blowers stop running and the blower proving switches open At the end of the Pump Delay cycle s the pump s will be turned off Q 0 CREST Installation amp Operation Manual COANE Ae En RE 10 Operating information IVEN RE T UCH Crest control module The Home Screen displays status modulation rate outlet water temperature inlet water temperature flue temperature system supply temperature system return temperature outdoor air temperature and domestic hot water tank temperature The boiler can be started and stopped by pressing the ON OFF button The Boiler Status Screen and Main Menu Screen can be accessed by pressing the appropriate button Figure 10 1 Home Screen
77. leaning 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 CREST Installation amp Operation Manual 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 18 This will cause flue gas spillage or appliance malfunction resulting in possible severe personal injury death or substantial property damage A WARNING Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions causing severe personal injury or death At the time of removal of an existing boiler the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation while the other appliances remaining connected to the common venting system are not in operation a Seal any unused openings in the common venting system b Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion or other deficiencies which could cause an unsafe condition Test vent system Insofar as is practical clo
78. let temperature exceeds 205 F 93 3 C Installer Adjustable Parameter integral manual reset high limit action occurs The boiler will shut down until the outlet water cools down and the boiler is reset through the user interface Low water cutoff protection A low water cutoff device with test and reset functionality is provided in the boiler as standard equipment Flow sensing device The SMART TOUCH control module uses temperature sensing of both supply and return temperatures of the heat exchanger If the flow rate is too low or the outlet temperatures too high the control module modulates down and will shut the boiler off This ensures boiler shutdown in the event of low flow conditions NOTICE If a mechanical flow switch is required to meet local code requirements the Crest boiler can be equipped with a field supplied outlet flow switch Please reference page 38 of this manual for more information Outdoor reset operation if used Target temperature with outdoor reset This feature improves the system s efficiency as the outdoor temperature warms up See the Crest Service Manual to change the settings Reset curve The reset curve looks at outdoor air temperature and adjusts the set point Installation amp Operation Manual PPE N ae Ee 10 Operating information Cascade When multiple boilers are installed they can be wired together in a cascade sequence A maximum of eight boilers can be cont
79. lorethylene 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 TABLE 1B MINIMUM RECOMMENDED COMBUSTION AIR SUPPLY TO EQUIPMENT ROOM Outside Air from 2 Openings Directly from Outdoors Model Number Outdoors Outside Air from 2 Ducts Delivered from Inside Air from 2 Ducts Delivered from Interior Space Outside Air from Different Opening Directly Stories from Outdoors in Same Story Total cm ir in Opening Top Opening o m 3000 500 9678 9678 19355 3226 Bottom HE in Top Bottom Top in Opening in Opening in ET Es 750 FB 1500 2420 2420 4839 4839 500 1000 1000 2000 2000 4000 667 FB 2000 SE 3226 6452 6452 12904 12904 25807 4304 mp 625 625 1250 1250 2500 2500 5000 833 500 4033 4033 8065 8065 16129 16129 32258 5381 750 750 1500 1500 3000 3000 6000 1000 4839 4839 9678 9678 19355 19355 38710 6452
80. lso recommended that the upper and lower front panels along with both front side panels be removed no tools required Do not drop the boiler or bump the jacket NOTICE Von the floor or pallet Damage to the boiler can result Figure 1 2 Boiler Mounted on Shipping Pallet BOLT WASHERS JW amp LOCKNUT 3X 3X Figure 1 3 Boiler Removed from Shipping Pallet REMOVE MIDDLE TOP COVER LIFTING LUGS LIFTING LUGS 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 11 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 Fue
81. lution Repair any leaks at once DO NOT adjust or attempt to measure gas valve outlet pressure The gas valve is factory set for the correct outlet pressure This setting is suitable for natural gas and propane requiring no field adjustment Attempting to alter or measure the gas valve outlet pressure could result in damage to the valve causing potential severe personal injury death or instances the odorant can fade and the gas may no longer have an odor Before startup and periodically thereafter have the propane supplier verify the correct odorant level in the gas Check thermostat circuit s 1 Disconnect the two external wires connected to the enable terminals on the connection board Connect a voltmeter across these two incoming wires Close each thermostat zone valve and relay in the external circuit one at a time and check the voltmeter reading across the incoming wires There should NEVER be a voltage reading 4 Ifa voltage does occur under any condition check and correct the external wiring This is a common problem when using 3 wire zone valves substantial property damage Figure 9 1 Condensate Trap 5 Once the external boiler enable wiring is checked and corrected if necessary reconnect the external thermostat circuit wires to the connection board Allow the boiler to cycle FROM CONDENSATE VENT ON BOILER FROM CONDENSATE DRAIN ON BOILER Inspect condensate system TO FLOOR DRA
82. m of quartz or cristobalite from occupational sources is carcinogenic to humans Group 1 Normal operating temperatures in this appliance are below the level to convert ceramic fibers to cristobalite Abnormal operating conditions would have to be created to convert the ceramic fibers in this appliance to cristobalite The ceramic fiber material used in this appliance is an irritant when handling or replacing the ceramic materials it is advisable that the installer follow these safety guidelines BI Avoid breathing dust and contact with skin and eyes Use NIOSH certified dust respirator N95 This type of respirator is based on the OSHA requirements for cristobalite at the time this document was written Other types of respirators be needed depending on the job site conditions Current NIOSH recommendations can be found on the NIOSH website at http www cdc gov niosh homepage html NIOSH approved respirators manufacturers and phone numbers are also listed on this website Wear long sleeved loose fitting clothing gloves and eye protection Apply enough water to the combustion chamber lining to prevent airborne dust Remove the combustion chamber lining from the boiler and place it in a plastic bag for disposal Wash potentially contaminated clothes separately from other clothing Rinse clothes washer thoroughly NIOSH stated First Aid Eye Irrigate immediately M Breathing Fresh ai
83. minating the vent and air a Position the vent termination where vapors will not damage nearby shrubs plants or air conditioning equipment or be objectionable b The flue products will form a noticeable plume as they condense in cold air Avoid areas where the plume could obstruct window views c Prevailing winds could cause freezing of condensate and water ice buildup where flue products impinge on building surfaces or plants d Avoid possibility of accidental contact of flue products with people or pets e Do not locate the terminations where wind eddies could affect performance or cause recirculation such as inside building corners near adjacent buildings or surfaces window wells stairwells alcoves courtyards or other recessed areas Installation amp Operation Manual CREST MEE A WARNING Sidewall vent and air inlet terminations must terminate in the same pressure zone f Do not terminate above any door or above or below any window Condensate can freeze causing ice formations g Locate or guard vent to prevent condensate damage to exterior finishes Figure 4 1 Sidewall Termination of Air and Vent NOTICE PVC CPVC or ABS is acceptable air inlet pipe material FROM BOILER VENT PIPE CONNECTION 36 MIN 48 MAX TO BOILER INTAKE AIR CONNECTION et P Tu GRADE OR SNOW LINE 3 Maintain clearances as shown in FIG s 4 1 thru 4 3 pages 21 and 22 The vent termination should n
84. monitors the flue temperature by a sensor located in the flue exhaust If the flue temperature exceeds 350 F 176 C the control will reduce the maximum fan speed If the flue temperature exceeds 400 F 204 C the control will shut the unit down The unit will restart automatically once the flue temperature drops 50 F 27 C and the minimum off time has expired The control monitors the temperature difference between the inlet and the outlet sensor If this difference exceeds 80 F 27 C the control will reduce the fan speed If the temperature difference exceeds 90 F 32 C the control will shut the unit down The unit will restart automatically once the temperature difference has dropped below 50 F 28 C and the minimum off time has expired Freeze protection DO NOT install the boiler in a room likely to freeze The following integral feature of the SMART TOUCH control module provides some protection for the boiler only not for the system The SMART TOUCH control module provides freeze up protection as follows when the boiler water temperature drops below 45 F 7 C Below 45 F 7 C the boiler and system pumps if enabled operate constantly Below 37 F 3 C the boiler turns on Boiler and pumps turn off if boiler temperature rises above 43 F 6 C A CAUTION This feature of the SMART TOUCH control module does not eliminate the possibility of freezing The installation must still use recognized d
85. n memory the last 10 blocking faults as well as the last 10 lockout faults The date and time of the occurrence will be recorded as well Only the 10 most recent occurrences will be held in memory Boiler temperature regulation Operating temperature target The SMART TOUCH control module senses water temperature and regulates boiler firing and firing rate to achieve a target temperature The target temperature can be set between 32 F 0 C and 185 F 85 C Target temperature is fixed when the outdoor sensor is not installed Target temperature is calculated as described under Outdoor Reset Operation and Target Temperature Boost when the outdoor sensor is connected 48 Installation amp Operation Manual CEN IEEE bie f Gre High limit operations The Crest SMART TOUCH control has two 2 integral limits one auto reset and one manual reset The Crest also has one auxiliary manual reset high limit The integral and auxiliary high limits are UL353 certified When the outlet temperature exceeds 195 F 90 6 C Installer Adjustable Parameter integral auto reset high limit action occurs The boiler will shut down until the outlet water cools down and the timer expires If the outlet temperature exceeds 200 F 93 3 C User Adjustable Dial auxiliary manual reset high limit action occurs The boiler will shut down until the outlet water cools down and the boiler is reset through the user interface If the out
86. nent literature A WARNING i i shipped with the boiler Failure to perform the service and maintenance could result in damage to the boiler or system Failure to follow the directions in this manual and component literature could result in severe personal injury death or substantial property damage The boiler should be inspected annually only by a qualified service technician In addition the maintenance A WARNING and care of the boiler designated in Table 11A and explained on the following pages must be performed to assure maximum boiler efficiency and reliability Failure to service and maintain the boiler and system could result in equipment failure Electrical shock hazard Turn off power to the boiler before any service operation on the boiler except as A WARNING oM CM noted otherwise in this instruction manual Failure to turn off electrical power could result in electrical shock causing severe personal injury or death Address reported problems Figure 11 1 Condensate Trap 1 Inspect any problems reported by the owner and correct before proceeding FROM CONDENSATE VENT ON BOILER FROM CONDENSATE DRAIN ON BOILER Inspect boiler area TO FLOOR DRAIN OR NEUTRALIZER KIT 1 Verify that boiler area is free of any combustible materials 1 PVC CPVC CONNECTION gasoline and other flammable vapors and liquids 2 Verify that air intake area is free of any of the contaminants Check all p i p
87. nes in good condition and sealed tight e Check system water pressure system piping expansion tank Check control settings Check the ignition and both flame sense electrodes sand off any deposits clean and reposition Check wiring and connections e Perform start up checkout and performance verification per Section 9 e Flame inspection stable uniform e Check both flame signals at least 10 microamps at high fire e Clean the heat exchanger Test low water cutoff reference the Crest Service Manual If combustion or performance indicate need Clean heat exchanger e Remove and clean burner using compressed air only Clean the blower wheels Installation amp Operation Manual Ow ner maintenance see the Crest User s Information Manual for Monthly Every 6 months End of season months instructions e Check boiler area e Check pressure temperature gauge e Check vent piping e Check air piping e Check air and vent termination screens e Check relief valve e Check condensate drain system Test low water cutoff Reset button low water cutoff e Check boiler piping gas and water for leaks Operate relief valve e Shut boiler down unless boiler used for domestic hot water 53 CREST Installation amp Operation Manual TENA Ze d Gre 1 1 Maintenance Follow the service and maintenance procedures given throughout this manual and in compo
88. ns off After the space heating call for heat ends the boiler pump will run for an additional period of time When a HWG call for heat starts the HWG pump is turned on If a space heating call for heat is on the boiler pump will turn Off a few seconds after the HWG pump turns on Louver When the boiler needs to control combustion air louvers connect a 24 VAC louver relay to the two 2 Louver Relay terminals Connect the Louver End Switch to the Louver Proving Switch input on the Low Voltage Connection Board Temperature control Modulation The Crest is capable of modulating its firing rate from a minimum of 1096 model specific to a maximum of 10096 The firing rate is dictated by the call for heat 1 space heating or hot water generation the heating load ramp delay if enabled and various other temperature limitations Installation amp Operation Manual TRAE Ze f Ger 10 Operating information Gradient limiting If during operation of the boiler the outlet water temperature is rising too quickly the control will reduce the firing rate to its lowest setting Outdoor air reset If an outdoor air sensor is connected the control module will calculate the set point based on the programmed reset curve The installer can change the slope of the reset curve by several adjustable parameters The user can limit the maximum set point for the system using the space heating set point Boost functi
89. o the Low Voltage Connection Board at the terminals marked for the outdoor air sensor on the Leader boiler FIG 7 3 If the outdoor air sensor is connected the Leader control will calculate the water temperature set point based on the programmed reset curve parameters If the outdoor air sensor is not connected the Leader control will maintain the fixed water temperature set point that is programmed into the control If a Thermostat enable output is available it should be wired to the Low Voltage Connection Board on the Leader boiler at the terminals marked Enable FIG 7 3 If the boilers are to run continuously connect a jumper wire between the 7 and 8 terminals at the Enable input This will initiate a call for heat on the Cascade If the SMART TOUCH control is being controlled by a Boiler Management System BMS a call for heat may be initiated by the voltage applied to the BMS 0 10 VDC input instead Communication between the Leader boiler and the Member boilers is accomplished by using shielded 2 wire twisted pair communication cable Connect one of the twisted pair wires to Cascade terminal A on each of the Low Voltage Connection boards and the other wire of the twisted pair to Cascade terminal B on each of the Low Voltage Connection Boards Connect the shield wires to one of the Cascade shield ground terminals on the Low Voltage Connection Boards FIG 7 3 If more than two boilers are on the Cascade daisy chain the wiring f
90. off valve and install a suitable 1 8 fitting field supplied for the manometer tubing Place the tubing of the manometer over the tap once the 1 8 12 Shut off the gas supply at the manual gas valve in the gas fitting is installed as shown in FIG 6 4 piping to the appliance 11 Turn the power switch to the OFF position 13 Remove the manometer from the pressure tap on top of the gas valve Remove the 1 8 3 mm field supplied fitting and reinstall the pipe plug removed in Step 3 33 6 Gas connections Do not check for gas leaks with an open A WARNING flame use the bubble test Failure to 14 15 16 17 use the bubble test or check for gas leaks can cause severe personal injury death or substantial property damage Turn on the gas supply at the manual gas valve Turn the power switch to the ON position Adjust the temperature set point on the control panel of the SMART TOUCH control module to the desired water temperature so the appliance will call for heat Check burner performance by cycling the system while you observe burner response The burner should ignite promptly Flame pattern should be stable Turn system off and allow burner to cool then cycle burner again to ensure proper ignition and flame characteristics Figure 6 4 Inlet Gas Supply Check EM O p O ll L a eil ds UV 2523 Cep 34 CRE OAR Aes ST Inst
91. on If outdoor air reset is active the boost temperature is not 0 a space heating demand has been active continuously for a set period of time time adjustable by installer and there has been no HWG demands the control will increase the set point by a fixed number of degrees adjustable by installer This process will continue until the space heating demand ends the set point reaches the programmed set point or a maximum of 20 increases has occurred Once the system heat demand is satisfied the set point will revert to the value determined by the reset curve Night setback The controller may be programmed to reduce the space heating set point and or Hot Water Generator set point for each demand during a certain time each day A start and stop time for each demand can be programmed for each day of the week The controller can be programmed to reduce the tank set point as well A different set of start and stop times can be programmed each day of the week Flame current support To prevent nuisance shutdowns when the boiler is firing at minimum rates the control will increase the firing rate when the flame signal drops too low ModBus The Crest boiler can be connected to and controlled by a Building Automation System through the ModBus interface Connect the A and B wires to the A and B terminals If connecting another cable in a daisy chain connect the shield wire of the first cable to one of the shield terminals and the shi
92. operational problems which could result in non repairable damage to the integrated controller or other components 3 Actual connector block locations may vary from those shown on diagrams Refer to actual components for proper connector block locations when using diagrams to troubleshoot unit LADDER DIAGRAM LBL20272 REV A Installation amp Operation Manual CREST Installation amp Operation Manual Ais fN cae d 12 Dia grams continued Figure 12 6 Wiring Diagram 5 0 Model BOX DEPICTS B OPTIONAL ITEMS DISCONNECT POWER MODBUS BOARD LARGE CONNECTION BOARD LOW VOLTAGE SHIELD GY X6 3 Hn xd INTEGRATED CONTROL 120 VAC IODBUS 5 9 HIGH VOLTAGE SHIELD RATE OUT BOILER PUMP OUT SYSTEM RETURN 208V SENSOR R N L1 L2 L3 1 5A EACH MAX SYSTEM SUPPLY L BB SYSTEM PUMP SENSOR W CONTACTOR TANK aR BOILER PUMP SENSOR CONTACTOR OUTDOOR L P DHW PUMP SENSOR W f CONTACTOR SC BL JUNCTION SYSTEM el PUNE I CASCADE INLET SENSOR SHIELD lt 7 GAS VALVE AX SMALL GAS VALVE LARGE RUN SMALL CONNECTION BOARD ALARM 1 CONTACTS 2 RUN TIME 3 R CONTACTS 4 R TANK 5 OR THERMOSTAT 6 OR ENABLE de i BL w 8 BK LOUVER BR PROVING R
93. ors fuel air delivery temperature to the burner Air inlet cover shipped loose Used with room air for combustion and to prevent debris from entering the boiler Fuses A low resistance resistor that acts as a sacrificial device to provide overcurrent protection of either the load or source circuit CREST Installation amp Operation Manual TMP A Ae Niii e The Crest How it works continued Models 1 5 5 0 9 Front View Hear View IMG00318 TIT 7 N A A M 7 AN N C 9 WA S N LT N Ah A KN Y AN 3 UN A CN WE CW TI Wee i EE Right Side inside unit Left Side inside unit CREST Installation amp Operation Manual 6 Ch IDEE Aer Ratings DOE CERTIFIED seed CERTIFIED Crest Other Specifications SE AHRI Rating Net Model Number Input AHRI Appliance MBH Ratings Water is Gas Inlet Se Water Content Size Note Change to Notes 4 8 MBH Gall Outlet L for L P gas models alions Note 2 s 200 a 9 s pe fe e ss 2050 Das pepe ee For LP models the minimum input is 420 MBH NOTICE Maximum allowed working pressure is located on the rating plate epe ave pe e om Notes 7 High altitude Crest Models 1 5 2 0 2 5 3 0 and 3 5 will 1 The ratings are based on standard test procedures de rate by 1 496 for each 1 000 feet above sea level
94. ot be located in traffic areas such as walkways adjacent buildings operable windows or doors Also maintain the following a Vent must terminate At least 6 feet 1 8 m from adjacent walls Notless than 7 feet 2 1 m above grade where located adjacent to public walkways No closer than 12 inches 305 mm below roof overhang At least 3 feet 9 m above any forced air intake within 10 feet 3 m e No closer than 4 feet 1 2 m horizontally from any door or window or any other gravity air inlet b Aur inlet must terminate at least 12 inches 305 m above grade or snow line at least 36 inches 914 mm below the vent termination c Do not terminate closer than 4 feet 1 2 m horizontally from any electric meter gas meter regulator relief valve or other equipment Never terminate above or below any of these within 4 feet 1 2 m horizontally 4 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 21 Installation amp Operation Manual CAE ADS ee GOrit 4 Sidewall direct venting Vent air termination sidewall Prepare wall penetrations Figure 4 2 Clearance to Doors and Windows 1 Air pipe penetration a Cutahole for the air pipe Size the air pipe hole as close as desired to the air pipe outside diameter Vent pipe penetration a Cutaholeforthevent pipe For either combustible or noncombustible cons
95. p the temperature of the system supply can be controlled The SMART TOUCH control automatically detects the presence of this sensor and controls the boiler firing rate to maintain the system supply temperature to the set point NOTICE DO NOT INSTALL THE SYSTEM SUPPLY SENSOR INTO IHE SYSTEM RETURN 2 For system supply sensor wiring information reference FIG 7 3 Unless a firing rate is being provided by NOTICE a BMS system a system supply sensor factory supplied MUST BE installed with Primary Secondary piping systems for proper boiler operation Boiler management system 1 An external control may be connected to control either the firing rate or the set point of the boiler Connect the 0 10 VDC terminals to the 0 10 VDC output of the external control The SMART TOUCH control can be enabled using the Enable output see page 38 or using the voltage applied to the 0 10 VDC input Reference the Crest Service Manual for more details 2 Make sure terminal 34 on the Low Voltage Connection Board is connected to the or COM output terminal of the external control and 0 10 VDC terminal 33 1s connected to the 0 10 VDC terminal of the external control Runtime contacts The SMART TOUCH control closes a set of dry contacts whenever the burner is running This is typically used by Building Management Systems to verify that the boiler is responding to a call for heat Alarm contacts The SMART TOUCH control clo
96. piping 1 Check system piping for leaks If found shut down the boiler and repair immediately See WARNINGS on pages 40 and 41 startup regarding failure to repair leaks 2 Vent any remaining air from the system using manual vents Air in the system will interfere with circulation and cause heat distribution problems and noise 42 Installation amp Operation Manual CEA EFE bh Ze f Ger Check vent piping and air piping 1 Check for gastight seal at every connection seam of air piping and vent piping A WARNING Venting system must be sealed gastight to prevent flue gas spillage and carbon monoxide emissions which will result in severe personal injury or death Check gas piping 1 Check around the boiler for gas odor following the procedure on page 31 of this manual connecting gas supply piping If you discover evidence of any gas leak shut down the boiler at once Find the leak source with a bubble test and repair immediately Do not start the boiler again until corrected Failure to comply could result in severe personal injury death or substantial property damage Check flame and combustion NOTICE For dual fuel models reference the Crest Dual Fuel Supplemental Manual Turn the main power off to the boiler by placing the On Off switch in the OFF position mJ 2 Remove the flue temperature sensor from the flue collector Note Combustion measurements will be made at this point
97. position could result in damage to the valve causing 6 Adjust the temperature set point on the control panel of dd ae ee injury death or the SMART TOUCH control module to call for heat or substantial property damage utilize Service Mode see page 44 of this manual The gas piping must be sized for the proper flow and length of 7 Observe the gas supply pressure as the burner fires at pipe to avoid excessive pressure drop Both the gas meter and 100 of rated input Percent of burner input will be the gas regulator must be properly sized for the total gas load displayed on the Modulation Screen If you experience a pressure drop greater than 1 inch w c 8 Ensure inlet pressure is within specified range 249 Pa the meter regulator or gas line is undersized or in Minimum and maximum gas supply pressures are need of service Perform the steps below when checking inlet specified in this section of the manual gas supply 9 If gas supply pressure is within normal range and no 1l Turn the main power switch to the OFF position adjustments are needed proceed on to Step 11 10 If the gas pressure is out of range contact the gas utility gas supplier qualified installer or service agency to determine the necessary steps to provide proper gas pressure to the control 2 Shut off gas supply at the manual gas valve in the gas piping to the appliance Remove the 1 8 pipe plug on the flange to the factory supplied gas shut
98. r 57 UORDEN SiMe 12 Diagrams Figure 12 1 Ladder Diagram_ 1 5 3 5 Models 58 120VAC NEUTRAL JUNCTION BOX 09 INTEGRATED CONTROL 4 ON OFF 1 5A EACH MAX oY SWITCH TERMINAL STRIP X1 6 SYSTEM PUMP CONTACTOR BOLIER PUMP CONTACTOR DHW PUMP CONTACTOR SMALL BLOWER RELAY LARGE BLOWER RELAY GAS VALVE LARGE GAS VALVE SMALL FLAME SENSE 2 SPARK ROD SPARK GENERATOR FLAME SENSE 1 X11 USB INTERFACE SMALL BLOWER SMALL BLOWER RELAY LARGE BLOWER LARGE BLOWER X141 X1 2 X1 3 FLUE DAMPER TRANSFORMER FLUE DAMPER 24V TRANSFORMER MA LWCO TEST PROBE SWITCH J93 LWCO RESET J2 1 INTEGRATED CONTROL oL gt ng amp GPS1 GPS2 GPS3 X6 15 BLOWER PROVING SWITCH LARGE BLOWER PROVING SWITCH SMALL BLOCKED FLUE SWITCH BLOCKED DRAIN SWITCH X5 BLOCK WIRING IS MODEL DEPENDANT HIGH LIMIT SWITCH Notes GROUND INTEGRATED CONTROL X8 20 X8 10 X8 1 X7 8 X7 7 X8 13 X8 14 X8 12 X8 11 X8 5 X8 15 X8 6 SMALL CONNECTION BOARD P OOO VY OY RIBBON CABLE X4 1 X4 2 X4 3 INLET SENSOR Installation amp Operation Manual Box DEPICTS OPTIONAL ITEM
99. r operate with water containing chlorine in excess of 200 ppm 2 Filling with chlorinated fresh water should be acceptable since drinking water chlorine levels are much lower 3 Do not use the boiler to directly heat swimming pool or spa water Test replace freeze protection fluid 1 For systems using freeze protection fluids follow fluid manufacturer s instructions 2 Freeze protection fluid must be replaced periodically due to degradation of inhibitors over time Follow all fluid manufacturer s instructions Freeze protection when used l Determine freeze protection fluid quantity using system water content following fluid manufacturer s instructions Boiler water content is listed on page 6 Remember to include expansion tank water content 2 Local codes may require a backflow preventer or actual disconnect from city water supply 3 When using freeze protection fluid with automatic fill install a water meter to monitor water makeup Freeze protection fluid may leak before the water begins to leak causing concentration to drop reducing the freeze protection level 40 Chor A Ae amp R Installation amp Operation Manual Fill and test water system 1 Fill system only after ensuring the water meets the requirements of this manual 2 Close manual and automatic air vents and boiler drain valve 3 Fillto correct system pressure Correct pressure will vary with each application a The min
100. reen by pressing the MAIN MENU button and then the SERVICE button On the Service Screen place heater into Service Mode by selecting the START button then selecting Set Gas Valve 1 High Insert the probe from a combustion analyzer into the hole left by the removal of the flue temperature sensor Once the heat exchanger has modulated up to rate measure the combustion The values should be in the range listed in Table 9A below CO levels should be less than 200 ppm for a properly installed unit If the combustion is not within range reference the Troubleshooting Section in the Crest Service Manual for possible causes and corrective actions Table 9A Flue Products Chart Propane Gas Valve Valve 1 High Valve 1 Low Valve 2 High Valve2Low 6 8 9 0 8 9 4 9 8 3 11 0 10 11 O CO 3 8 6 6 7 9 9 1 6 9 4 8 9 6 11 2 After Gas Valve 1 is set repeat the same procedure for the second gas train by selecting Set Gas Valve 2 High on the Service Screen Once the heater analysis is complete test the safety shutoff device by turning the manual shutoff valve to the OFF position and ensuring that the heater shuts down and registers an alarm Open the manual shutoff valve and reset the control Turn the main power off to the boiler and replace the flue temperature sensor into the flue pipe connection Place the boiler back into normal operation A WARNING You must replace the
101. ressure water supply The water will drain through the condensate connection Allow the heat exchanger to thoroughly dry Reconnect the condensate drain line to the condensate trap Close isolation valves on piping to isolate boiler from system Attach a hose to the boiler drain and flush boiler thoroughly with clean water by using purging valves to allow water to flow through the water make up line to the boiler When securing the burner be sure to tighten the nuts but DO NOT over tighten Tighten the nuts to a torque setting of no more than 6 2 ft lbs When securing the burner mounting plate be sure to tighten the nuts but DO NOT over tighten Tighten the nuts to a torque setting of no more than 15 5 ft Ibs i MER AP ie d Perte EPR FN 15 16 Installation amp Operation Manual Replace the burner mounting plate assembly and gas air manifold assembly Ensure gaskets are in good condition and positioned properly Restore boiler to operation Perform start up and check out procedures in the Check Flame and Combustion Section 9 Startup on pages 42 and 44 of this manual Handling ceramic fiber materials REMOVAL OF COMBUSTION CHAMBER LINING ARNING The combustion chamber insulation in this appliance contains ceramic fiber material Ceramic fibers can be converted to cristobalite in very high temperature applications The International Agency for Research on Cancer IARC has concluded Crystalline silica in the for
102. rolled from a single control In this application one boiler would be designated as the Leader control and all others would be designated as Member controls Once the Leader boiler receives a call for heat from the Enable input the 0 10 VDC input or ModBus the control will determine what the set point will be If outdoor air reset 1s desired connect the outdoor air sensor to the terminals on the Low Voltage Connection Board on the Leader boiler The set point will be calculated based on the programmed reset curve parameters See the Crest Service Manual to program the reset curve If outdoor air reset is not desired do not connect the outdoor air sensor A fixed temperature set point can be programmed into the control or provided through the ModBus interface If the water temperature at the controlling sensor is less than the set point the turn off offset the off on differential the control will initiate a call for heat on the Cascade see the Crest Service Manual for an explanation of the offset and differential The Leader will energize the lead boiler on the Cascade For a new startup this will be the Leader boiler The two 2 types of Cascade control are listed below Efficiency optimization Efficiency optimization is chosen when the application is such that overall heating efficiency is most important The Cascade will fire the boilers in a way that is the most efficient This allows more boilers to fire at one time at a low
103. rom the Cascade terminals on the second boiler to the Cascade terminals on the third boiler then from the third to the forth and so on The connections between boilers can be made in any order regardless of the addresses of the boilers Try to keep each cable as short as possible 37 Installation amp Operation Manual ONDAN Ae MOi CREST f Field wiring Z HOLIMS xnv HOLIMS xnv NOLLVOINDININOO g S AVIS 7 H3AnO01 Y37108 S IG LAALNO 1 S 2 i EE ils HOLIMS MOSN3S Mina W31SAS RULL 8 Ree L ONIAONd YOSNAS AlddNS W31SAS GT I 0 ie SAANG MOSN3S yny Gee D de 391430 5 He SNITSVN3 NOSN3S B M lie WALSAS 1 alt Y 1V ISOINH3H L LAANI AOL 0 YNYL aa 1 WALSAS LXAN OL BOO LNAWS9OVNV ONICTING YAO SNOIAAYd NON PCCSSSSF Figure 7 3 Low Voltage Field Wiring Connections 38 8 Condensate disposal Condensate drain 1 The Crest is a high efficiency appliance that produces condensate The rear of the boiler has a 1 inch 25 4 mm stainless steel drain fitting and a 3 8 inch 9 8 mm stainless steel vent line for connection to the condensate trap Connect the 1 inch 25 4 mm fitting to the 1 inch 25 4 mm fitting on the condensate trap with the factory supplied silicone hose Secure the hose to the condensate trap and the boiler using the factory supplied hose clamps
104. s consult factory Line voltage connections Models 4 0 5 0 1 Connect 208 VAC 3 wye power wiring to the line voltage terminal strip in the junction box as shown in FIG 7 1 2 Provide and install a fused disconnect or service switch sized per the boiler amp draw shown on the boiler rating plate as required by the code see FIG 7 1 3 Whenconnecting the boiler system and hot water generator pumps connect the wiring to the line voltage terminal strip as shown in FIG 7 1 Maximum current is 1 5 amps Install a field supplied contactor between the pump s and the boiler connections 4 For alternate voltages consult factory Figure 7 1 Boiler Line Voltage Field Wiring Connections MODELS 1 5 3 5 NEUTRAL W GROUND G LINE BK o TEN SERVICE SWITCH a r SANI RA lt lt SYSTEM PUMP E DRY CONTACT Le s o LENS UNI v Z BOILER PUMP ESL 7 agi GH JE DRY CONTACT H Se DE 7 lo HWG PUMP EL R K 2 f DRY CONTACT RII INS CONTACTOR FIELD SUPPLIED MODELS 4 0 5 0 GROUND G NEUTRAL W Se L1 BK d o ES 77 L3 BL 4 o SA SERVICE SWITCH Le rap E Tm an 2 BOILER PUMP tq 463 5 DRY CONTACT JE le 5 r DHW PUMP WO el S DRY CONTACT Gi e i CONTACTOR FIELD SUPPLIED IMG00319 35 f Field wiring Low voltage connections 1 Route all low volta
105. se 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 10 Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously 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 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 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
106. sediment Prepare roof penetrations 1 Air pipe penetration a Cuta 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 Cuta hole for the vent pipe For either combustible or noncombustible construction size the vent pipe hole per the vent manufacturer s instructions b Insert a galvanized metal thimble in the vent pipe hole when required by local codes 3 Space the air and vent holes to provide the minimum spacing shown in FIG 3 1 4 Follow all local codes for isolation of vent pipe when passing through floors ceilings and roofs 5 Provide flashing and sealing boots sized for the vent pipe and air pipe Termination and fittings 1 Prepare the vent termination coupling and the air termination elbow FIG 3 1 by inserting bird screens Bird screens should be obtained locally 2 The air piping must terminate in a down turned 180 return bend as shown in FIG 3 1 Locate the air inlet pipe no further than 2 feet 6 m from the center of the vent pipe This placement avoids recirculation of flue products into the combustion air stream 19 Installation amp Operation Manual COMER NIC TONER Vertical direct venting 3 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
107. ses another set of contacts whenever the boiler is locked out or the power is turned off This can be used to turn on an alarm or signal a Building Management System that the boiler is down System return sensor 1 Install the system return sensor into the return of the primary loop 2 Connect the terminals to the system return sensor as shown in FIG 7 3 Installation amp Operation Manual PPM A eee Ee Wiring of the cascade When wiring the boilers for Cascade operation select one boiler as the Leader boiler The remaining boilers will be designated as Members See page 45 Configuration of the Cascade for a detailed explanation of this procedure Connect the system supply sensor system return sensor and outdoor air sensor if used to the Leader boiler Unless a firing rate is being provided by a NOTICE BMS system a system supply sensor factory supplied MUST BE installed with Primary Secondary piping systems for proper boiler operation The location of the system supply sensor should be downstream of the boiler connections in the main system loop FIG s 5 5 and 5 6 The system supply sensor should be wired to the Low Voltage Connection Board at the terminals marked for the system supply sensor see FIG 7 3 The Leader control will use the water temperature at the system supply sensor to control the operation of the Cascade If outdoor air reset is desired the outdoor air sensor should be wired t
108. sible for all equipment and detailing required by local codes CREST Installation amp Operation Manual TRAE NI PET 5 Hydronic piping continea Circulator sizing The Crest heat exchanger does have a pressure drop which must be considered in your system design Refer to the graph in FIG 5 1 for pressure drop through the Crest heat exchanger Figure 5 1 Pressure Drop vs Flow CREST Pressure Drop Curve FBN1500 FBN2000 ie FBN2500 FBN3000 o d LL 4 im e im L 2 im e N WwW A DN CO Flow Rate GPM Table 5A Sizing Information for Temperature Rise 20 F 40 60 F TEMPERATURE RISE APPLICATIONS BOILER a e a ow oy The drop reflected in FIG 5 1 is It is required that boiler piping systems for the boiler only Additional allowances utilize Primary Secondary or Fixed or be made for piping especially if Variable Flow Primary configurations as SURE for Primary Secondary shown in FIG s 5 2 thru 5 5 The use of applications other boiler piping configurations could result in improper building and system flow rates leading to inadvertent boiler high limit shutdowns and poor system performance 25 CREST Installation amp Operation Manual 5 Hydronic piping Near boiler piping components A syst
109. skets are in good condition and positioned correctly FIG 11 2 When securing the burner be sure to tighten the nuts but DO NOT over tighten Tighten the nuts to a torque setting of no more than 6 2 ft lIbs When securing the burner mounting plate be sure to tighten the nuts but DO NOT over tighten Tighten the nuts to a torque setting of no more than 15 5 ft Ibs Figure 11 2 Burner Assembly INSULATION AIR GAS MANIFOLD MANIFOLD GASKET BURNER ASSEMBLY BURNER GASKET BURNER PLATE FIBERBOARD Check flame signal l At high fire of each combustion system the flame signal shown on the display should be at least 10 microamps A lower flame signal may indicate a fouled or damaged flame sense electrode If cleaning the flame sense electrodes does not improve ground wiring is in good condition and ground continuity is satisfactory replace the flame sense electrode See Section 3 Troubleshooting in the Crest Service Manual for other procedures to deal with low flame signal 1 1 Maintenance continued Review with owner 1 Cleaning boiler heat exchanger 1 Review the Crest User s Information Manual with the owner Emphasize the need to perform the maintenance schedule specified in the Crest User s Information Manual and in this manual as well Remind the owner of the need to call a licensed contractor should the boiler or system exhibit any unusual behavior Remind the owner to
110. sult 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 e 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 To avoid electric shock disconnect electrical supply before performing maintenance To avoid severe burns allow boiler to cool before
111. t be set when the boiler is installed and anytime the boiler has been powered off for more than one day Use the following procedure to set the clock 1 To set the clock highlight Clock using the arrows and press the SELECT button Use the left and right arrows to select hours minutes AM PM and the up and down arrows to set 2 To set the date highlight Date using the arrows and press the SELECT button Use the left and right arrows to select the day of the week and the up and down arrows to set Installation amp Operation Manual CREAN IEEE Ze d Gre The internal clock does not adjust for ROUGE Daylight Savings Time and therefore will require a manual adjustment Configuration of the cascade When installed in a Cascade system the individual controls must be programmed for cascade operation To program the cascade parameters access the Cascade Menu found in the Setup Menu by pressing the following buttons After pressing SETUP the correct installer password MUST BE entered 1 Once in the Cascade Setup Menu select the appropriate parameter using the arrows and press the SELECT button 2 The description of the selected parameter and its current setting will appear at the bottom of the screen 3 To adjust the parameter press the or buttons to change the value being displayed 4 Make the correct adjustments and then press the SAVE button 5 Once all the parameters have been adjusted press the B
112. the single pipe method Figure 4 7 Room Air Installation AIR INLET COVER 5 Hydronic piping System water piping methods The Crest is designed to function in a closed loop pressurized system not less than 12 psi 83 kPa A temperature and pressure gauge is included to monitor system pressure and outlet temperature and should be located on the boiler outlet It is important to note that the boiler has a pressure drop which must be figured in when sizing the circulators Each boiler installation must have an air elimination device which will remove air from the system Install the boiler so the gas ignition system components are protected from water dripping spraying etc during appliance operation or basic service of circulator replacement valves and others Observe a minimum of 1 4 inch 6 mm clearance around all uninsulated hot water pipes when openings around the pipes are not protected by non combustible materials Low water cutoff device An electronic low water cutoff is provided as standard equipment on all models The low water cutoff should be inspected every 6 months Chilled water system If the boiler supplies hot water to heating coils in air handler units flow control valves or other devices must be installed to prevent gravity circulation of heater water in the coils during the cooling cycle A chilled water medium must be piped in parallel with the heater Freeze protection Freeze protection for new
113. ting any relief valve ensure that it is piped with its discharge in a safe area to avoid severe scald potential Read Section 5 Hydronic Piping before proceeding further CB ERE MSIE Installation amp Operation Manual Safety relief valves should be re inspected ae ic AT LEAST ONCE EVERY THREE YEARS by a licensed plumbing contractor or authorized inspection agency to ensure that the product has not been affected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally Certain naturally occurring conditions may corrode the valve or its components over time rendering the valve inoperative Such conditions are not detectable unless the valve and its components are physically removed and inspected This inspection must only be conducted by a plumbing contractor or authorized inspection agency not by the owner Failure to re inspect the boiler relief valve as directed could result in unsafe pressure buildup which can result in severe personal injury death or substantial property damage Following installation the valve lever A WARNING must be operated AT LEAST ONCE A YEAR to ensure that waterways are clear Certain naturally occurring mineral deposits may adhere to the valve rendering it inoperative When manually operating the lever water will discharge and precautions must be taken to avoid contact with hot water and to avoid water damage Befor
114. tions 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 e Seal With prior requirements met the system should be tested to the procedure listed in parts c through f of the Removal of an Existing Boiler Section on page 10 With stainless steel vent seal and connect all pipe and components as specified by the vent manufacturer used If any of these conditions are not met the existing system must be updated or replaced for that concern Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions causing severe personal injury or death Table 1A Corrosive Contaminants and Sources Products to avoid Spray cans containing chloro fluorocarbons Permanent wave solutions Chlorinated waxes cleaners Chlorine based swimming pool chemicals Calcium chloride used for thawing Sodium chloride used for water softening Refrigerant leaks Paint or varnish removers Hydrochloric acid muriatic acid Cements and glues Antistatic fabric softeners used in clothes dryers Chlorine type bleaches detergents and cleaning solvents found in household laundry rooms Adhesives used to fasten building products and other similar products Areas likely to have contaminants Dry c
115. to another location per this manual A 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 17 CREST Installation amp Operation Manual 2 General venting Common venting Table 2D Flue Damper Kits Crest boilers may be common vented however the following criteria MUST BE followed 1 Only Crest boilers may be connected to the common Flue Damper Kits vent DO NOT mix other manufacturer s appliances or other Lochinvar models FB1500 DRH30000 2 Crest boilers connected to the common vent must all be FB2000 DRH30001 of the same size FB2500 DRH30002 3 Each Crest boiler must have a Lochinvar supplied flue FB3000 DRH30003 damper installed see Table 2D FB3500 DRH30003 4 Only vertical direct vent positive pressure Category FB4000 DRH30004 IV or vertical chimney vent negative pressure Category II may be used when common venting Crest boilers Sidewall venting is not allowed FB5000 DRH30005 5 Crest boilers in a common vent must be connected and controlled with the integral Crest SMART TOUCH
116. to maintain this Once the HWG call has been satisfied the Leader control will place that boiler back into the Cascade sequence Switching of the boiler between HWG operation and SH operation when there is a call for both does not occur in Cascade Mode When HWG is programmed for Zone Mode connect the HWZG thermostat or tank sensor to the Leader boiler When a HWG call is received the Leader will modulate the entire Cascade to bring the system supply temperature up to the HWG boiler set point if higher Night Setback and Ramp Delay operations with cascade Night Setback and Ramp Delay operation of the boilers within the Cascade are available Programming will be done through the Leader boiler Refer to the Crest Service Manual for information regarding Night Setback and Ramp Delay 49 CREST Installation amp Operation Manual VE REF I 10 Operating information Sequence of operation Note This unit is equipped with two 2 gas train systems Gas Train 1 will fire first If the demand cannot be met by the first gas train the second gas train Gas Train 2 will fire Upon a call for heat the control turns on the appropriate pumps system and boiler pumps for a space heating call HWG pump for a hot water generator call The control confirms that the low water cutoff contacts are closed and energizes the louvers optional and damper optional relays The control confirms that the gas pressure switch blocked drain
117. to troubleshoot unit WIRING DIAGRAM LBL20271 REV 63 Revision Notes Revision A ECO C07970 initial release Revision B ECO 608023 reflects changes made to FIG 6 3 on page 32 for Mass approval and changes made to FIG 5 3 on page 28 Revision ECO 608179 reflects the addition of three 3 new vent manufacturers pg 16 Table 2A Revision D ECO C08585 reflects edits made to FIG 4 4 and the addition of Fixed or Variable Flow Primary in place of Full Flow Revision E ECO C08841 reflects changes made to 3 on page 42 additional information added to the humidity warning on page 7 along with references to the Dual Fuel Supplemental Manual Revision ECO C09629 reflects the update of the AHRI and ASME logos on page 6 and the update of condensate disposal information and Figure 8 1 on page 39 Revision G ECO C10325 reflects a kit number correction Neutralizer kit and the aadition of version 4 software update pg 49 Revision H ECO C10391 reflects the change in the Label and Wiring diagrams on pages 58 and 59 ECO C10391 Revision ECO C11129 reflects changes made to the Ratings page 6 the Common Venting section page 18 and ECR 05455 the addition 4 e ei Lochinvar of 7 in the Before Locating the Boiler section on page 7 V High Efficiency Water Heaters Boilers and Pool Heaters 300 Maddox Simpson Parkway Revision J ECO C11613 reflects the addition of models 4 0 and 5 0 Leb
118. trol which has been under water OPERATING INSTRUCTIONS 1 STOP Read the safety information 8 Turn gas shutoff valve clockwise to ON above on this label Handle will be parallel to pipe 2 Setthe thermostat to lowest setting 9 Install front door 3 Turn off all electric power to the 10 Turn on all electric power to appliance appliance 11 Set thermostat to desired setting 4 This appliance is equipped with an 12 If the appliance will not operate follow the ignition device which automatically lights instructions To Tum Off Gas To Appliance and Do nottry to light the burner call your service technician or gas supplier SEN Gas Valve Gas Valve 5 Remove front door OPEN CLOSED 6 Tum gas shutoff valve counterclockwise mA mS m to OFF Handle will be perpendicular to to CLOSE E to OPEN pipe Do not force 7 Waitfive 5 minutes to clear out any gas If you then smell gas STOP Follow B in the safety information above this label If you dont smell gas go to next step TO TURN OFF GAS TO APPLIANCE Set the thermostat to lowest setting 4 Turn gas shut off valve counterclockwise to Turn off all electric power to the appliance OFF Handle will be perpendicular to pipe if service isto be performed Do not force Remove front door 5 Install front door LBL20053 REV B 43 9 Start up Check flame and combustion continued 4 Navigate to the Service Screen from the Home Sc
119. truction size the vent pipe hole per the vent manufacturer s instructions 2 Install the vent and air intake piping Seal all gaps between the pipes and wall with RTV silicone sealant 3 all wall cavities Termination and fittings 1 The air termination must be oriented at least 12 inches above grade or snow line as shown in FIG 4 1 page 2l 2 Maintain the required dimensions of the finished termination piping as shown in FIG 4 1 page 21 3 Do not extend exposed vent pipe outside of the building more than what is shown in this document Condensate could freeze and block vent pipe Figure 4 3 Clearance to Forced Air Inlets 4 Stainless steel terminations are designed to penetrate walls with a thickness up to 9 25 inches of standard construction IF LESS THAN 10 VENT TERMINATION 36 MIN Multiple vent air terminations 1 When terminating multiple Crest boilers terminate each vent air connection as described in this manual FIG 4 4 waRNING All vent pipes and air inlets must terminate at the same height to avoid FORCED AIR possibility of severe personal injury INLET death or substantial property damage AIR TERMINATION A CAUTION Sidewall venting commercial products will result in large exhaust plumes in cold climates Consideration should be taken when locating in proximity to windows doors walkways etc EM 5 CRES Installation amp Operation Manual ADEN
120. ttached Check control settings 1 Navigate to the Setup Screen and check all settings See Section 1 of the Crest Service Manual Adjust settings if necessary See Section 1 of the Crest Service Manual for adjustment procedures Check settings of external limit controls if any and adjust if necessary Perform start up and checks Be Start boiler and perform checks and tests specified in Section 9 Start up Verify cold fill pressure is correct and that operating pressure does not go too high Check burner flame Inspect flame through observation windows If the flame is unsatisfactory at either high fire or low fire remove and clean the burner Clean the burner thoroughly using a vacuum cleaner or compressed air Do not use compressed air to clean the burner if cleaning is performed inside a building 56 Installation amp Operation Manual Chor M eee FTUMIPMM E FP Shut down the boiler Follow the To Turn Off Gas to Appliance instructions for the boiler in Section 9 Startup Do not drain the boiler unless it will be exposed to freezing temperatures If using freeze prevention fluid in system do not drain Allow time for the boiler to cool to room temperature if it has been firing Remove the top access panel to remove the gas air manifold assembly Remove the nuts securing the burner to the burner mounting plate Remove the burner FIG 11 2 When replacing the burner ensure ga
121. ump and shut the boiler pump off The system pump will remain on For stand alone boilers if the space heating call is still active while the HWG call is in operation the control will wait for 30 minutes time adjustable by installer then it will switch back to the space heating demand There 1s a timer to switch from space heating to HWG and a timer to switch from HWG to space heating The control will switch back and forth until one of the heat demands end This function does not apply to cascade systems Controlling sensor The control module is programmed to use the outlet sensor as the control sensor by default If a system supply sensor is connected the control automatically uses it as the control sensor The control module may be programmed to use the inlet sensor as the control sensor instead In this case the control will use the system return sensor if it is connected Anti cycling After a space heating demand has been satisfied the control will delay the next space heating call for a set time period time is adjustable by the installer The time delay will be bypassed if the inlet water temperature drops too far during the delay Boiler system and HWG pump control When a space heating call for heat starts and no HWG call is on the boiler pump is turned on The system pump will turn on also if it is programmed to do so If a HWG call for heat is on the boiler pump will wait to turn on until just before the HWG pump tur
122. up to 5 500 prescribed by the United States Department of Energy feet and 1 896 for each 1 000 feet above 5 500 feet 2 Net AHRI ratings are based on net installed radiation of 9 High altitude Crest Models 4 0 and 5 0 will not de rate up to sufficient quantity for the requirements of the building 5 500 feet and nothing need be added for normal piping and pickup 9 For Crest Models 4 0 and 5 0 installations above 5 500 feet Ratings are based on a piping and pickup allowance of contact the factory 10 Ratings have been confirmed by the Hydronics Section of 3 Crest boilers require special gas venting Use only AHRI the vent materials and methods specified in the Crest Installation and Operation Manual P adi Standard Crest boilers equipped to operate from sea level to 4 500 feet only with no adjustments UNIT EQUIPPED FOR High altitude Crest Models 1 5 2 0 2 5 3 0 and 3 5 HIGH ALTITUDE boilers are equipped to operate from 3 000 to 12 000 feet and high altitude Crest Models 4 0 and 5 0 boilers 3000 FT TO 12 000 FT are equipped to operate from 3 000 to 5 500 feet High altitude models are manufactured with different control parameters for high altitude operation but the sequence of operation given in this manual remains the same as the standard boilers A high altitude label as shown in FIG A is also affixed to the unit Standard Crest boilers will de rate by 2 2 for each 1 000 feet above sea level up to 4 500 feet when
123. 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 A DANGER DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury A WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury A CAUTION CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury CAUTION CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not avoided may result in property damage NOTICE NOTICE indicates special instructions on installation operation or maintenance that are important but not related to personal injury or property damage Installation amp Operation Manual dr gt amp om TRAE bie d Gre Please read before proceeding A WARNING Installer Read all instructions including When servicing boiler this manual and the Crest Service Manual NOTICE A WARNING A WARNING 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 re
124. 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 2596 Check with louver manufacturers for exact net free area of louvers Where two openings are provided one must be within 12 30 cm of the ceiling and one must be within 12 30 cm of the floor of the equipment room Each opening must have a net free area as specified in Table 1B Single openings shall commence within 12 30 cm of the ceiling The minimum dimension of air openings shall not be less than 3 80 mm Under no circumstances should 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 perch
125. wn 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 blowers 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 windows Two large high temperature quartz observation windows provide views of each independent burner surface during firing 13 Dual flame sensors The dual flame sensors are used by the control module to detect the presence of a burner flame at both independent burner surfaces 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
126. word will allow access to all Installer Level adjustable parameters Press ENTER without a password to access the User Level parameters 1 To change a set point use the arrows to highlight a user set point parameter and press the SELECT button 2 The description of the selected parameter and its current setting will appear at the bottom of the screen 3 To adjust the set point press the following buttons to change the value being displayed Be 4 Once the set point has been adjusted to the desired setting press the SAVE button to change the set point 5 Once all the necessary adjustments have been made press the HOME button to return to the Home Screen Note The SAVE button must be pressed to ensure proper programming of the controls Failure to press the SAVE button will require all changes to be reprogrammed 9 Sta rt up continued Set Hot Water Generator HWG operation Verify HWG mode There are two 2 modes of operation for HWG In Normal Mode when a HWG demand begins the control will start the HWG pump turn off the boiler pump if running and modulate to bring the outlet temperature to the HWG boiler set point The maximum firing rate may be limited in this mode if desired In Zone Mode it is assumed that the indirect HWG tank is piped as a zone on the primary loop When a HWG demand begins the control will turn on the HWG pump output and raise the system temperature set point to the HWG boiler s

continued - Lochinvar

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