Page 2 - DANGER
2 Contents Hazard definitions The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product. DANGER WARNING CAUTION CAUTION NOTICE DANGER indicates an imminently ha...
Page 3 - Installation & Operation Manual; Please read before proceeding; Installer –; Read all instructions, including; User –; This manual is for use only; When servicing boiler –; Thoroughly flush the system (without boiler; Freeze protection fluids –; WHAT TO DO IF YOU SMELL GAS; Installation and service must be; WARNING
Installation & Operation Manual Please read before proceeding Installer – Read all instructions, including this manual and the Crest Service Manual, before installing. Perform steps in the order given. User – This manual is for use only by a qualified heating installer/service technician. Refer ...
Page 5 - Models; Front View
Left Side (inside unit) Right Side (inside unit) The Crest - How it works... (continued) 5 Installation & Operation Manual Models 1.5 - 2.0 - 2.5 - 3.0 - 3.5 2 11 1 39 Front View 7 36 6 35 9 29 5 19 10 Rear View 33 1213 17 34 3 37 25 26 21 22 29 20 12 27 14 32 4 15 16 23 19 28 31 30 34 18
Page 6 - Ratings; Crest; NOTICE; UNIT EQUIPPED FOR; HIGH ALTITUDE; Figure A High Altitude Label Location
6 Installation & Operation Manual Ratings Crest AHRI Rating Model Number Note: Change “N” to “L” for L.P. gas models. InputMBH (Note 4) Min Max Gross Output MBH (Note 1) Net AHRI Ratings Water, MBH (Note 2) FB(N,L)1500 60 1500 1380 1200 FB(N,L)2000 80 2000 1840 1600 FB(N,L)2500 125 2500 2300 200...
Page 7 - Installation must comply with:; Determine boiler location; Figure 1-1 Recommended Service Clearances
7 Installation & Operation Manual 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/A...
Page 8 - Provide air openings to room:; No air ventilation openings into the boiler room are; Flooring and foundation
Installation & Operation Manual 8 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 th...
Page 9 - Areas likely to have contaminants; Table 1A Corrosive Contaminants and Sources; When using an existing vent system to
Installation & Operation Manual 9 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...
Page 10 - When removing a boiler from existing
Installation & Operation Manual 1 Determine boiler location 10 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, result...
Page 11 - Remove boiler from wood pallet; Figure 1-2 Boiler Mounted on Shipping Pallet; Venting
Installation & Operation Manual 1 Determine boiler location (continued) Remove boiler from wood pallet 1. After removing the outer shipping crate and plastic from the boiler, remove the parts package (packaged parts inside the controls compartment of the boiler inside the lower front access pane...
Page 12 - Combustion and ventilation air; appliance only; Figure 1-6_Combustion Air from Interior Space
1 Determine boiler location Installation & Operation Manual 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 Nat...
Page 13 - CAUTION
Installation & Operation Manual 4. If a single combustion air opening is provided to bring combustion air in directly from the outdoors, the opening must be sized based on a minimum free area of one square inch per 3000 Btu/hr (7 cm 2 per kW). This opening must be located within 12” (30 cm) of t...
Page 14 - Vertical; General; Sidewall; Direct venting; Vertical Vent, Sidewall Air; Optional room air
14 Installation & Operation Manual Vertical 2 General venting Sidewall Direct venting Vertical Vent, Sidewall Air Sidewall Vertical Optional room air
Page 15 - Install vent and combustion air piping; Air inlet pipe materials:
15 Installation & Operation Manual 2 General venting (continued) Install vent and combustion air piping DANGER The Crest must be vented and supplied with combustion and ventilation air as described in this section. Ensure the vent and air piping and the combustion air supply comply with these ...
Page 16 - Air intake/vent connections; Combustion Air Intake Connector; Figure 2-1 Combustion Air Adapter; Vent and air piping; Table 2A Approved Stainless Steel Vent Manufacturers; Approved Stainless Steel Vent Manufacturers
16 Installation & Operation Manual 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 liste...
Page 17 - —OR—; Removing from existing vent; Table 2B Direct Vent Minimum / Maximum Allowable Air / Vent Lengths
17 Installation & Operation Manual 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 pip...
Page 18 - Common venting; Table 2D Flue Damper Kits; Flue Damper Kits
Installation & Operation Manual 18 2 General venting Common venting Crest boilers may be common vented; however, the following criteria MUST BE followed: 1. Only Crest boilers may be connected to the common vent. DO NOT mix other manufacturer’s appliances or other Lochinvar models. 2. Crest boil...
Page 19 - Vertical direct venting; Vent/air termination – vertical; Prepare roof penetrations; Determine location; Figure 3-1 Vertical Termination of Air and Vent
Installation & Operation Manual 19 3 Vertical direct venting Vent/air termination – vertical Prepare roof penetrations 1. Air pipe penetration: a. Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter. 2. Vent pipe penetration: a. Cut a hole for...
Page 20 - Multiple vent/air terminations; Figure 3-3 Vertical Terminations with Multiple Boilers
20 Installation & Operation Manual 3 Vertical direct venting Multiple vent/air terminations 1. When terminating multiple Crest boilers, terminate each vent/air connection as described in this manual (FIG. 3-3). Terminate all vent pipes at the same height and all air pipes at the same height to a...
Page 21 - Figure 4-1 Sidewall Termination of Air and Vent; Sidewall direct; Vent/air termination – sidewall
Installation & Operation Manual 3. Maintain clearances as shown in FIG.’s 4-1 thru 4-3, pages 21 and 22. The vent termination should not 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...
Page 22 - Sidewall direct venting; Figure 4-2 Clearance to Doors and Windows; Figure 4-3 Clearance to Forced Air Inlets; Prepare wall penetrations
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 21. 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...
Page 23 - Place wall penetrations to obtain minimum clearance; DIRECT VENT TERMINATIONS; Figure 4-5 Direct Vent Terminations; Room air; Figure 4-7 Room Air Installation
Installation & Operation Manual 4 Sidewall direct venting (continued) 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...
Page 24 - Hydronic piping; System water piping methods
24 Installation & Operation Manual 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 locat...
Page 25 - Primary/Secondary or Fixed or; boiler; . Additional allowances; ressu; CREST Pressure Drop Curve
Installation & Operation Manual 5 Hydronic piping (continued) It is required that boiler piping systems utilize Primary/Secondary or Fixed or Variable Flow Primary configurations as shown in FIG.’s 5-2 thru 5-5. The use of other boiler piping configurations could result in improper building and ...
Page 26 - Near boiler piping components; Table 5B1 Minimum Flow Rate with the Boiler at Full Fire
Installation & Operation Manual 5 Hydronic piping Near boiler piping components 1. Boiler piping: Boiler system piping should be sized per the pipe requirements listed in Tables 5A and 5C. 2. Boiler circulating pump: Field supplied. When using Primary/Secondary piping the boiler circulating pump...
Page 28 - Model; Table 5C Multiple Boilers - Common Header - Primary / Secondary Flow
28 Installation & Operation Manual 5 Hydronic piping 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. NOTICE HOT W ATER GENERATOR W ATER GENERATOR CIRCULATOR BOILER PUMP (TYPIC...
Page 31 - Gas connections; Connecting gas supply piping; Figure 6-1 Gas Supply Piping; Table 6A Gas Inlet Size
31 Installation & Operation Manual 6 Gas connections Connecting gas supply piping 1. Refer to FIG. 6-1 to pipe 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 G...
Page 32 - Figure 6-2 Inlet Pipe with Backup Wrench; Figure 6-3 Gas Supply Piping to Regulator
32 Installation & Operation Manual 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 compo...
Page 33 - Table 6B Natural Gas Pipe Size Chart; Check inlet gas supply
33 Table 6B Natural Gas Pipe Size Chart The gas piping must be sized for the proper flow and length of pipe, to avoid excessive pressure drop. Both the gas meter and the gas regulator must be properly sized for the total gas load. If you experience a pressure drop greater than 1 inch w.c. (249 Pa), ...
Page 34 - Gas Pressure; Figure 6-4 Inlet Gas Supply Check
34 Installation & Operation Manual WARNING Do not check for gas leaks with an open flame -- use the bubble test. Failure to use the bubble test or check for gas leaks can cause severe personal injury, death, or substantial property damage. 14. Turn on the gas supply at the manual gas valve. 15...
Page 35 - Field wiring; Connect 120 VAC power wiring to the line voltage terminal; CONTACTOR
35 Installation & Operation Manual 7 Field wiring ELECTRICAL SHOCK HAZARD – For your safety, 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. Wiring must be N.E.C. Class ...
Page 36 - Figure 7-2 Routing Field Wiring
Installation & Operation Manual Low voltage connections 1. Route all low voltage 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...
Page 37 - By installing the system supply sensor into the supply
37 Installation & Operation Manual 7 Field wiring (continued) Auxiliary switch 1 & 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 insta...
Page 38 - Figure 7-3 Low Voltage Field Wiring Connections
38 Installation & Operation Manual 7 Field wiring 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 AL AR M CON TA CT S RUN T IM E CON TA CT S TA NK TH ER M OS TA T ENA BL E LO UV ER PROVI NG LO UVER REL AY AU X SWI TCH 1 AU X SWI TCH 2 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 1...
Page 39 - Condensate disposal; Condensate drain; Figure 8-1 Condensate Disposal
Installation & Operation Manual 8 Condensate disposal Condensate drain 1. The Crest is a high efficiency appliance that produces condensate. 2. 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 cond...
Page 40 - Check/control water chemistry; Hardness less than 7 grains; Fill and test water system
40 Installation & Operation Manual 9 Start-up Check/control water chemistry 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. Con...
Page 41 - Check for gas leaks; Inspect/check condensate lines and fittings; Figure 9-1 Condensate Trap
41 Installation & Operation Manual 9 Start-up (continued) Check for gas leaks Before 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 n...
Page 42 - Final checks before starting the boiler
42 Installation & Operation Manual 9 Start-up Final checks before starting the boiler 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. Verify the boiler and system are full of water an...
Page 43 - FOR YOUR SAFETY READ BEFORE OPERATING; WHAT T O DO IF YOU SMELL GAS; OPERATING INSTRUCTIONS; Figure 9-2 Operating Instructions
43 Installation & Operation Manual FOR YOUR SAFETY READ BEFORE OPERATING WARNING: I f you do not follow these inst ructions exact ly, a fire or explosion may result causing property damage, personal injury, or loss of life. A. T his appliance does n ot have a pil ot. It is equipped wi th an igni...
Page 44 - Check flame and combustion; Set Gas Valve; Troubleshooting; Set space heating operation; Installer Level; Gas Valve 1
44 Installation & Operation Manual 9 Start-up Check flame and combustion (continued) 4. Navigate to the Service Screen from the Home Screen by pressing the MAIN MENU button and then the SERVICE button. 5. On the Service Screen place heater into Service Mode by selecting the START button, then se...
Page 45 - Verify HWG circulator mode; Installer
45 Installation & Operation Manual Set Hot Water Generator (HWG) operation Verify HWG circulator mode The HWG Mode is programmed to heat an indirect hot water tank. When a tank thermostat or a tank sensor initiates a call for heat, the SMART TOUCH control will turn on the HW pump and turn off th...
Page 46 - How the boiler operates; This input tells the boiler to provide water for space heating.; Temperature control; Operating information
46 Installation & Operation Manual 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 ...
Page 47 - Protection features; DO NOT install the boiler in a room likely to freeze.
10 Operating information (continued) 47 Installation & Operation Manual 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, ...
Page 48 - Boiler temperature regulation; sensor is not installed.; Outdoor reset operation, if used; See the Crest Service Manual to change the settings.
48 Installation & Operation Manual 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...
Page 49 - Cascade; Efficiency optimization; required; NOT; allowed in a; Sequence of the cascade
10 Operating information (continued) 49 Installation & Operation Manual Cascade When multiple boilers are installed, they can be wired together in a cascade sequence. A maximum of eight boilers can be controlled from a single control. In this application one boiler would be designated as the Lea...
Page 50 - Sequence of operation
10 Operating information 50 Installation & Operation Manual Sequence of operation 1. Upon a call for heat, the control turns on the appropriate pumps (system and boiler pumps for a space heating call, HW pump for a domestic hot water call). 2. The control confirms that the low water cutoff conta...
Page 51 - Crest control module; Figure 10-1 Home Screen
10 Operating information (continued) 51 Installation & Operation Manual 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 sen...
Page 52 - Figure 10-2 Main Menu Screen
52 Installation & Operation Manual 10 Operating information Figure 10-2 Main Menu Screen 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...
Page 53 - Maintenance; Table 11A Service and Maintenance Schedules; Service technician; (see the following pages for instructions); Owner maintenance; (see the Crest User’s Information Manual for
53 Installation & Operation Manual 11 Maintenance Maintenance and annual startup Table 11A Service and Maintenance Schedules Service technician (see the following pages for instructions) General: • Address reported problems, if any • Inspect interior; clean and vacuum if necessary; • Clean conde...
Page 54 - Address reported problems; Flush condensate trap with water; Gas Connections; Check all piping for leaks; Figure 11-1 Condensate Trap
54 Installation & Operation Manual 11 Maintenance Follow the service and maintenance procedures given throughout this manual and in component literature shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler or system. Failure to follow the d...
Page 55 - Flue vent system and air piping; Check boiler relief valve; Hydronic Piping
55 Installation & Operation Manual 11 Maintenance (continued) Flue vent system and air piping 1. 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 pr...
Page 56 - Figure 11-2 Burner Assembly
56 Installation & Operation Manual 11 Maintenance Inspect ignition and flame sense electrodes 1. Remove the ignition and both flame sense electrodes from the burner plate. 2. Remove any deposits accumulated on the ignition/ flame sense electrodes using sandpaper. If the electrodes cannot be clea...
Page 57 - Cleaning boiler heat exchanger; REMOVAL OF COMBUSTION CHAMBER; Review with owner
57 Installation & Operation Manual 11 Maintenance (continued) The boiler contains ceramic fiber materials. Use care when handling these materials per instructions on this page. Failure to comply could result in severe personal injury. WARNING Cleaning boiler heat exchanger 1. Shut down boiler:...
Page 58 - Diagrams; Figure 12-1 Ladder Diagram
58 Installation & Operation Manual JUNCTION BOX TERMINAL STRIP120V SUPPLY "L" TERMINAL STRIP120V SUPPLY "N" 120VAC NEUTRAL INTEGRATED CONTROL ON/OFF SW ITCH F2 3.15 A F4 5.0 A SYSTEM PUMP RELAY BOILER PUMP RELAY DHW PUMP RELAY X1-1 X1-2 X1-4 X1-8 X2-4 SMALL BLOW ER RELAY LARGE BL...
Page 59 - Figure 12-2 Wiring Diagram
59 Installation & Operation Manual 12 Diagrams (continued) Figure 12-2 Wiring Diagram -T -T -T -T -T -T -T -T -T 2 3 1 1 2 4 5 3 2 3 1 1 2 4 5 3 M 1 2 3 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...
