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
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 - Front View
Right Side (inside unit) The Crest - How it works... (continued) 5 Installation & Operation Manual IMG01025 2 39 1 11 Front View IMG01128 36 7 19 12 29 20 6 5 35 3 18 Rear View IMG01130 33 17 16 34 37 9 41 IMG01129 2526 2122 15 4 30 31 28 14 32 10 40 42 2423 19 Left Side (inside unit)
Page 6 - Ratings; Crest; NOTICE; 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 (Notes 4 - 6) Min Max Gross Output MBH (Note 1) Net AHRI Ratings Water, MBH (Note 2) FB(N,L)0751 50 750 720 626 FB(N,L)1001 50 1000 960 835 FB(N,L)1251 62 1250 1200 1043...
Page 7 - Installation must comply with:; Determine boiler location; Figure 1-1 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:; Venting
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; WARNING
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 19. 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; Figure 1-3 Boiler Removed from Shipping Pallet
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 IMG01033 2 General venting IMG01059 IMG01056 Sidewall Direct venting Vertical Vent, Sidewall Air Sidewall IMG01057 Vertical IMG01058 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; This product; Table 2A-1 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 18 - Air contamination; —OR—; Removing from existing vent
18 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 19 - Common venting; Table 2D Flue Damper Kits; Flue Damper Kits; Installing vent and air piping
Installation & Operation Manual 19 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 common flue applications. DO NOT mix other manufacturer’s appliances or other Lochinvar models. Comm...
Page 20 - Table 2E PVC/CPVC Vent Pipe, and Fittings; Approved PVC/CPVC Vent Pipe and Fittings; PVC Schedule 40
Installation & Operation Manual 20 2 General venting (continued) 5. Dry fit vent or air piping to ensure proper fit up before assembling any joint. The pipe should go a third to two-thirds into the fitting to ensure proper sealing after cement is applied. 6. Priming and Cementing: a. Handle fitt...
Page 21 - Model; Polypropylene; Table 2F Polypropylene Vent Pipe and Fittings
Installation & Operation Manual 21 2 General venting Model Manufacturer Vent Model Vent Type Adapter Number Joint Connector Sidewall Kit* Retaining Bracket / Adapter* 751-1001 Centrotherm Eco Systems Innoflue Single-Wall Flex ISAAL0606 -- -- IATP0606 / ISTAGL0606 DuraVent (M & G) PolyPro Sin...
Page 22 - Vertical direct venting; Vent/air termination – vertical; Prepare roof penetrations; Determine location; Figure 3-1 Vertical Termination of Air and Vent
Installation & Operation Manual 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 th...
Page 23 - Multiple vent/air terminations; Figure 3-3 Vertical Terminations with Multiple Boilers
23 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 24 - Figure 4-1A Sidewall Termination of Air and Vent; Sidewall direct; Vent/air termination – sidewall
Installation & Operation Manual 3. Maintain clearances as shown in FIG.’s 4-1A thru 4-4, pages 24 thru 26. 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...
Page 25 - Sidewall direct venting; Table 4A Sidewall Vent Kits
25 Installation & Operation Manual 4 Sidewall direct venting Vent/air termination – sidewall TO BOILER INTAKE AIR CONNECTION FROM BOILER VENT PIPE CONNECTION VENT / AIR TERMINATION GRADE OR SNOW LINE 12" MIN 12" MIN TO OVER- HANG POSSIBLE ORIENTATIONS Figure 4-1C PVC/CPVC/Polypropylene S...
Page 26 - Figure 4-3 Clearance to Doors and Windows; Figure 4-4 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. 4-1A, page 24. 2. Maintain the required dimensions of the finished termination piping as shown in FIG. 4-1A, page 24. 3. Do not extend exposed vent pipe outside of the buildi...
Page 27 - Place wall penetrations to obtain minimum clearance; DIRECT VENT TERMINATIONS; Figure 4-6 Direct Vent Terminations; Room air; Figure 4-8 Room Air Installation
Installation & Operation Manual 4 Sidewall direct venting 2. Place wall penetrations to obtain minimum clearance of 12 inches (305 mm) between vent pipe and adjacent air inlet, as shown in FIG. 4-5 for U.S. installations. For Canadian installations, provide clearances required by CSA B149.1 Inst...
Page 28 - Hydronic piping; System water piping methods; IMPORTANT
28 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 29 - Primary/Secondary or Fixed or; boiler; . Additional allowances; CREST Pressure Drop Curve
Installation & Operation Manual 5 Hydronic piping 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 system flow ...
Page 30 - Near boiler piping components; Table 5B1 Minimum Flow Rate with the Boiler at Full Fire
Installation & Operation Manual 5 Hydronic piping (continued) 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 circ...
Page 32 - Table 5C Multiple Boilers - Common Header - Primary / Secondary Flow
32 Installation & Operation Manual 5 Hydronic piping (continued) Please note that these illustrations are meant to show piping concepts only, the installer is responsible for all equipment. The installer must follow all manufacturer’s installation instructions for each system component. The inst...
Page 35 - Gas connections; Connecting gas supply piping; Table 6A Gas Inlet Size; Gas supply; Figure 6-1 Gas Supply Piping
35 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. Do not check...
Page 36 - Figure 6-2 Inlet Pipe with Backup Wrench; Figure 6-3 Gas Supply Piping to Regulator
Installation & Operation Manual 6 Gas connections (continued) 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 l...
Page 37 - Table 6B Natural Gas Pipe Size Chart; Check inlet gas supply
37 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 gas pressure drops more than 1 inch w.c. (249 Pa) between maximum ...
Page 38 - Gas valve replacement; Figure 6-4 Inlet Gas Supply Check
38 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 39 - Field wiring; Connect 120 VAC power wiring to the line voltage terminal
39 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 40 - 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 42 of this manual and the boiler wiring diagram...
Page 41 - By installing the system supply sensor into the supply
41 Installation & Operation Manual 7 Field wiring 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 installing the sy...
Page 42 - Figure 7-3 Low Voltage Field Wiring Connections
42 Installation & Operation Manual 7 Field wiring (continued) 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 2...
Page 43 - 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 44 - Check/control fill water chemistry; Hardness between 5 and 15 grains per gallon; Freeze protection; Fill water; Test / replace freeze protection fluid
44 Installation & Operation Manual 9 Start-up Check/control fill water chemistry Conduct water quality testing prior to installing the appliance. Various solutions are available to adjust water quality. Hardness between 5 and 15 grains per gallon 1. Consult local water treatment companies for ha...
Page 45 - Oxygen prevention; Fill and test water system; Boiler water
45 Installation & Operation Manual 9 Start-up (continued) Oxygen prevention Dissolved oxygen can have a negative effect on the boiler system. Oxygen can cause iron oxide to generate iron deposits. Oxygen may also increase the rate of corrosion on non-stainless steel parts of the system. A low pH...
Page 46 - Check for gas leaks; Inspect/check condensate lines and fittings; Figure 9-1 Condensate Trap
46 Installation & Operation Manual 9 Start-up 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 not proceed w...
Page 47 - Final checks before starting the boiler
47 Installation & Operation Manual 9 Start-up (continued) Final checks before starting the boiler Read the Crest Service Manual to familiarize yourself with SMART TOUCH control module operation. Read this manual, page 48 for proper steps to start boiler. Verify the boiler and system are full...
Page 48 - FOR YOUR SAFETY READ BEFORE OPERATING; WHAT T O DO IF YOU SMELL GAS; OPERATING INSTRUCTIONS; Figure 9-2 Operating Instructions
48 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 49 - Check flame and combustion; Set Gas Valve 1 - High; Troubleshooting; Natural Gas; Propane; Figure 9-3 Service Maintenance Screen
49 Installation & Operation Manual 9 Start-up (continued) Check flame and combustion (continued) 4. Navigate to the Service Maintenance Screen from the Home Screen by pressing the SETUP button, enter the installer password, and then using the scrolling menu feature on the left side, scroll down ...
Page 50 - Set space heating set point temperature; setting, press the SAVE button to save changes to the set; Set space heating operation; Verify space heat circulator mode; Figure 9-4 Set Point Screen
50 Installation & Operation Manual 9 Start-up Set space heating set point temperature During normal operation, space heating set point temperatures can be adjusted from the Home Screen by pressing the DETAILS button on the bottom of the screen (see FIG. 9-4). 1. To change a set point, use the se...
Page 51 - For more detailed instructions, please refer to the; Verify HW mode; Press the RAPID SETUP button in the menu on the left.; Figure 9-5 Rapid Setup Screen
51 Installation & Operation Manual Set Hot Water Generator (HW) operation Note: For more detailed instructions, please refer to the Crest Service Manual. Verify HW mode There are two (2) modes of operation for HW. In Normal Mode, when a HW demand begins, the control will start the HW pump, turn ...
Page 52 - Figure 9-6 Cascade Screen; Configuration of the cascade; For more detailed instructions, please refer to the Crest
52 Installation & Operation Manual 9 Start-up SETUP BUTTON SCROLLING MENU FEATURE CASCADE BUTTON SEND UPDATE BUTTON Figure 9-6 Cascade Screen Configuration of the cascade Note: For more detailed instructions, please refer to the Crest Service Manual. When installed in a Cascade system, the indiv...
Page 53 - How the boiler operates; This input tells the boiler to provide water for space heating.; Temperature control; Operating information
53 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 blower pulls in air and pushes flue products out of the boiler through the heat exchanger and flu...
Page 54 - Protection features; DO NOT install the boiler in a room likely to freeze.
10 Operating information 54 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, the control ...
Page 55 - Boiler temperature regulation; sensor is not installed.; Outdoor reset operation, if used; See the Crest Service Manual to change the settings.
55 Installation & Operation Manual 10 Operating information (continued) 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 ext...
Page 56 - Cascade; Efficiency optimization; allowed in a common; Sequence of the cascade
10 Operating information 56 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 Leader control ...
Page 57 - Sequence of operation
10 Operating information (continued) 57 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 hot water generator call). 2. The control confirms that the low water...
Page 58 - Navigation; Figure 10-1 Home Screen; System
10 Operating information 58 Installation & Operation Manual • The Navigation Section is located across the top of the screen. There are three (3) main sections located next to the Lochinvar icon: Home, View, and Setup. The Home Section is the screen shown above. The View Section takes you to sev...
Page 59 - 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
59 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 60 - Flush condensate trap with water; Gas Connections; Figure 11-1 Condensate Trap
60 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 61 - Hydronic Piping
61 Installation & Operation Manual 11 Maintenance (continued) Check expansion tank 1. 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...
Page 62 - Check flame signal; Check burner flame
62 Installation & Operation Manual 11 Maintenance Check flame signal 1. At high fire of each combustion system, the flame signal shown on the display should be at least 10 microamps. 2. A lower flame signal may indicate a fouled or damaged flame sense electrode. If cleaning the flame sense elect...
Page 63 - Cleaning boiler heat exchanger; Check Burner Flame; Handling ceramic fiber materials; REMOVAL OF COMBUSTION CHAMBER; Review with owner
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 64 - Diagrams; Figure 12-1 Ladder Diagram
64 Installation & Operation Manual 12 Diagrams Figure 12-1 Ladder Diagram TERMINAL STRIP TERMINAL STRIP 16 15 13 12 11 10 9 6 5 3 2 1 39 36 35 33 32 31 30 29 26 25 23 22 21 20 19 OUTLET SENSOR (S9) OUTLET SENSOR (S1) FLUE SENSOR FLUE SENSOR (S10) 120VAC NEUTRAL ON/OFF SWITCH GAS VALVE (LARGE) GA...
Page 65 - Figure 12-2 Wiring Diagram
65 Installation & Operation Manual 12 Diagrams (continued) Figure 12-2 Wiring Diagram 39 36 35 33 32 31 30 29 26 25 23 22 21 20 19 FLUE SENSOR (S10) FLUE SENSOR OUTLET SENSOR (S1) OUTLET SENSOR (S9) 6 5 3 2 1 9 10 11 12 13 15 16 1 2 3 Notes: diagrams to troubleshoot unit. ALARM CONTACTS CONTACTS...
Page 66 - Notes
