FB-I-O Rev H Installation & Operation Manual Models: 1.5 - 2.0 - 2.5 - 3.0 - 3.5 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, or substantial property damage. Save this manual for future reference.
Contents HAZARD DEFINITIONS .................................................... 2 PLEASE READ BEFORE PROCEEDING ........................ 3 THE CREST -- HOW IT WORKS ................................... 4-5 RATINGS ........................................................................... 6 1. DETERMINE BOILER LOCATION Clearances ......................................................................... 7 Provide Air Openings to Room .......................................... 8 Flooring and Foundation ......
Installation & Operation Manual Please read before proceeding WARNING Installer – Read all instructions, including this manual and the Crest Service Manual, before installing. Perform steps in the order given. User – This manual is for use only by a qualified heating installer/ service technician. Refer to the User’s Information Manual for your reference. NOTICE When servicing boiler – • To avoid electric shock, disconnect electrical supply before performing maintenance.
Installation & Operation Manual 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.
Installation & Operation Manual The Crest - How it works... (continued) Models 1.5 - 2.0 - 2.5 - 3.0 - 3.
Installation & Operation Manual Ratings Crest AHRI Rating Model Number Input MBH Note: Change “N” to “L” for L.P. gas models.
Installation & Operation Manual 1 Determine boiler location Installation must comply with: WARNING • 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.
Installation & Operation Manual 1 Determine boiler location Provide air openings to room: Vent and air piping The Crest alone in boiler room The Crest requires a special gas vent system, designed for pressurized venting. 1. No air ventilation openings into the boiler room are needed when clearances around the Crest are at least equal to the SERVICE clearances shown in FIG. 1-1. For spaces that do NOT supply this clearance, provide two openings as shown in FIG. 1-1.
Installation & Operation Manual 1 Determine boiler location When using an existing vent system to install a new boiler: 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: • Material - For materials listed for use with this appliance, see Section 2 - General Venting, Table 2A.
Installation & Operation Manual 1 Determine boiler location When removing a boiler from existing common vent system: DANGER WARNING 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.
Installation & Operation Manual 1 Determine boiler location Remove boiler from wood pallet (continued) Figure 1-3 Boiler Removed from Shipping Pallet 1. After removing the outer shipping crate and plastic from the boiler, remove the parts package (packaged parts inside the controls compartment of the boiler inside the lower front access panel). 2. To remove the boiler from the pallet: a.
Installation & Operation Manual 1 Determine boiler location Combustion and ventilation air requirements for appliances drawing air from the equipment room Provisions for combustion and ventilation air must be in accordance with Air for Combustion and Ventilation, of the latest edition of the National Fuel Gas Code, NFPA 54 / ANSI Z223.1, in Canada, the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment, or applicable provisions of the local building codes.
Installation & Operation Manual 1 4. Determine boiler location (continued) If a single combustion air opening is provided to bring combustion air in directly from the outdoors, the opening must be sized based on a minimum free area of one square inch per 3000 Btu/hr (7 cm2 per kW). This opening must be located within 12” (30 cm) of the top of the enclosure (see FIG. 1-7). Combustion air requirements are based on the latest edition of the National Fuel Gas Code, NFPA 54 / ANSI Z223.
Installation & Operation Manual 2 General venting Direct venting Sidewall Vertical Vent, Sidewall Air Vertical Optional room air Sidewall 14 Vertical
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 instructions regarding vent system, air system, and combustion air quality. See also Section 1 of this manual.
Installation & Operation Manual 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. DANGER Failure to properly seal all joints and seams as required in the air inlet piping may result in flue gas recirculation, spillage of flue products and carbon monoxide emissions causing severe personal injury or death.
Installation & Operation Manual 2 General venting (continued) Table 2B Direct Vent Minimum / Maximum Allowable Air / Vent Lengths AIR INLET Model Air Intake Diameter FB 1500 FB 2000 7" 8" 12' 12' FB 2500 8" FB 3000 FB 3500 VENT Air Intake Air Intake Min. Length Max. Length Input De-Rate per Vent Max. Length 25 feet of Vent Vent Diameter Vent Min.
Installation & Operation Manual 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. Table 2D Flue Damper Kits Flue Damper Kits Model Damper Size Kit Number FB1500 7" DRH30000 2. Crest boilers connected to the common vent must all be of the same size. FB2000 8" DRH30001 FB2500 9" DRH30002 3.
Installation & Operation Manual 3 Vertical direct venting Vent/air termination – vertical WARNING Follow instructions below when determining vent location to avoid possibility of severe personal injury, death or substantial property damage. 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.
Installation & Operation Manual 3 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 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.
Installation & Operation Manual 4 Sidewall direct venting Vent/air termination – sidewall WARNING WARNING Follow instructions below when determining vent location to avoid possibility of severe personal injury, death, or substantial property damage. 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.
Installation & Operation Manual 4 Sidewall direct venting Vent/air termination – sidewall Prepare wall penetrations Figure 4-2 Clearance to Doors and Windows 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. Vent pipe penetration: a. Cut a hole for the vent pipe. For either combustible or noncombustible construction, size the vent pipe hole per the vent manufacturer’s instructions. 2.
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 B149.1 Installation Code. Figure 4-6 Room Air (Direct Exhaust Terminations) ROOM AIR (DIRECT EXHAUST TERMINATIONS) Vent Termination 3. The air inlet of a Crest is part of a direct vent connection.
Installation & Operation Manual 5 Hydronic piping System water piping methods General piping information 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. 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).
Installation & Operation Manual 5 Hydronic piping (continued) 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.
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 should be sized per Table 5A. 3. Hot Water Generator circulating pump: Field supplied. When installed in a Primary/Secondary arrangement, the Crest requires an additional pump for the Hot Water Generator Loop.
Installation & Operation Manual 5 Hydronic piping (continued) Figure 5-2 Single Boiler - Recommended - Primary / Secondary Piping with a Hot Water Generator FROM SYSTEM SYSTEM RETURN SENSOR 12" MAX BALL VALVE (TYPICAL) RELIEF VALVE HOT WATER GENERATOR AIR SEPERATOR DRAIN PORT (TYPICAL) SYSTEM SUPPLY SENSOR SYSTEM CIRCULATOR TO SYSTEM BOILER DRAIN PRESSURE REDUCING VALVE WATER GENERATOR CIRCULATOR EXPANSION TANK PRESSURE GAUGE BACK FLOW PREVENTER MAKE UP WATER Y-STRAINER (RECOMMENDED) FLOW
Installation & Operation Manual 5 Hydronic piping Table 5C Multiple Boilers - Common Header - Primary / Secondary Flow Model 2 FB FB FB FB FB 4 4 5 5 5 1500 2000 2500 3000 3500 Number of Units 3 4 5 6 7 Recommended Common Header Pipe Sizes in Inches 4 5 5 6 6 5 5 6 7 7 5 6 7 7 8 6 7 7 8 10 8 6 7 8 10 10 7 8 10 10 10 [Based on a boiler ΔT of 30°F.] NOTICE A system supply sensor (factory supplied) MUST BE installed for proper boiler operation.
Installation & Operation Manual 5 Hydronic piping (continued) Figure 5-4 Single Boiler - Alternate - Fixed or Variable Flow Primary System Piping RELIEF VALVE BALL VALVE (TYPICAL) FROM SYSTEM AIR SEPERATOR BOILER DRAIN DRAIN PORT (TYPICAL) SYSTEM CIRCULATOR Y-STRAINER (RECOMMENDED) EXPANSION TANK PRESSURE GAUGE NOTICE TO SYSTEM PRESSURE REDUCING VALVE BACK FLOW PREVENTER MAKE UP WATER Please note that these illustrations are meant to show system piping concept only, the installer is responsi
Installation & Operation Manual 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) SYSTEM RETURN SENSOR AIR SEPERATOR DRAIN PORT (TYPICAL) SYSTEM SUPPLY SENSOR SYSTEM CIRCULATOR Y-STRAINER (RECOMMENDED) (TYPICAL) TO SYSTEM EXPANSION TANK PRESSURE GAUGE BACK FLOW PREVENTER MAKE UP WATER PRESSURE REDUCING VALVE NOTICE Please note that these illustrations are meant
Installation & Operation Manual 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 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. 3. Purge all air from the gas supply piping. 4. Before placing the boiler in operation, check the boiler and its gas connection for leaks. a.
Installation & Operation Manual 6 Gas connections WARNING 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. Figure 6-2 Inlet Pipe with Backup Wrench Natural gas supply pressure requirements 1. Pressure required at the gas valve inlet pressure port: • Maximum 14 inches w.c. (3.
Installation & Operation Manual 6 Gas connections (continued) Table 6B Natural Gas Pipe Size Chart TABLE - 6B GAS PIPING SIZE CHART Nominal Iron Pipe Size Inches 10 20 30 40 50 60 70 80 90 100 125 150 175 1½ 2,150 1,500 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 2 4,100 2,820 2,260 1,950 1,720 1,560 N/A N/A N/A N/A N/A N/A N/A 2½ 6,460 4,460 3,610 3,100 2,720 2,460 2,310 2,100 2,000 1,900 1,700 1,540 N/A 3 11,200 7,900 6,400 5,400 4,870 4,410 4,000
Installation & Operation Manual 6 Gas connections Do not check for gas leaks with an open WARNING 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. Turn the power switch to the “ON” position. 16.
Installation & Operation Manual 7 Field wiring WARNING 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 1. NOTICE If original wiring as supplied with boiler must be replaced, use only type 105°C wire or equivalent.
Installation & Operation Manual 7 Field wiring Low voltage connections ModBus 1. Route all low voltage wires through the knockouts in the rear of the boiler, as shown in FIG. 7-2. 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. 2.
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 installing the system supply sensor into the supply of the primary loop, the temperature of the system supply can be controlled.
AUX SWITCH 2 AUX SWITCH 1 LOUVER RELAY LOUVER PROVING SWITCH ENABLING DEVICE TANK THERMOSTAT BUILDING MANAGEMENT SYSTEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 LOUVER PROVING LOUVER RELAY AUX SWITCH 1 AUX SWITCH 2 ALARM CONTACTS RUN TIME CONTACTS TANK THERMOSTAT ENABLE 17 SHIELD 40 SHIELD 39 B CASCADE 38 A 37 SHIELD 36 - SYSTEM PUMP 35 + IN 34 BMS 33 + IN 32 OUTDOOR 31 SENSOR 30 TANK 29 SENSOR 28 SYSTEM SUPPLY 27 SENSOR 26 SYSTEM RETURN 25 SENSOR 24 - BOILER PUMP 23 + OUT 22 RATE 21 + OUT 20 SH
Installation & Operation Manual 8 Condensate disposal Condensate drain 9. Do not expose condensate line to freezing temperatures. 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 condensate trap. 3. 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.
Installation & Operation Manual 9 Start-up Check/control water chemistry 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.
Installation & Operation Manual 9 Start-up (continued) Check for gas leaks WARNING WARNING 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 with startup if there is any indication of a gas leak. Use an approved leak detection solution. Repair any leaks at once.
Installation & Operation Manual 9 Start-up Final checks before starting the boiler Check vent piping and air piping 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. 1. Check for gastight seal at every connection, seam of air piping, and vent piping. Verify the boiler and system are full of water and all system components are correctly set for operation.
Installation & Operation Manual 9 Start-up (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. A. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand. B. BEFORE OPERATING smell all around the appliance area for gas.
Installation & Operation Manual 9 Start-up Check flame and combustion (continued) Set space heating operation 4. Navigate to the Service Screen from the Home Screen by pressing the MAIN MENU button and then the SERVICE button. Verify space heat circulator mode 5. On the Service Screen place heater into Service Mode by selecting the START button, then selecting Set Gas Valve 1 - High. 6. Insert the probe from a combustion analyzer into the hole left by the removal of the flue temperature sensor. 7.
Installation & Operation Manual 9 Start-up (continued) 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 the boiler pump (if running). If the system pump is running, it will remain on.
Installation & Operation Manual 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.
Installation & Operation Manual 10 Operating information (continued) Gradient limiting Ramp Delay 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. 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.
Installation & Operation Manual 10 Operating information Monitor external limits High limit operations 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. 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.
Installation & Operation Manual 10 Operating information (continued) 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 and all others would be designated as Member controls.
Installation & Operation Manual 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. 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.
Installation & Operation Manual 10 Operating information (continued) 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.
Installation & Operation Manual 10 Operating information 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.
Installation & Operation Manual 11 Maintenance Maintenance and annual startup Table 11A Service and Maintenance Schedules Service technician (see the following pages for instructions) Owner maintenance (see the Crest User’s Information Manual for instructions) General: • Address reported problems, if any • Inspect interior; clean and vacuum if necessary; • Check boiler area Daily • Check pressure/temperature gauge • Clean condensate trap and fill with fresh water • Check for leaks (water, gas, fl
Installation & Operation Manual 11 Maintenance WARNING 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 directions in this manual and component literature could result in severe personal injury, death, or substantial property damage.
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 properly sealed. 2. Verify that boiler vent discharge and air intake are clean and free of obstructions.
Installation & Operation Manual 11 Maintenance Inspect ignition sense electrodes and flame 1. Remove the ignition and both flame sense electrodes from the burner plate. • 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. 2.
Installation & Operation Manual 11 Maintenance (continued) Review with owner 1. Review the Crest User’s Information Manual with the owner. 2. Emphasize the need to perform the maintenance schedule specified in the Crest User’s Information Manual (and in this manual as well). 3. Remind the owner of the need to call a licensed contractor should the boiler or system exhibit any unusual behavior. 4.
Installation & Operation Manual 12 Diagrams Figure 12-1 Ladder Diagram 120VAC NEUTRAL JUNCTION BOX BOX DEPICTS OPTIONAL ITEMS TERMINAL STRIP 120V SUPPLY "N" TERMINAL STRIP 120V SUPPLY "L" BOX DEPICTS DUAL SENSOR SINGLE HOUSING INTEGRATED CONTROL X1-3 1.5A EACH MAX ON/OFF SWITCH X1-12 X1-6 F2 F4 3.15 A 5.
Installation & Operation Manual 12 Diagrams (continued) Figure 12-2 Wiring Diagram BOX DEPICTS OPTIONAL ITEMS BOX DEPICTS DUAL SENSOR SINGLE HOUSING MODBUS BOARD X1-1 X1-2 X1-3 X6-3 X6-1 X6-2 X4-1 X4-2 X4-3 LARGE CONNECTION BOARD 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 SHIELD MODBUS OPTION A B SHIELD RATE + 0-10V OUT BOILER + 0-10V PUMP OUT SYSTEM RETURN SENSOR SYSTEM SUPPLY SENSOR TANK SENSOR OUTDOOR SENSOR BMS + IN - 0-10V SYSTEM + PUMP IN - 0-10V SHIELD CA
Revision Notes: Revision A (ECO #C07970) initial release. Revision B (ECO #C08023) reflects changes made to FIG. 6-3 on page 32 for Mass approval and changes made to FIG. 5-3 on page 28. Revision C (ECO #C08179) 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.