Lochinvar 1.5 - 2.0 - 2.5 - 3.0 - 3.5 User Manual

FB-I-O Rev C

Installation & Operation Manual

Models: 1.5 - 2.0 - 2.5 - 3.0 - 3.5

 WARNING

Save this manual for future reference.

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.

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 ................................................... 8

Vent and Air Piping ............................................................ 8

Prevent Combustion Air Contamination ............................. 8

Using an Existing Vent System to Install a New Boiler ..... 9

Corrosive Contaminants and Sources ............................... 9

Removing a Boiler from Existing Common Vent .............. 10

Remove Boiler from Wood Pallet ..................................... 11

Combustion and Ventilation Air Requirements ........... 12-13

2. GENERAL VENTING

Direct Venting Options - Sidewall Vent ............................ 14

Direct Venting Options - Vertical Vent .............................. 14

Direct Venting Options - Vert. Vent, Opt. Rm Air ............. 14

Direct Venting Options - Vert. Vent, Sidewall Air ............. 14

Install Vent and Combustion Air Piping ........................... 15

Air Inlet Pipe Materials ................................................ 15

Requirements for Installation in Canada .......................... 15

Vent and Air Piping .......................................................... 16

Air Intake / Vent Connections .......................................... 16

Min./Max. Combustion Air & Vent Piping Lengths ........... 17

Vent and Air Piping .......................................................... 17

Common Venting ............................................................. 18

3. VERTICAL DIRECT VENTING

Vent/Air Termination - Vertical ......................................... 19

Determine Location ..................................................... 19

Prepare Roof Penetrations ......................................... 19

Termination and Fittings ........................................ 19-20

Multiple Vent/Air Terminations .................................... 20

4. SIDEWALL DIRECT VENTING

Vent/Air Termination - Sidewall ................................... 21-23

Determine Location ................................................ 21-23

Prepare Wall Penetrations .......................................... 22

Termination and Fittings ............................................. 22

Multiple Vent/Air Terminations ............................... 22-23

Room Air ..................................................................... 23

5. HYDRONIC PIPING

System Water Piping Methods ......................................... 24

Low Water Cutoff Device ................................................. 24

Chilled Water System ....................................................... 24

Freeze Protection ............................................................. 24

General Piping Information .............................................. 24

Circulator Sizing ............................................................... 25

Near Boiler Piping Components .................................. 26-30

6. GAS CONNECTIONS

Connecting Gas Supply Piping ........................................ 31

Natural Gas ...................................................................... 32

Pipe Sizing for Natural Gas ........................................ 32

Natural Gas Supply Pressure Requirements ............. 32

Propane Gas .................................................................... 32

Pipe Sizing for Propane Gas ...................................... 32

Propane Supply Pressure Requirements ................... 32

Check Inlet Gas Supply .............................................. 33-34

Gas Pressure ................................................................... 34

Gas Valve Replacement .................................................. 34

7. FIELD WIRING

Line Voltage Connections ................................................ 35

Low Voltage Connections ................................................ 36

Wiring of the Cascade ...................................................... 37

8. CONDENSATE DISPOSAL

Condensate Drain ............................................................ 39

9. STARTUP ............................................................... 40-45

10. OPERATING INFORMATION

General ........................................................................ 46-48

Cascade ........................................................................... 49

Sequence of Operation .................................................... 50

Status Screen ................................................................... 51

Main Screen ..................................................................... 52

11. MAINTENANCE

Maintenance & Annual Startup .............................. 53-57

12. DIAGRAMS

Ladder Diagrams ........................................................ 58

Wiring Diagram ........................................................... 59

Revision Notes .................................................. Back Cover

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 hazardous situation which, if not avoided, will result in death or serious injury.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.

NOTICE indicates special instructions on installation, operation, or maintenance that are important but not related to personal injury or property damage.

Please read before proceeding

Installation & Operation Manual

 WARNING

NOTICE

 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.

Have this boiler serviced/inspected by a qualified service technician, at least annually.

Failure to comply with the above could result 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.

• 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.

When servicing boiler –

• To avoid electric shock, disconnect electrical supply before performing maintenance.

• To avoid severe burns, allow boiler to cool before 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.

• 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.

• 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 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 water temperature. If selected as the controlling sensor, the control module will adjust the boiler firing rate so the inlet temperature matches the set point.

7. Boiler outlet temperature sensor

The boiler outlet temperature sensor monitors boiler outlet water temperature. If selected as the controlling sensor, the control module will adjust the boiler firing rate so the outlet 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 turndown.

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 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.

Installation & Operation Manual

19. 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.

20. Ignition electrode

An electrical spark across the electrodes will ignite the first burner.

21. 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).

22. Line voltage wiring connections (knockouts)

Conduit connection points for the high voltage junction box.

23. 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.

24. 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.

25. Low voltage connection board(s)

Connection boards used to connect external low voltage devices.

26. Low voltage wiring connections (knockouts) Conduit connection points for the low voltage connection boards.

27. 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.

28. Power switch The On/Off power switch provides the ability to turn line voltage

power to the boiler on and off.

29. 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.

30. Reset switch

Reset switch for the low water cutoff. Hold the switch for 10 seconds to reset.

31. 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.

32. Firetube heat exchanger

High grade stainless steel WAVETM firetube design that extracts heat from flue gases and transfers it directly into boiler water.

33. Temperature and pressure gauge

Monitors the outlet temperature of the boiler as well as the system water pressure.

34. Venturis

Separate venturis control air and gas flow into two (2) independent burner sections.

35. Water inlet

A 4" ANSI flange connects the return water from the system to the heat exchanger.

36. Water outlet

A 4" ANSI flange connects the hot water supply from the boiler to the system.

37. Ignition transformer

The transformer provides voltage to the ignition electrode (item

20).

38. Air arm temperature sensors (not shown)

Monitors fuel-air delivery temperature to the burner.

39. Air inlet cover (shipped loose)

Used with room air for combustion and to prevent debris from entering the boiler.

The Crest - How it works... (continued)

Models 1.5 - 2.0 - 2.5 - 3.0 - 3.5

Installation & Operation Manual

Front View

12 27

21 22

25 26

Rear View

33 12 13

Left Side (inside unit)

Right Side (inside unit)

Ratings

Installation & Operation Manual

Crest

I=B=R Rating

Model Number

Note: Change “N” to

“L” for L.P. gas models.

Min Max

FB(N,L)1500 60 1500 1380 1200

FB(N,L)2000 80 2000 1840 1600

FB(N,L)2500 125 2500 2300 2000

FB(N,L)3000 150 3000 2760 2400

FB(N,L)3500 200* 3500 3220 2800

Input MBH

(Note 4)

*For LP models the minimum input is 420 MBH.

NOTICE

Maximum allowed working pressure is located on the rating plate.

Notes:

1. The ratings are based on standard test procedures prescribed by the United States Department of Energy.

2. Net I=B=R ratings are based on net installed radiation of sufficient quantity for the requirements of the building and nothing need be added for normal piping and pickup. Ratings are based on a piping and pickup allowance of 1.15.

3. Crest boilers require special gas venting. Use only the vent materials and methods specified in the Crest Installation and Operation Manual.

4. Standard Crest boilers are equipped to operate from sea level to 4,500 feet only with no adjustments.

5. High altitude Crest boilers are equipped to operate from 3,000 to 12,000 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 afﬁ xed to the unit.

6. The boiler will de-rate by 4% for each 1,000 feet above sea level up to 4,500 feet and 4.5% for each 1,000 feet above 4,500 feet.

7. Ratings have been conﬁ rmed by the Hydronics Institute, Section of AHRI.

Gross

Output

MBH

(Note 1)

Other Specifications

Net

I=B=R

Ratings

Water,

MBH

(Note 2)

Appliance

Water Content Gallons

132 4" 4" 1 1/2" 8" 8" 3055

161 4" 4" 2" 8" 9" 3650

181 4" 4" 2” 10" 10" 4125

215 4" 4" 2” 10" 10" 4750

Pipe

Pipe Size Inlet

Gas Inlet

Size

Outlet

96 4" 4" 1 1/2" 7" 7" 2500

UNIT EQUIPPED FOR

HIGH ALTITUDE

3,000 FT. TO 12,000 FT.

Figure A High Altitude Label Location

Size

Air

Size

Vent Size

(Note 3)

Weight

w/Water

(lbs.)

1 Determine boiler location

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/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.

NOTICE

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 of its components.

3. Check area around the boiler. Remove any combustible materials, gasoline and other flammable liquids.

 WARNING

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. If a new boiler will replace an existing boiler, check for and correct system problems, such as:

• 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.

Failure to keep boiler area clear and free of combustible materials, gasoline, and other flammable liquids and vapors can result in severe personal injury, death, or substantial property damage.

 WARNING

This appliance is certified as an indoor appliance. 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°C).

Failure to install the appliance indoors could result in severe personal injury, death, or substantial property damage.

 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:

NOTICE

Clearances from combustible materials

- Hot water pipes ........................................................ 1/4"

- Sides .......................................................................... 0"

- Rear ........................................................................... 0"

- Front ......................................................................... 0"

- Top ........................................................................... 0"

- Floor ....................................................... Combustible

- Vent pipe - Follow special vent system manufacturer’s instructions

Recommended clearances for service access

- Sides .......................................................................... 24"

- Rear ........................................................................... 24"

- Front ......................................................................... 30"

- Top ........................................................................... 24"

Figure 1-1 Recommended Service Clearances

24" LEFT

24"

REAR

If you do not provide the recommended service clearances shown, it may not be possible to service the boiler without removing it from the space.

1/4" (6 MM) MINIMUM CLEARANCE AROUND HOT WATER PIPES

24"

TOP

VENTILATING* AIR OPENING

CLOSED DOOR

24"

RIGHT

30"

FRONT

VENTILATING* AIR OPENING

1 Determine boiler location

Installation & Operation Manual

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 NOT 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

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).

The space must 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.

Flooring and foundation

Flooring

The Crest is approved for installation on combustible flooring, but must never be installed on carpeting.

 WARNING

If flooding is possible, elevate the boiler sufficiently to prevent water from reaching the boiler.

Do not install the boiler on carpeting even if foundation is used. Fire can 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.

 WARNING

Ensure that the combustion air will not contain any of the contaminants in Table 1A, page 9. Contaminated 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.

 WARNING

Assure that the floor and structure is sufficient to support the installed weight of the 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.

1 Determine boiler location (continued)

When using an existing vent system to install a new boiler:

Table 1A Corrosive Contaminants and Sources

Installation & Operation Manual

 WARNING

Check the following venting components before installing:

• 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 instructions 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.

• 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.

 WARNING

Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

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.

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 cleaning/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

1 Determine boiler location

When removing a boiler from existing common vent system:

Installation & Operation Manual

 DANGER

 WARNING

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.

c. Test vent system – Insofar as is practical, close 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.

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.

Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

d. Place in operation the appliance being inspected.

Follow the lighting instructions. Adjust thermostat so appliance will operate continuously.

e. 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.

f. 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.

g. 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 resizing 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 Gas Code, ANSI Z223.1/NFPA 54 and/or CAN/CSA B149.1, Natural Gas and Propane Installation Code.

1 Determine boiler location (continued)

Installation & Operation Manual

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 panel).

2. To 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).

b. 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.

 WARNING

d. 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 also recommended that the upper and lower front panels along with both front side panels be removed (no tools required).

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.

Figure 1-3 Boiler Removed from Shipping Pallet

REMOVE MIDDLE TOP COVER

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.

NOTICE

Do not drop the boiler or bump the jacket on the floor or pallet. Damage to the boiler can result.

Figure 1-2 Boiler Mounted on Shipping Pallet

BOLT, WASHERS & LOCKNUT (3X)

FRONT

REAR

LAG BOLTS & TABS (3X)

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.

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.

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 cm2 per kW) of input (see FIG. 1-5).

Installation & Operation Manual

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”3.

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 Z223.1.

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 cm2 per kW) of input, but not less than 100 square inches (645 cm2) (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 cm2 per kW).

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 4000 Btu/hr input (5.5 cm2 per kW) (see FIG. 1-4).

Figure 1-7_Combustion Air from Outside - Single Opening

1 Determine boiler location (continued)

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 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 Z223.1; 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 25%. 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).

 CAUTION

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, perchlorethylene, 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

FIG. 1-4 FIG. 1-5 FIG. 1-6 FIG. 1-7

Inside Air from

Same Story

Opening, in

Bottom

(cm2)

1500

(9678)

2000

(12904)

2500

(16129)

3000

(19355)

3500

(22581)

Different

Opening, in

Stories

Total

(cm2)

3000

(19355)

4000

(25807)

5000

(32258)

6000

(38710)

7000

(45162)

*Outside Air from 1 Opening Directly from Outdoors, in

(cm2)

500

(3226)

667

(4304)

833

(5381)

1000

(6452)

1167

(7530)

Model

Number

FB 1500

FB 2000

FB 2500

FB 3000

FB 3500

*Outside Air from

2 Openings Directly from

Bottom

Opening, in

(cm2)

375

(2420)

500

(3226)

625

(4033)

750

(4839)

875

(5646)

Outdoors

Top

Opening, in

(cm2)

375

(2420)

500

(3226)

625

(4033)

750

(4839)

875

(5646)

*Outside Air from

2 Ducts Delivered from

Outdoors

Top

Opening, in

(cm2)

750

(4839)

1000

(6452)

1250

(8065)

1500

(9678)

1750

(11291)

Bottom

Opening, in

(cm2)

750

(4839)

1000

(6452)

1250

(8065)

1500

(9678)

1750

(11291)

2 Ducts Delivered from Interior Space

Top

Opening, in

(cm2)

1500

(9678)

2000

(12904)

2500

(16129)

3000

(19355)

3500

(22581)

The above requirements 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. Buildings MUST NOT be of *“Tight Construction”3.

Outside 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.

2 General venting

Installation & Operation Manual

Direct venting

Sidewall

Vertical Vent, Sidewall Air

Optional room air

Vertical

Sidewall

Vertical

2 General venting (continued)

Install vent and combustion air piping

Installation & Operation Manual

 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.

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 “B” 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.

Sealing of Type “B” 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. Seal all 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 inlet 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.

*Plastic pipe may require an adapter (not provided) to transition between the air inlet connection on the appliance and the plastic air inlet pipe.

 WARNING

NOTICE

Using vent or air intake materials other than those specified, failure to properly seal all seams and joints 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 material for the combustion air inlet pipe is recommended in cold climates to prevent the condensation of airborne moisture in the incoming combustion air.

2 General venting

Installation & Operation Manual

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.

Vent and air piping

This product has been approved for use with stainless steel vent systems.

 WARNING

NOTICE

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.

Installation of a stainless steel vent system should adhere to the stainless steel vent manufacturer’s installation instructions supplied with the vent system.

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)

SHIPPED LOOSE

WITH THE BOILER

VENT PIPE

(FIELD SUPPLIED)

ADAPTER

GASKET

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.

The Crest uses model specific combustion air intake and vent piping sizes as detailed in Tables 2B and 2C on page 17.

NOTICE

Increasing or decreasing combustion air or vent piping to sizes not specified in this manual is not authorized.

Table 2A Approved Stainless Steel Vent Manufacturers

Approved Stainless Steel Vent Manufacturers

Make Model

ProTech Systems (Simpson Dura-Vent Co.) FasNSeal Vent Z-Flex (Nova Flex Group) Z-Vent Heat Fab (Selkirk Corporation) Saf-T Vent Metal Fab Corr/Guard Securities Chimneys International Secure Seal SS Schebler Chimney Systems eVent

CONNECTOR

2 General venting (continued)

Table 2B Direct Vent Minimum / Maximum Allowable Air / Vent Lengths

Installation & Operation Manual

AIR INLET VENT

Model

FB 1500 7" 12' 100' 7" 12' 100' 2%

FB 2000 8" 12' 100' 8" 12' 100' 2%

FB 2500 8" 12' 100' 9" 12' 100' 2%

FB 3000 10" 12' 100' 10" 12' 100' 2%

FB 3500 10" 12' 100' 10" 12' 100' 2%

Table 2C Room Air Minimum / Maximum Allowable Air / Vent Lengths

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.

Air Intake

Diameter

Model

FB 1500 7" 12' 100' 1%

FB 2000 8" 12' 100' 1%

FB 2500 9" 12' 100' 1%

FB 3000 10" 12' 100' 1%

FB 3500 10" 12' 100' 1%

Air Intake

Min. Length

Vent

Diameter

Air Intake

Max. Length

Min. Length

Vent

Diameter

Vent

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.

Vent

Min. Length

Vent

Max. Length

Vent

Max. Length

De-Rate per

25 feet of Vent

Input De-Rate per

25 feet of Vent

Input

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:

NOTICE

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.

 WARNING

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.

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.

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 to another location, per this manual.

 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.

2 General venting

Common venting

Installation & Operation Manual

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 boilers connected to the common vent must all be of the same size.

3. Each Crest boiler must have a Lochinvar supplied flue damper installed (see Table 2D).

4. Only vertical venting may be used when common venting Crest boilers. Sidewall venting is not allowed.

5. Crest boilers in a common vent must be connected and controlled with the integral Crest SMART TOUCH Cascade. a. 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. b. The Cascade (Members) must be controlled by the Crest Leader boiler using the efficiency optimized Cascade.

Table 2D Flue Damper Kits

Flue Damper Kits

Model Damper Size Kit Number

FB1500 7" DRH30000

FB2000 8" DRH30001

FB2500 9" DRH30002

FB3000 10" DRH30003

FB3500 10" DRH30003

For approved common vent sizing, contact the factory.

 WARNING

When Crest boilers are common vented, the criteria above MUST BE followed. Failure to follow all these requirements will result in severe personal injury, death, or substantial property damage.

+ 42 hidden pages