Page 1
FBII-I-O_100208043_2000004587 Rev E
Installation & Operation Manual
Models: 751 - 2001
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.
Page 2
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
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 ............................................................. 19
PVC/CPVC .................................................................. 19-20
Polypropylene ................................................................... 21
3. VERTICAL DIRECT VENTING
Vent/Air Termination - Vertical ......................................... 22
Determine Location ..................................................... 22
Prepare Roof Penetrations ......................................... 22
Termination and Fittings ........................................ 22-23
Multiple Vent/Air Terminations .................................... 23
4. SIDEWALL DIRECT VENTING
Vent/Air Termination - Sidewall ................................... 24-26
Determine Location ................................................ 24-26
Prepare Wall Penetrations .......................................... 26
Termination and Fittings ............................................. 26
Multiple Vent/Air Terminations ............................... 26-27
Room Air ..................................................................... 27
5. HYDRONIC PIPING
System Water Piping Methods ......................................... 28
Low Water Cutoff Device ................................................. 28
Chilled Water System ....................................................... 28
Freeze Protection ............................................................. 28
General Piping Information .............................................. 28
Circulator Sizing ............................................................... 29
Near Boiler Piping Components .................................. 30-34
6. GAS CONNECTIONS
Connecting Gas Supply Piping ........................................ 35
Natural Gas ...................................................................... 36
Pipe Sizing for Natural Gas ........................................ 36
Natural Gas Supply Pressure Requirements ............. 36
Propane Gas .................................................................... 36
Pipe Sizing for Propane Gas ...................................... 36
Propane Supply Pressure Requirements ................... 36
Check Inlet Gas Supply .............................................. 37-38
Gas Valve Replacement .................................................. 38
7. FIELD WIRING
Line Voltage Connections ................................................ 39
Low Voltage Connections ................................................ 40
Wiring of the Cascade ...................................................... 41
8. CONDENSATE DISPOSAL
Condensate Drain ............................................................ 43
9. STARTUP ............................................................... 44-52
10. OPERATING INFORMATION
General ........................................................................ 53-55
Cascade ........................................................................... 56
Sequence of Operation .................................................... 57
Home Screen ................................................................... 58
11. MAINTENANCE
Maintenance & Annual Startup .............................. 59-63
12. DIAGRAMS
Ladder Diagram .......................................................... 64
Wiring Diagram ........................................................... 65
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
2
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.
Page 3
Please read before proceeding
WARNING
NOTICE
WARNING
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 –
Boiler operation –
Boiler water –
Freeze protection fluids –
Installation & Operation Manual
WARNING
• To avoid electric shock, disconnect electrical supply
before performing maintenance.
• To avoid severe burns, allow boiler to cool before
performing maintenance.
• 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.
• 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.
• 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 California Safe Drinking Water and
Toxic Enforcement Act requires the
Governor of California to publish a list of
substances known to the State of California
to cause cancer, birth defects, or other
reproductive harm, and requires businesses
to warn of potential exposure to such
substances.
This product contains a chemical known to
the State of California to cause cancer, birth
defects, or other reproductive harm. This
boiler can cause low level exposure to some
of the substances listed in the Act.
WARNING
DO NOT install units in rooms or
environments that contain corrosive
contaminants (see Table 1A on page 9).
Failure to comply could result in severe
personal injury, death, or substantial
property damage.
3
Page 4
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. Blower
The blower pulls in air and gas through the venturi (item
34). Air and gas mix inside the blower and is 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)
Single chamber design with a stress free metal fiber outer mesh
and durable stainless steel structure. Provides firing rates up to
15:1 turndown (Model 751), 20:1 turndown (Models 1001 -
1251) and 25:1 turndown (Models 1501 - 2001).
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 blower, 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 window
Two large high temperature quartz observation windows
provide views of the burner surface during firing.
13. Dual flame sensors (not shown)
Two flame sensors are provided to monitor the main burner
and transition flame.
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
blower, allowing gas to flow only if the gas valves are powered
and combustion air is flowing.
18. Condensate trap
The condensate trap is sized for a 1" PVC outlet connection
pipe.
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.
Installation & Operation Manual
20. Ignition electrode
An electrical spark across the electrodes will ignite the 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
Monitors gas supply pressure to the boiler 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 - not shown)
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. Venturi
The venturi controls air and gas flow into the burner.
35. Water inlet
A 3" (Models 751 - 1251) or 4” (Models 1501 - 2001)
ANSI flange connects the return water from the system to the
heat exchanger.
36. Water outlet
A 3" (Models 751 - 1251) or 4" (Models 1501 - 2001)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 sensor (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.
40. Fuses
A low resistance resistor that acts as a sacrificial device to provide
over current protection, of either the load or source circuit.
41. Air metering valve
The air metering valve is used to control the amount of air used
when firing.
42. Air metering valve air pressure switch
The air metering valve air pressure switch is used to ensure the air
metering valve is open when firing gas valve 2.
4
Page 5
The Crest - How it works... (continued)
2
39
Installation & Operation Manual
29
7
19
1
11
Front View
21
22
25
26
15
IMG01025
4
24
23
36
12
20
6
5
18
Rear View
34
41
3
IMG01128
35
37
33
10
40
42
14
32
Left Side (inside unit)
30
31
28
IMG01129
19
16
17
9
IMG01130
Right Side (inside unit)
5
Page 6
Ratings
Installation & Operation Manual
Crest
AHRI Rating
Model Number
Note: Change “N” to
“L” for L.P. gas models.
Min Max
FB(N,L)0751 50 750 720 626
FB(N,L)1001 50 1000 960 835
FB(N,L)1251 62 1250 1200 1043
FB(N,L)1501 60 1500 1440 1252
FB(N,L)1751 70 1750 1680 1460
FB(N,L)2001 80 2000 1920 1670
NOTICE
Maximum allowed working pressure is located on the rating plate.
Input
MBH
(Notes 4 - 6)
Notes:
1. The ratings are based on standard test procedures
prescribed by the United States Department of Energy.
2. Net AHRI 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. The boiler will de-rate by 1.4%
for each 1,000 feet above sea level up to 4,500 feet.
5. High altitude Crest Models are equipped to operate from
3,000 to 12,000 feet only. e boiler will not de-rate up
to 5,500 feet and will de-rate by 1.6% for each 1,000 feet
above 5,500 feet. e operation given in this manual
remains the same as the standard boilers. A high altitude
label (as shown in FIG A.) is also a xed to the unit.
De-rate values are based on proper combustion
calibration and
CO2’s adjusted to the recommended
levels.
Gross
Output
MBH
(Note 1)
Other Specifications
Net
AHRI
Ratings
Water,
MBH
(Note 2)
Figure A High Altitude Label Location
Appliance
Water
Content
Gallons
106 4" 4" 1 1/2" 8" 8" 2458
111 4" 4" 1 1/2" 8" 8" 2570
UNIT EQUIPPED FOR
HIGH ALTITUDE
3,000 FT. TO 12,000 FT.
Pipe
Pipe
Size
Inlet
Gas Inlet
Size
Outlet
73 3" 3" 1 1/4" 6" 6" 1768
77 3" 3" 1 1/4" 6" 6" 1838
87 3" 3" 1 1/4" 6" 8" 1975
94 4" 4" 1 1/2" 8" 8" 2307
Size
Air
Size
Vent
Size
(Note 3)
IMG01026
Weight
w/Water
(lbs.)
6
Page 7
Installation & Operation Manual
A
1 Determine boiler location
Installation must comply with:
• Local, state, provincial, and national codes, laws,
regulations, and ordinances.
• National Fuel Gas Code, NFPA 54 / ANSI Z223.1 –
latest edition.
• Standard for Controls and Safety Devices for
Automatically Fired Boilers, ANSI/ASME CSD-1 latest edition, when required.
• National Electrical Code, NFPA 70 - latest edition.
• For Canada only: CSA B149.1 Installation Code,
CSA C22.1 Canadian Electrical Code Part 1 and any
local codes.
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.
7. If the optional neutralizing kit is to be used, elevate
the boiler at least 3" above the floor.
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.
8. Check around the boiler for any potential air contaminants
that could risk corrosion to the boiler or the boiler combustion
air supply (see Table 1A on page 9). Prevent combustion air
contamination. Remove any of these contaminants from the boiler
area.
WARNING
DO NOT install units in rooms or environments that
contain corrosive contaminants (see Table 1A on page
9). Failure to comply could 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).
Do not install the appliance where the relative humidity
may exceed 93%. Do not install the appliance where
condensation may form on the inside or outside of
the appliance, or where condensation may fall onto
the appliance.
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:
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
Figure 1-1 Clearances
1" (25 MM) MINIMUM CLEARANCE
ROUND HOT WATER P IPES
0"
LEFT
FLOOR: COMBUSTIBLE
0"
REAR
VENT PIPE:
FOLLOW SPECIAL VENT SYSTEM
MANUFACTURER'S INSTRUCTIONS
0"
TOP
VENTILATING*
AIR OPENING
CLOSED DOOR
VENTILATING*
0"
RIGHT
0"
FRONT
IMG01027
7
Page 8
1 Determine boiler location
Installation & Operation Manual
NOTICE
Recommended clearances for service access
- Sides .............................................................................. 24"
- Rear ............................................................................... 24"
- Front ............................................................................. 30"
- Top ................................................................................ 24"
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.
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.
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 27 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.
8
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.
WARNING
Do not install the boiler on carpeting even if
foundation is used. Fire can result, causing
severe personal injury, death, or substantial
property damage.
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.
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 27 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.
Page 9
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-1. 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-1 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
9
Page 10
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 19.
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 re-sizing any portion of the
common venting system, the common venting system
should be resized to approach the minimum size as
determined using the appropriate tables in Part 11 of
the National Fuel Gas Code, ANSI Z223.1/NFPA 54
and/or CAN/CSA B149.1, Natural Gas and Propane
Installation Code.
10
Page 11
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
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
IMG01028
LIFTING
LUGS
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).
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)
11
Page 12
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
IMG01030
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.
IMG01031
Figure 1-6_Combustion Air from Interior Space
3. If air is taken from another interior space combined with
the equipment room:
(a) Two spaces on same story: Each of the two openings
specified above should have a net free area of one square
inch for each 1000 Btu/hr (22 cm
2
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
2
Btu/hr (44 cm
per kW).
IMG01029
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).
12
IMG01032
Figure 1-7_Combustion Air from Outside - Single Opening
Page 13
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
2
Opening, in
(11291)
(12904)
Bottom
(cm2)
750
(4839)
1000
(6452)
1250
(8065)
1500
(9678)
1750
2000
Different
Stories
2
Openings, in
(9678)
(12904)
(16129)
(19355)
(22581)
(25807)
Total
(cm2)
1500
2000
2500
3000
3500
4000
2
*Outside Air from
1 Opening Directly
from Outdoors, in
(cm2)
2
250
(1613)
333
(2149)
417
(2691)
500
(3226)
583
(3762)
667
(4304)
2
1
Model
Number
FB 0751
FB 1001
FB 1251
FB 1501
FB 1751
FB 2001
*Outside Air from
2 Openings Directly from
2
1
Bottom
Opening, in
(cm2)
188
(1213)
250
(1613)
313
(2020)
375
(2420)
438
(2826)
500
(3226)
Outdoors
Top
Opening, in
(cm2)
188
(1213)
250
(1613)
313
(2020)
375
(2420)
438
(2826)
500
(3226)
*Outside Air from
2 Ducts Delivered from
Outdoors
2
Top
Opening, in
(cm2)
2
375
(2420)
500
(3226)
625
(4033)
750
(4839)
875
(5646)
1000
(6452)
1
Bottom
Opening, in
(cm2)
375
(2420)
500
(3226)
625
(4033)
750
(4839)
875
(5646)
1000
(6452)
2 Ducts Delivered from Interior Space
Top
2
Opening, in
(cm2)
750
(4839)
1000
(6452)
1250
(8065)
1500
(9678)
1750
(11291)
2000
(12904)
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.
1
Outside air openings shall directly communicate with the outdoors.
2
Combined interior space must be 50 cubic feet per 1,000 Btu/hr input. Buildings MUST NOT be of *“Tight Construction”.
3
”Tight Construction” is defined as a building with less than 0.40 ACH (air changes per hour). For buildings of “Tight
Construction”, provide air openings into the building from outside.
13
Page 14
2 General venting
Installation & Operation Manual
Direct venting
Sidewall
IMG01033
Vertical Vent, Sidewall Air
Optional room air
IMG01056
IMG01057
Vertical
14
Sidewall
IMG01058
IMG01059
Vertical
Page 15
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.
15
Page 16
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
The Crest is certified as a Category II/IV boiler. This product
has been approved for use with stainless steel vent systems.
All venting systems used with a Crest boiler must be suitable
for Category IV operation except for factory approved
common vent systems operating as allowed in the Common
Venting Section on page 19.
WARNING
NOTICE
NOTICE
NOTICE
Use only the materials, vent systems,
and terminations listed in Table 2A-1.
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.
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.
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)
ROOM AIR BOX
SHIPPED WITH
UNIT
VENT PIPE
(FIELD SUPPLIED)
IMG01034
CONNECTOR SIZED FOR STAINLESS STEEL
FLUE PIPE
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-1 Approved Stainless Steel Vent Manufacturers
Approved Stainless Steel Vent Manufacturers
Make Model
ProTech Systems (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
ICC VIC
Jeremias --
16
Page 17
Installation & Operation Manual
2 General venting
Table 2A-2 Approved Stainless Steel Terminations and Adapters - Category IV
Model
751-1001
1251
1501-2001
Model
751-1001
1251
1501-2001
Model
751-1001
ProTech Z Flex Heat Fab
Adapter Intake Adapter Intake Adapter Flue Intake
810003974 810003269 2SVDSA06 2SVEE0690 9601MAD CCK06TM
810003980 810003281 2SVDSA06 2SVEE0690 9801MAD CCK08TM
810003980
810003357
810003369
2SVDSA08 2SVEE0890 9801MAD CCK08TM
9690
9692
9690
9692
9890
9892
Metal-Fab Security Chimney ICC
Adapter Flue Intake Adapter Flue Intake Adapter Flue Intake
SS6ST90AU
SSD0STAUK
4" - 24"
SS6ST90AU
SSD0STAUK
4" - 24"
SSE8E9OU
SD0STAUK
4" - 24"
HE-6DSA-F
HE-8DSA-F
HE-8DSA-F
HE-6MC-F
HE-6RC-F
HE-8SCR-F
HE-8MC-F
HE-8SCR-F
HE-8MC-F
HE-6E90-F
HE-6SCR-F
HE-6E90-F
HE-6SCR-F
HE-8E90-F
HE-8SCR-F
6FCGPVCA
8FCGLCA
8FCGLCA
MC
6-36"
MC
6-36"
MC
6-36"
6FCGSW90L SS6PVCU
6FCGSW90L SS8CRESTU
8FCGSW90 SS8CRESTU
SS0MCU
4" - 24"
SS0MCU
4" - 24"
SS0MCU
4" - 24"
Jeremias
Adapter Flue Intake
SWKL6-KLC SWKL6-WRC SWKL6-90ET
1251
1501-2001
SWKL8-KLC SWKL8-WRC SWKL6-90ET
SWKL8-KLC SWKL8-WRC SWKL8-90ET
Table 2B Direct Vent Minimum / Maximum Allowable Air / Vent Lengths
AIR INLET VENT
Model
FB 0751 6" 12' 100' 6" 18' 100' 0%
FB 1001 6" 12' 100' 6" 18' 100' 0%
FB 1251 6" 12' 100' 8" 18' 100' 0%
FB 1501 8" 12' 100' 8" 18' 100' 0%
FB 1751 8" 12' 100' 8" 18' 100' 0%
FB 2001 8" 12' 100' 8" 18' 100' 0%
Air Intake
Diameter
Air Intake
Min. Length
Air Intake
Max. Length
Vent
Diameter
Vent
Min. Length
Vent
Max. Length
De-Rate per
25 feet of Vent
Table 2C Room Air Minimum / Maximum Allowable Air / Vent Lengths
Model
FB 0751 6" 18' 100' 0%
FB 1001 6" 18' 100' 0%
FB 1251 8" 18' 100' 0%
FB 1501 8" 18' 100' 0%
FB 1751 8" 18' 100' 0%
FB 2001 8" 18' 100' 0%
Vent
Diameter
Vent
Min. Length
Vent
Max. Length
Input De-Rate per
25 feet of Vent
Input
17
Page 18
2 General venting (continued)
Installation & Operation Manual
When determining equivalent combustion air and vent
length, add 5 feet (1.5m) for each 90° elbow and 3 feet (.9 m)
for each 45° elbow.
EXAMPLE: 20 feet (6 m) of pipe + (4) 90° elbows + (3) 45°
elbows = 49 equivalent feet (15 m) of piping.
Removing from existing vent
Follow the instructions in Section 1, page 10 of this manual
when removing a boiler from an existing vent system.
Vent and air piping
Vent and air system:
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.
Vent, air piping and termination:
The Crest vent and air piping can be installed through the roof
or through a sidewall. Follow the procedures in this manual for
the method chosen. Refer to the information in this manual to
determine acceptable vent and air piping length.
Air contamination
Pool and laundry products and common household and hobby
products often contain fluorine or chlorine compounds. When
these chemicals pass through the boiler, they can form strong
acids. The acid can eat through the boiler wall, causing serious
damage and presenting a possible threat of flue gas spillage or
boiler water leakage into the building.
Please read the information given in Table 1A, page 9,
listing contaminants and areas likely to contain them. If
contaminating chemicals will be present near the location of the
boiler combustion air inlet, have your installer pipe the boiler
combustion air and vent to another location, per this manual.
WARNING
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.
18
Page 19
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 common flue
applications. DO NOT mix other manufacturer’s
appliances or other Lochinvar models. Common air
intake is not allowed.
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 direct vent, positive pressure, Category
IV or vertical/chimney vent, negative pressure, Category
II 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 Lead/Lag Cascade
option.
For approved common vent sizing, contact the factory.
WARNING
NOTICE
NOTICE
NOTICE
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.
When Crest boilers are common vented,
hot water generators MUST BE piped
to the primary heating loop and tank
thermostats must not be connected to the
Crest.
A field supplied inline condensate
collection section MUST BE installed
directly above the backflow preventer.
When using polypropylene common
vent a field supplied polypropylene to
stainless steel adapter MUST BE installed
between the backflow preventer and the
unit connection.
Table 2D Flue Damper Kits
Flue Damper Kits
Model Damper Size Kit Number
FB0751 6" 100056142
FB1001 6" 100056142
FB1251 8" 100141561
FB1501 8" 100141561
FB1751 8" 100141561
FB2001 8" 100141561
PVC/CPVC
This product has been approved for use with the PVC/CPVC
vent materials listed in Table 2E on page 20.
NOTICE
Installing vent and air piping
WARNING
NOTICE
NOTICE
WARNING
Factory installed vent connections are sized
for stainless steel venting.
The vent connection to the appliance
must be made with the starter CPVC pipe
section provided with the appliance if
PVC/CPVC vent is to be used. The field
provided vent fittings must be cemented
to the CPVC pipe section using an “All
Purpose Cement” suitable for PVC and
CPVC pipe. Use only the vent materials,
primer, and cement specified in Table 2E
to make the vent connections. Failure to
follow this warning could result in fire,
personal injury, or death.
Use only cleaners, primers, and solvents
that are approved for the materials which
are joined together.
All PVC vent pipes must be glued, properly
supported, and the exhaust must be
pitched a minimum of a 1/4 inch per foot
back to the boiler (to allow drainage of
condensate).
Insulation should not be used on PVC
or CPVC venting materials. The use of
insulation will cause increased vent wall
temperatures, which could result in vent
pipe failure.
19
Page 20
2 General venting (continued)
Installation & Operation Manual
Table 2E PVC/CPVC Vent Pipe, and Fittings
Approved PVC/CPVC Vent Pipe and Fittings
Item Material Standard
PVC Schedule 40, 80 ANSI/ASTM D1785
Vent pipe
Vent fittings
Pipe Cement /
Primer
NOTICE: DO NOT USE CELLULAR (FOAM) CORE PIPE
NOTE: In Canada, CPVC and PVC vent pipe, ttings and cement/
primer must be ULC-S636 certi ed.
1. Work from the boiler to vent or air termination. Do not
exceed the lengths given in this manual for the air or vent
piping.
2. Cut pipe to the required lengths and deburr the inside
and outside of the pipe ends.
3. Chamfer outside of each pipe end to ensure even
cement distribution when joining.
4. Clean all pipe ends and fittings using a clean dry rag.
(Moisture will retard curing and dirt or grease will prevent
adhesion.)
PVC - DWV ANSI/ASTM D2665
CPVC Schedule 40, 80 ANSI/ASTM F441
PVC Schedule 40 ANSI/ASTM D2466
PVC Schedule 80 ANSI/ASTM D2467
CPVC Schedule 80 ANSI/ASTM F439
PVC ANSI/ASTM D2564
CPVC ANSI/ASTM F493
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 fittings and pipes carefully to prevent
contamination of surfaces.
b. Apply a liberal even coat of primer to the fitting
socket and to the pipe end to approximately 1/2"
beyond the socket depth.
c. Apply a second primer coat to the fitting
socket.
d. While primer is still wet, apply an even coat of
approved cement to the pipe equal to the
depth of the fitting socket along with an even
coat of approved cement to the fitting socket.
e. Apply a second coat of cement to the pipe.
f. While the cement is still wet, insert the pipe into
the fitting, if possible twist the pipe a 1/4 turn as
you insert it. NOTE: If voids are present,
sufficient cement was not applied and joint could
be defective.
g. Wipe excess cement from the joint removing
ring or beads as it will needlessly soften the
pipe.
Figure 2-2 Near Boiler PVC/CPVC Venting - Models 751 1001 (Flue connections from the factory are sized for stainless
steel venting.)
6" PVC PIPE
(FIELD SUPPLIED)
6" PVC COUPLING
(FIELD SUPPLIED)
6" CPVC PIPE
STARTER PIECE
(FACTORY SUPPLIED)
6" PVC TO STAINLESS ADAPTER
(FACTORY SUPPLIED)
NOTE: CPVC VENT OR STAINLESS STEEL
PIPE AND VENT FITTINGS MUST BE USED
IN CLOSET AND ALCOVE INSTALLATIONS.
IMG01146
Figure 2-3 Near Boiler PVC/CPVC Venting - Model 1251
- 2001 (Flue connections from the factory are sized for stainless
steel venting.)
8" PVC PIPE
(FIELD SUPPLIED)
8" PVC COUPLING
(FIELD SUPPLIED)
8" CPVC PIPE
STARTER PIECE
(AVAILABLE FROM FACTORY
W/KIT #100267012)
8" PVC TO STAINLESS
ADAPTER (AVAILABLE FROM
FACTORY W/KIT #100267012)
NOTE: CPVC VENT OR STAINLESS STEEL
PIPE AND VENT FITTINGS MUST BE USED
IN CLOSET AND ALCOVE INSTALLATIONS.
IMG01147
20
Page 21
2 General venting
A
Polypropylene
This product has been approved for use with polypropylene
vent with the manufacturers listed in Table 2F.
NOTICE
Factory installed vent connections are sized
for stainless steel venting.
WARNING
Installation & Operation Manual
Use only the adapters and vent system listed
in Tables 2F and 2G. DO NOT mix vent
systems of different types or manufacturers.
Failure to comply could result in severe
personal injury, death, or substantial
property damage.
All terminations must comply with listed options in this
manual and be a single-wall vent offering.
For support and special connections required, see the
manufacturer's instructions. All vent is to conform to standard
diameter and equivalent length requirements established.
When determining equivalent combustion air and vent length
for polypropylene single-wall piping contact the manufacturer.
Table 2F Polypropylene Vent Pipe and Fittings
Approved Polypropylene Vent Manufacturers
Make Model
Centrotherm Eco Systems
Duravent (M & G Group)
NOTICE
The installer must use a specific vent starter
adapter at the flue collar connection. The
PolyPro Single-Wall / PolyPro Flex
InnoFlue SW/Flex
adapter is supplied by the vent manufacturer
to adapt to its vent system. See Table 2F
for approved vent adapters. Discard CPVC
starter piece.
NOTICE
All vent connections MUST be secured by
the vent manufacturer's joint connector
(FIG. 2-4).
WARNING
Insulation should not be used on
polypropylene venting materials. The use
of insulation will cause increased vent wall
temperatures, which could result in vent pipe
failure.
NOTICE
Installations must comply with applicable
national, state, and local codes. For
Canadian installation, polypropylene vent
must be listed as a ULC-S636 approved
system.
NOTICE
Installation of a polypropylene vent system
should adhere to the vent manufacturer’s
installation instructions supplied with the
vent system.
Figure 2-4 Near Boiler Polypropylene Venting
6" POLYPROPYLENE
PIPE (FIELD SUPPLIED)
6" POLYPROPYLENE
DAPTER (FIELD
SUPPLIED)
IMG01148
MODELS 751 - 1001
8" POLYPROPYLENE
PIPE (FIELD SUPPLIED)
8" POLYPROPYLENE
ADAPTER (FIELD
SUPPLIED)
MODELS 1251 - 2001
IMG01149
Table 2G Approved Polypropylene Terminations
Model Manufacturer Vent Model Vent Type Adapter Number Joint Connector Sidewall Kit*
Centrotherm
751-1001
1251-2001
* These parts are only needed if the sidewall termination assembly is used (see FIG. 4-1C on page 25).
Eco Systems
DuraVent
(M & G)
Centrotherm
Eco Systems
DuraVent
(M & G)
Innoflue
PolyPro
Innoflue Single-Wall ISAA0808 -- -- --
PolyPro Single-Wall FSA-AU8-8PP -- 8PPS-HSTL --
Single-Wall
Flex
Single-Wall
Flex
ISAAL0606 -- --
FSA-6PVCM-
6PPS
-- 6PPS-HLK --
Retaining Bracket /
Adapter*
IATP0606 /
ISTAGL0606
21
Page 22
3 Vertical direct venting
A
Vent/air termination – vertical
Installation & Operation Manual
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 19. Failure to comply could result in
severe personal injury, death, or substantial
property damage.
NOTICE
Installation must comply with local
requirements and with the National Fuel
Gas Code, NFPA 54 / ANSI Z223.1 - latest
edition for U.S. installations or CSA B149.1
Installation Code for Canadian installations.
Determine location
Locate the vent/air terminations using the following guidelines:
1. The total length of piping for vent or air must not exceed
the limits given in the General Venting Section on page 17
of this manual.
2. The vent must terminate at least 3 feet above the highest
place in which the vent penetrates the roof and at least 2 feet
above any part of a building within 10 horizontal feet.
3. The air piping must terminate in a down-turned 180°
return pipe no further than 2 feet (.6 m) from the center of
the vent pipe. This placement avoids recirculation of flue
products into the combustion air stream.
4. The vent piping must terminate in an up-turned coupling
as shown in FIG. 3-1. The top of the coupling or the rain
cap must be at least 36" (914 mm) above the air intake. The
air inlet pipe and vent pipe can be located in any desired
position on the roof, but must always be no further than 2
feet (.6 m) apart and with the vent termination at least 36"
(914 mm) above the air intake.
WARNING
Rooftop vent and air inlet terminations
must terminate in the same pressure zone,
unless vertical vent sidewall air is set up as
shown in the General Venting - Vertical
Vent, Sidewall Air Section.
Figure 3-2 Vertical Termination of Air and Vent w/Rain
Cap
5. Locate terminations so they are not likely to be damaged
by foreign objects, such as stones or balls, or subject to
buildup of leaves or sediment.
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 the vent pipe. For either combustible
or noncombustible construction, size the vent pipe
hole per the vent manufacturer’s instructions.
b. Insert a galvanized metal thimble in the vent pipe
hole (when required by local codes).
3. Space the air and vent holes to provide the minimum
spacing shown in FIG. 3-1.
4. Follow all local codes for isolation of vent pipe when
passing through floors, ceilings, and roofs.
5. Provide flashing and sealing boots sized for the vent pipe
and air pipe.
Termination and fittings
Figure 3-1 Vertical Termination of Air and Vent
BIRD SCREEN
[TYPICAL]
1. Prepare the vent termination coupling and the air
termination elbow (FIG. 3-1) by inserting bird screens.
Bird screens should be obtained locally.
2. The air piping must terminate in a down-turned 180°
return bend as shown in FIG. 3-1. Locate the air inlet
VENT OUTLET
36" MINIMUM
BOVE AIR INLET
VENT
COMBUSTION AIR
12" [305 MM] MINIMUM
ABOVE ROOF /
SNOW LINE
pipe no further than 2 feet (.6 m) from the center of the
vent pipe. This placement avoids recirculation of flue
products into the combustion air stream.
22
Page 23
3 Vertical direct venting
Installation & Operation Manual
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.
4. Maintain the required dimensions of the finished
termination piping as shown in FIG. 3-1.
5. Do not extend exposed vent pipe outside of building
more than shown in this document. Condensate could
freeze and block vent pipe.
Multiple vent/air terminations
1. When terminating multiple Crest boilers, terminate
each vent/air connection as described in this manual
(FIG. 3-3).
WARNING
Terminate all vent pipes at the same
height and all air pipes at the same height
to avoid recirculation of flue products and
the possibility of severe personal injury,
death, or substantial property damage.
Figure 3-4 Alternate Vertical Terminations with Multiple
Boilers
36” (914 MM)
12”
(305 MM)
36” (914 MM)
12”
(305 MM)
2. Place roof penetrations to obtain minimum clearance of
12 inches (305 mm) between edge of air intake elbow and
adjacent vent pipe of another boiler for U.S. installations
(see FIG. 3-3). For Canadian installations, provide
clearances required by CSA B149.1 Installation Code.
3. The air inlet of a Crest boiler is part of a direct vent
connection. It is not classified as a forced air intake with
regard to spacing from adjacent boiler vents.
Figure 3-3 Vertical Terminations with Multiple Boilers
36” (914 MM)
36” (914 MM)
12”
(305 MM)
12”
(305 MM)
12”
(305 MM)
12”
(305 MM)
12”
(305 MM)
12”
(305 MM)
23
Page 24
4 Sidewall direct venting
Vent/air termination – sidewall
Installation & Operation Manual
WARNING
Follow instructions below when
determining vent location to avoid
possibility of severe personal injury, death,
or substantial property damage.
WARNING
A gas vent extending through an exterior
wall shall not terminate adjacent to a wall
or below building extensions such as eaves,
parapets, balconies, or decks. Failure to
comply could result in severe personal
injury, death, or substantial property
damage.
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 19. Failure to comply could
result in severe personal injury, death, or
substantial property damage.
CAUTION
Sidewall venting commercial products will
result in large exhaust plumes in cold
climates. Consideration should be taken
when locating in proximity to windows,
doors, walkways, etc.
NOTICE
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.
Determine location
Locate the vent/air terminations using the following
guidelines:
1. The total length of piping for vent or air must not exceed
the limits given in the General Venting Section on page
17 of this manual.
2. You must consider the surroundings when terminating
the vent and air:
a. Position the vent termination where vapors will
not damage nearby shrubs, plants or air
conditioning equipment or be objectionable.
b. The flue products will form a noticeable plume as
they condense in cold air. Avoid areas where the
plume could obstruct window views.
c. Prevailing winds could cause freezing of condensate
and water/ice buildup where flue products impinge
on building surfaces or plants.
d. Avoid possibility of accidental contact of flue
products with people or pets.
e. Do not locate the terminations where wind eddies
could affect performance or cause recirculation,
such as inside building corners, near adjacent
buildings or surfaces, window wells, stairwells,
alcoves, courtyards, or other recessed areas.
24
WARNING
Sidewall vent and air inlet terminations
must terminate in the same pressure
zone.
f. Do not terminate above any door or above or
below any window. Condensate can freeze, causing
ice formations.
g. Locate or guard vent to prevent condensate
damage to exterior finishes.
Figure 4-1A Sidewall Termination of Air and Vent
NOTICE
PVC/CPVC or ABS is acceptable air inlet pipe material.
FROM BOILER VENT
PIPE CONNECTION
TO BOILER INTAKE
AIR CONNECTION
36" MIN
48" MAX
12" MIN
GRADE OR
SNOW LINE
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 6 feet (1.8 m) from adjacent walls.
• Not less than 7 feet (2.1 m) above grade where located
adjacent to public walkways.
• No closer than 12 inches (305 mm) below roof
overhang.
• At least 3 feet (.9 m) above any forced air intake
within 10 feet (3 m).
• No closer than 4 feet (1.2 m) horizontally
from any door or window or any other gravity air
inlet.
b. Air inlet must terminate at least 12 inches (305 m)
above grade or snow line; at least 36 inches
(914 mm) below the vent termination.
c. Do not terminate closer than 4 feet (1.2 m)
horizontally from any electric meter, gas meter,
regulator, relief valve, or other equipment. Never
terminate above or below any of these within 4 feet
(1.2 m) horizontally.
4. Locate terminations so they are not likely to be damaged
by foreign objects, such as stones or balls, or subject to
buildup of leaves or sediment.
Page 25
4 Sidewall direct venting
Installation & Operation Manual
Vent/air termination – sidewall
Figure 4-1B PVC/CPVC/ Polypropylene Sidewall
Termination of Air and Vent w/Field Supplied Fittings
36” (914 MM) MIN
48” (1219 MM) MAX
12” (305 MM)
MIN
3. The air piping must terminate in a down-turned elbow
as shown in FIG. 4-1B. This arrangement avoids
recirculation of flue products into the combustion air
stream.
4. The vent piping must terminate in an elbow pointed
outward or away from the air inlet, as shown in FIG. 4-1B.
WARNING
Figure 4-1C PVC/CPVC/Polypropylene Sidewall
Termination of Air and Vent
POSSIBLE ORIENTATIONS
Table 4A Sidewall Vent Kits
Model Kit # Air Vent
751 - 1001 100157612 6" (152 mm) 6" (152 mm) 7 3/4" (197 mm)
Do not exceed the maximum lengths of the
outside vent piping shown in FIG. 4-1C.
Excessive length exposed to the outside could
cause freezing of condensate in the vent pipe,
resulting in potential boiler shutdown.
TO BOILER
INTAKE AIR
CONNECTION
FROM BOILER
VENT PIPE
CONNECTION
VENT / AIR
TERMINATION
GRADE OR
SNOW LINE
12"
MIN
TO
OVERHANG
12"
MIN
Centerline
Width
Figure 4-2A PVC/CPVC/ Polypropylene Sidewall
Termination w/Field Supplied Fittings
BIRD SCREEN
36" (914 MM) MIN
48" (1219 MM) MAX
BIRD SCREEN
FROM BOILER
VENT PIPE
CONNECTION
TO BOILER
INTAKE AIR
CONNECTION
GRADE OR
SNOW LINE
12" (305 MM) MIN
Figure 4-2B Stainless Steel Sidewall Termination w/Field
Supplied Fittings
TO BOILER INTAKE
NOTICE
AIR CONNECTION
FROM BOILER VENT
PIPE CONNECTION
GRADE OR
SNOW LINE
PVC/CPVC or ABS is acceptable air inlet pipe material.
36" (914 MM) MIN
48" (1219 MM) MAX
12" (305 MM) MIN
5. Maintain clearances as shown in FIG.’s 4-1A thru 4-4,
pages 24 thru 26. Also maintain the following:
a. Vent must terminate:
• At least 6 feet (1.8 m) from adjacent walls.
• No closer than 12 inches (305 mm) below roof
overhang.
• At least 7 feet (2.1 m) above any public walkway.
• At least 3 feet (.9 m) above any forced air intake
within 10 feet (3 m).
• No closer than 4 feet (1.2 m) below or
horizontally from any door or window or any other
gravity air inlet.
b. Air inlet must terminate at least 12 inches (305 mm)
above grade or snow line; at least 3 feet (.9 m)
below the vent termination (FIG. 4-1B); and the vent
pipe must not extend more than 24 inches (610 mm)
vertically outside the building.
c. Do not terminate closer than 4 feet (1.2 m)
horizontally from any electric meter, gas meter,
regulator, relief valve, or other equipment. Never
terminate above or below any of these within 4 feet
(1.2 m) horizontally.
25
Page 26
4 Sidewall direct venting (continued)
Vent/air termination – sidewall
Installation & Operation Manual
6. Locate terminations so they are not likely to be damaged by
foreign objects, such as stones or balls, or subject to buildup
of leaves or sediment.
Figure 4-3 Clearance to Doors and Windows
4'
4'
Figure 4-4 Clearance to Forced Air Inlets
Prepare wall 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.
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. Install the vent and air intake piping. Seal all gaps
between the pipes and wall with RTV silicone sealant.
3. Seal all wall cavities.
Termination and fittings
1. The air termination must be oriented at least 12 inches
above grade or snow line as shown in FIG. 4-1A, 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
building more than what is shown in this document.
Condensate could freeze and block vent pipe.
4. Stainless steel terminations are designed to penetrate
walls with a thickness up to 9.25 inches of standard
construction.
VENT TERMINATION
CAUTION
26
IF LESS THAN 10’
36” MIN.
FORCED AIR
INLET
AIR TERMINATION
Sidewall venting commercial products will
result in large exhaust plumes in cold
climates. Consideration should be taken
when locating in proximity to windows,
doors, walkways, etc.
Multiple vent/air terminations
1. When terminating multiple Crest boilers terminate
each vent/air connection as described in this manual
(FIG. 4-5).
WARNING
All vent pipes and air inlets must
terminate at the same height to avoid
possibility of severe personal injury,
death, or substantial property damage.
Page 27
4 Sidewall direct venting
Installation & Operation Manual
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 Installation Code.
3. The air inlet of a Crest is part of a direct vent
connection. It is not classified as a forced air intake
with regard to spacing from adjacent boiler vents.
Figure 4-5 Multiple Vent Terminations (must also
comply with Figure 4-1A)
12"
36" MIN
48" MAX
12"
12" MIN
36"
Figure 4-6 Direct Vent Terminations
VENT
AIR
Figure 4-7 Room Air (Direct Exhaust Terminations)
ROOM AIR (DIRECT EXHAUST TERMINATIONS)
Vent Termination
23° Elbow
45° Elbow
90° Elbow
Room air
The Crest boiler may be installed with a single pipe carrying the
flue products to the outside while using combustion air from
the equipment room.
Follow the requirements in the General Venting, Sidewall
Direct Venting, and Vertical Direct Venting sections for vent
material specifications, vent length requirements, and vent
termination requirements.
Install the air inlet cover (shipped loose with the boiler) per
FIG. 4-8. Combustion and ventilation air must be supplied to
the equipment room per the requirements on pages 12 and 13
of this manual for proper operation of the Crest boiler when
utilizing the single pipe method.
DIRECT VENT TERMINATIONS
Air Inlet Vent Termination
Dryer Inlet Straight
90° Elbow Mitered
23° Elbow
Figure 4-8 Room Air Installation
AIR INLET COVER
IMG01036
27
Page 28
5 Hydronic piping
Installation & Operation Manual
System water piping methods
The Crest is designed to function in a closed loop pressurized
system not less than 12 psi (83 kPa). A temperature and
pressure gauge is included to monitor system pressure and
outlet temperature and should be located on the boiler outlet.
It is important to note that the boiler has a pressure drop
which must be figured in when sizing the circulators. Each
boiler installation must have an air elimination device, which
will remove air from the system.
Install the boiler so the gas ignition system components
are protected from water (dripping, spraying, etc.) during
appliance operation or basic service of circulator replacement,
valves, and others.
Observe a minimum of 1/4 inch (6 mm) clearance around all
uninsulated hot water pipes when openings around the pipes
are not protected by non-combustible materials.
Low water cutoff device
An electronic low water cutoff is provided as standard
equipment on all models. The low water cutoff should be
inspected every 6 months.
Chilled water system
If the boiler supplies hot water to heating coils in air handler
units, flow control valves or other devices must be installed to
prevent gravity circulation of heater water in the coils during
the cooling cycle. A chilled water medium must be piped in
parallel with the heater.
Freeze protection
Freeze protection for new or existing systems must use
glycol that is specially formulated for this purpose. This
includes inhibitors, which prevent the glycol from attacking
the metallic system components. Make certain to check that
the system fluid is correct for the glycol concentration and
inhibitor level. The system should be tested at least once
a year and as recommended by the producer of the glycol
solution. Allowance should be made for the expansion of the
glycol solution in the system piping.
WARNING
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.
General piping information
IMPORTANT
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).
1. Connect the system return to the flanged connection
marked “Inlet”, make sure to install with a suitable gasket
between flanges.
2. Connect the system supply to the flanged connection
marked “Outlet”, make sure to install with a suitable gasket
between flanges.
3. Install purge and balance valve or shutoff valve and drain
on system return to purge air out of each zone.
4. Install a backflow preventer on the cold feed make-up
water line.
5. Install a pressure reducing valve on the cold feed make-up
water line, (15 psi (103 kPa) nominal). Check temperature
and pressure gauge, which should read a minimum pressure
of 12 psi (83 kPa).
6. Install the circulators as shown on the piping diagrams in
this section. Make sure the circulators are properly sized
for the system and friction loss. Install check valves with
each boiler circulator.
7. Install an expansion tank on the system supply. Consult the
tank manufacturer’s instruction for specific information
relating to tank installation. Size the expansion tank for the
required system volume and capacity.
8. Install an air elimination device on the system supply.
9. This appliance is supplied with a relief valve sized in
accordance with ASME Boiler and Pressure Vessel Code,
Section IV (“Heating Boilers”). The safety relief valve is
installed at the factory and is located on the rear of the
boiler. Pipe the discharge of the safety relief valve to
prevent injury in the event of pressure relief. Pipe the
discharge to a drain. Provide piping that is the same size as
the safety relief valve outlet. Never block the outlet of the
safety relief valve.
10. On any pre-existing system, it is good practice to install
a field supplied strainer to prevent damage to the heat
exchanger.
11. It is recommended to install an inlet water strainer to
prevent debris from entering the heat exchanger or system.
See the piping illustrations included in this section, FIG.’s 5-2
thru 5-5 for suggested guidelines in piping the Crest.
All boiler piping must contain an oxygen
barrier. This will help prevent any excess
oxygen from entering the system.
28
NOTICE
Please note that these illustrations are meant
to show system piping concept only, the
installer is responsible for all equipment and
detailing required by local codes.
Page 29
Installation & Operation Manual
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360
Pressure Drop (Fe et of Head)
Flow Rate (GPM)
CREST Pressure Drop Curve
FB2001 FB1751 FB1501
FB1251 FB1001 FB751
5 Hydronic piping
Circulator sizing
The Crest heat exchanger does have a pressure drop, which must be considered in your system design. Refer to the graph in
FIG. 5-1 for pressure drop through the Crest heat exchanger.
Figure 5-1 Pressure Drop vs. Flow
Table 5A Sizing Information for Temperature Rise Applications_20°F, 40°F and 60°F
TEMPERATURE RISE APPLICATIONS
Model
BOILER
CONNECTION SIZE
GPM FT/HD GPM FT/HD GPM FT/HD
FB 0751 3" 72 1.5 36 0.5 24 0.2
FB 1001 3" 96 2.1 48 0.6 32 0.3
FB 1251 3" 120 3.0 60 0.9 40 0.4
FB 1501 4" 144 3.1 72 0.9 48 0.5
FB 1751 4" 168 3.7 84 1.1 56 0.5
FB 2001 4" 192 4.3 96 1.3 64 0.6
[Crest models are based on 96% AHRI Effi ciency]
NOTICE
The pressure drop reflected in FIG. 5-1 is
for the boiler only. Additional allowances
must be made for piping, especially if
sizing pumps for Primary/Secondary
applications.
20°F 40°F 60°F
NOTICE
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
rates leading to inadvertent boiler high limit
shutdowns and poor system performance.
29
Page 30
5 Hydronic piping (continued)
Installation & Operation Manual
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. The pump should
be sized per Table 5A. Consult the indirect water
heater operating guide to determine flow characteristics
for the selected product used. The pump’s total flow and
heat requirements are the sum of the boiler and the indirect
water heater.
4. Boiler isolation valves:
Field supplied. Full port valves are required. Failure
to use full port valves could result in a restricted flow
rate through the boiler.
5. Check valves:
Field supplied. Check valves are required for
installation as shown in FIG.’s 5-2 and 5-3. Failure to
install check valves could result in a reverse flow
condition during pump(s) off cycle.
6. Domestic indirect hot water isolation valves:
Field supplied. Full port valves are required. Failure to use
full port valves could result in a restricted flow rate through
the boiler.
NOTICE
10. Y-Strainer:
Field supplied. A Y-strainer or equivalent multipurpose
strainer is recommended at the inlet of the heat
exchanger to remove system particles from older
hydronic systems and protect newer systems.
CAUTION
NOTICE
Table 5B1 Minimum Flow Rate with the Boiler at Full Fire
TEMPERATURE RISE APPLICATIONS
MODEL FLOW RATE (GPM)
FB(N,L)0751 18
FB(N,L)1001 24
FB(N,L)1251 30
FB(N,L)1501 36
FB(N,L)1751 42
A system supply sensor (factory supplied)
MUST BE installed with Primary/Secondary
systems for proper boiler operation.
The maximum allowable water flow rate
through a single Crest boiler is 350 GPM.
Exceeding this flow rate will result in damage
to the heat exchanger and/or piping.
Reference Table 5B1 for the minimum
recommended flow rate through a single
Crest boiler at full fire to maintain a 80°F
temperature rise. Reference Table 5B2 for
the absolute minimum flow rate through a
single Crest boiler.
7. Anti-scald mixing valve:
Field supplied. An anti-scald mixing valve is
recommended when storing domestic hot water above
115°F (46°C).
8. Pressure relief valve:
Factory supplied. The pressure relief valve is sized to
ASME specifications.
9. System temperature sensor:
Lochinvar supplies a system temperature sensor.
The sensor is to be installed in the heating loop
downstream from the boiler hot water piping and
heating loop junction. The sensor should be
located far enough downstream to sense system diluted
water temperature.
30
FB(N,L)2001 48
[Based on 80°F Temperature Rise]
Table 5B2 Absolute Minimum Flow Rate
ABSOLUTE MINIMUM FLOW RATE
MODEL FLOW RATE (GPM)
FB(N,L)0751 18
FB(N,L)1001 18
FB(N,L)1251 18
FB(N,L)1501 25
FB(N,L)1751 25
FB(N,L)2001 25
Page 31
Installation & Operation Manual
5 Hydronic piping
Figure 5-2 Single Boiler - Recommended - Primary / Secondary Piping with a Hot Water Generator
FROM SYSTEM
SYSTEM RETURN
HOT WATER
GENERATOR
RELIEF
VALVE
SENSOR
12"
MAX
BALL VALVE
(TYPICAL)
AIR SEPERATOR
DRAIN PORT
(TYPICAL)
SYSTEM SUPPLY
SENSOR
SYSTEM
CIRCULATOR
WATER
GENERATOR
CIRCULATOR
BOILER PUMP
NOTICE
NOTICE
BOILER
DRAIN
FLOW CHECK
VALVE (TYPICAL)
Y-STRAINER
(RECOMMENDED)
EXPANSION
TANK
PRESSURE
REDUCING VALVE
PRESSURE
GAUGE
BACK FLOW
PREVENTER
TO SYSTEM
MAKE UP
WATER
IMG01035
System flow should always remain higher than the required flow for the boiler(s) when the boiler(s) is in
operation to prevent short cycling and high limit issues.
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 installer is responsible for compliance with local codes.
31
Page 32
5 Hydronic piping (continued)
Table 5C Multiple Boilers - Common Header - Primary / Secondary Flow
Number of Units
Model
FB 0751
FB 1001
FB 1251
FB 1501
FB 1751
FB 2001
234567 8
Recommended Common Header Pipe Sizes in Inches
445566 7
455677 8
556778 10
567781010
5 6 7 8 10 10 10
6 6 8 8 10 10 12
[Based on a boiler ΔT of 30°F.]
Installation & Operation Manual
NOTICE
A system supply sensor (factory supplied) MUST BE installed for proper boiler operation.
Figure 5-3 Multiple Boilers - Common Header - Recommended - Primary / Secondary Flow
FROM SYSTEM
* See page 19 for special instructions when
common venting Crest boilers.
RELIEF
*
HOT WATER
GENERATOR
GENERATOR
CIRCULATOR
WATER
VALVE
BOILER DRAIN
(TYPICAL)
BOILER PUMP
(TYPICAL)
SYSTEM RETURN
SENSOR
Y-STRAINER
(RECOMMENDED)
FLOW CHECK
VALVE (TYPICAL)
BALL VALVE
(TYPICAL)
AIR SEPERATOR
DRAIN PORT
(TYPICAL)
SYSTEM SUPPLY
SENSOR
BACK FLOW
PREVENTER
PRESSURE
REDUCING VALVE
PRESSURE
GAUGE
EXPANSION
TANK
SYSTEM
CIRCULATOR
TO SYSTEM
MAKE UP
WATER
IMG01037
NOTICE
NOTICE
32
System flow should always remain higher than the required flow for the boiler(s) when the boiler(s) is in
operation to prevent short cycling and high limit issues.
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 installer is responsible for compliance with local codes.
Page 33
Installation & Operation Manual
5 Hydronic piping
Figure 5-4 Single Boiler - Alternate - Fixed or Variable Flow Primary System Piping
RELIEF
VALVE
BALL VALVE
(TYPICAL)
FROM SYSTEM
BOILER DRAIN
Y-STRAINER
(RECOMMENDED)
PRESSURE REDUCING VALVE
(OPTIONAL)
BYPASS
EXPANSION
TANK
PRESSURE
GAUGE
AIR SEPERATOR
DRAIN PORT
(TYPICAL)
PRESSURE
REDUCING VALVE
SYSTEM
CIRCULATOR
BACK FLOW
PREVENTER
TO SYSTEM
MAKE UP
WATER
IMG01038
NOTICE
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 installer is responsible for compliance with local codes.
33
Page 34
Installation & Operation Manual
5 Hydronic piping (continued)
Figure 5-5 Multiple Boilers - Alternate - Common Header - Fixed or Variable Flow Primary
RELIEF
VALVE
(TYPICAL)
ISOLATION
VALVE
2-WAY MOTORIZED
FROM SYSTEM
VALVE (OPTIONAL)
BOILER
(TYPICAL)
DRAIN
AIR SEPERATOR
NOTICE
NOTICE
SYSTEM RETURN
SENSOR
Y-STRAINER
(RECOMMENDED)
(TYPICAL)
EXPANSION
TANK
PRESSURE
GAUGE
DRAIN PORT
(TYPICAL)
SYSTEM SUPPLY
SENSOR
BACK FLOW
PREVENTER
PRESSURE
REDUCING VALVE
SYSTEM
CIRCULATOR
TO SYSTEM
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 installer is responsible for compliance with local codes.
When installing multiple Crest boilers in fixed or variable flow primary applications, utilize a reverse-return
or other piping method to ensure balanced flow through each boiler.
MAKE UP
WATER
IMG01039
34
Page 35
6 Gas connections
Gas supply
NOTICE
1. It is recommended to install one (1) gas regulator for each
Crest boiler.
2. Gas regulators should be installed in a horizontal
orientation unless otherwise recommended by the
regulator manufacturer.
3. It is recommended to install a filter at the inlet of a gas
regulator to prevent debris from entering the regulator.
4. Gas regulators should be installed the greater of either 20
inches or 10 pipe diameters from the nearest fitting, elbow,
or valve to the outlet of the regulator.
5. It is recommended that the gas regulator outlet size match
the gas inlet size of the boiler and to not change the pipe
size between them. If the pipe diameter must be increased,
a bell reducer type fitting should be located at the regulator
outlet and the boiler inlet, maintaining the distance
indicated in Step 4.
6. Gas regulators must be properly vented to ensure proper
function:
a. Vent pipe must be no smaller than the regulator vent
connection size.
b. Each regulator must have a separate vent line.
c. Vent lines must not be combined together or with any
other equipment that also requires atmospheric vents.
d. Excessive gas regulator vent length will detrimentally
affect regulator performance:
• Gas regulators must be properly vented according to
the regulator manufacturer’s instructions.
• It is recommended that regulator vent length not
exceed 15 equivalent feet (4.5 m).
• When regulator vent must exceed 15 equivalent feet, it
is recommended to use a ventless regulator equipped
with a vent limiter.
• If a ventless regulator cannot be utilized, it is
recommended to increase vent diameter by one pipe
size after the initial 15 equivalent feet and every additional
10 equivalent feet.
e. Proper measures must be taken to prevent water,
snow, insects, or other debris from obstructing the vent.
Connecting gas supply piping
NOTICE
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.
Ensure that the high gas pressure regulator
is at least 10 feet (3 m) upstream of the
appliance.
For dual fuel models, reference the Crest
Dual Fuel Supplemental Manual.
Installation & Operation Manual
Figure 6-1 Gas Supply Piping
UNION
(FACTORY
SUPPLIED)
GAS SUPPLY
MANUAL SHUTOFF
VALVE
(FACTORY SUPPLIED)
SEDIMENT TRAP/
DRIP LEG CLEAN OUT
(FACTORY SUPPLIED)
2. Support piping with hangers, not by the boiler or its
accessories.
WARNING
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. The appliance must be disconnected from the gas
supply piping system during any pressure testing of
that system at a test pressure in excess of 1/2 PSIG
(3.5 kPa).
b. The appliance must be isolated from the gas supply
piping system by closing a manual shutoff valve
during any pressure testing of the gas supply piping
system at test pressures equal to or less than 1/2 PSIG
(3.5 kPa).
c. The appliance and its gas connection must be leak
tested before placing it in operation.
WARNING
5. Use pipe sealing compound compatible with propane
gases. Apply sparingly only to male threads of the pipe
joints so that pipe dope does not block gas flow.
WARNING
Table 6A Gas Inlet Size
Model Gas Inlet Size
FB0751 1 1/4"
FB1001 1 1/4"
FB1251 1 1/4"
FB1501 1 1/2"
FB1751 1 1/2"
FB2001 1 1/2"
The gas valve and blower will not support
the weight of the piping. Do not attempt
to support the weight of the piping with
the boiler or its accessories. Failure to
comply could result in severe personal
injury, death, or substantial property
damage.
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.
Failure to apply pipe sealing compound as
detailed in this manual can result in severe
personal injury, death, or substantial
property damage.
35
Page 36
6 Gas connections (continued)
Installation & Operation Manual
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
IMG01132
USE BACK UP WRENCH TO PREVENT
PIPE FROM ROTATING
NOTICE
Maximum inlet gas pressure must not
exceed the value specified. Minimum
value listed is for the purposes of input
adjustment.
Natural gas:
WARNING
Pipe sizing for natural gas
1. Refer to Table 6B for pipe length and diameter. Based on
rated boiler input (divide by 1,000 to obtain cubic feet per
hour).
a. Table 6B is only for natural gas with specific gravity
0.60, with a pressure drop through the gas
piping of 0.3 inches w.c.
b. For additional gas pipe sizing information, refer to
the National Fuel Gas Code, NFPA 54 / ANSI Z223.1
- latest edition, or in Canada CSA B149.1 Installation
Code.
Check boiler rating plate to determine
which fuel the boiler is set for. Crest
boilers CANNOT be field converted.
Failure to comply could result in severe
personal injury, death, or substantial
property damage.
3. Install 100% lockup gas pressure regulator in supply line for
each boiler if inlet pressure exceeds 14 inches w.c. (3.5 kPa).
4. Gas valves used on Crest boilers are rated for at least 27
inches w.c. (6.7 kPa).
Propane Gas:
WARNING
Pipe sizing for propane gas
1. Contact gas supplier to size pipes, tanks, and 100% lockup
gas pressure regulator.
Propane Supply Pressure Requirements
1. Target a supply pressure of 11 inches w.c. (2.7 kPa)
measured when the boiler is operating at minimum input
rate. Gas pressure can be adjusted higher or lower than 11
inches w.c. as needed.
2. Adjust propane supply regulator provided by the gas
supplier for 14 inches w.c. (3.5 kPa) maximum pressure.
3. Pressure required at gas valve inlet pressure port:
• Maximum 14 inches w.c. (3.5 kPa) with boiler operating.
• Minimum 4 inches w.c. (.99 kPa) with boiler operating.
Figure 6-3 Gas Supply Piping to Regulator
Check boiler rating plate to determine which
fuel the boiler is set for. Crest boilers CAN
NOT be field converted. Failure to comply
could result in severe personal injury, death,
or substantial property damage.
10'
MINIMUM
*MANUAL SHUT
OFF VALVE
(FIELD SUPPLIED)
*IN COMPLIANCE WITH
248 CMR7.04(9)(f), PROVISIONS
SHALL BE MADE SO THE GAS
SUPPLY TO THE BOILER(S) MAY
BE SHUT OFF FROM A LOCATION
OUTSIDE THE BOILER ROOM.
GAS PRESSURE
REGULATOR
(FIELD SUPPLIED)
Natural gas supply pressure requirements
1. Target a supply pressure of 7 inches w.c. (1.7 kPa)
measured when the boiler is operating at minimum input
rate. Gas pressure can be adjusted higher or lower than 7
inches w.c. as needed.
2. Pressure required at the gas valve inlet pressure port:
• Maximum 14 inches w.c. (3.5 kPa) with boiler operating.
• Minimum 4 inches w.c. (.99 kPa) with boiler operating.
36
IMG01040
Page 37
6 Gas connections
Table 6B Natural Gas Pipe Size Chart
Capacity of Schedule 40 Metallic Pipe in Cubic Feet of Natural Gas Per Hour
(based on .60 specific gravity, 0.30" w.c. pressure drop)
Installation & Operation Manual
TABLE - 6B
Pipe
Size
(Inches)
1 1/4 1,060 726 583 499 442 400 368 343 322 304 269 244 224 209
1 1/2 1,580 1,090 873 747 662 600 552 514 482 455 403 366 336 313
2 3,050 2,090 1,680 1,440 1,280 1,160 1,060 989 928 877 777 704 648 602
2 1/2 4,860 3,340 2,680 2,290 2,030 1,840 1,690 1,580 1,480 1,400 1,240 1,120 1,030 960
3 8,580 5,900 4,740 4,050 3,590 3,260 3,000 2,790 2,610 2,470 2,190 1,980 1,820 1,700
4 17,500 12,000 9,660 8,270 7,330 6,640 6,110 5,680 5,330 5,040 4,460 4,050 3,720 3,460
10 20 30 40 50 60 70 80 90 100 125 150 175 200
Length of Pipe in Straight Feet
Check inlet gas supply
WARNING
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 and minimum input rate, the meter, regulator, or gas
line may be undersized or in need of service. Perform the steps
below when checking inlet gas supply:
1. Turn the main power switch to the “OFF” position.
2. Shut off gas supply at the manual gas valve in the gas
piping to the appliance.
3. Remove the 1/8" pipe plug on the flange to the factory
supplied gas shutoff valve and install a suitable 1/8"
fitting (field supplied) for the manometer tubing. Place the
tubing of the manometer over the tap once the 1/8"
fitting is installed as shown in FIG. 6-4.
DO NOT adjust or attempt to measure gas
valve outlet pressure. Attempting to alter
or measure the gas valve outlet pressure
could result in damage to the valve, causing
potential severe personal injury, death, or
substantial property damage.
4. Slowly turn on the gas supply at the factory installed
manual gas valve.
5. Turn the power switch to the “ON” position.
6. Adjust the temperature set point on the control panel of
the SMART TOUCH control module to call for heat or
utilize Service Mode, see page 50 of this manual.
7. Observe the gas pressure with the burner
operating at 100% of rated input. Without turning
off the boiler, reduce the burner to the minimum input
rate and observe the gas pressure with the burner at
the minimum input rate. Percent of burner input will be
displayed on the Modulation Screen.
8. Ensure inlet pressure is within specified range.
Minimum and maximum gas supply pressures are
specified in this section of the manual.
9. If gas supply pressure is within normal range and no
adjustments are needed, proceed on to Step 11.
10. If the gas pressure is out of range, contact the gas utility,
gas supplier, qualified installer or service agency to
determine the necessary steps to provide proper gas
pressure to the control.
11. Turn the power switch to the “OFF” position.
12. Shut off the gas supply at the manual gas valve in the gas
piping to the appliance.
13. Remove the manometer from the pressure tap on top of
the gas valve. Remove the 1/8" (3 mm) field supplied
fitting and reinstall the pipe plug removed in Step 3.
37
Page 38
6 Gas connections (continued)
Installation & Operation Manual
WARNING
14. Turn on the gas supply at the manual gas valve.
15. Turn the power switch to the “ON” position.
16. Adjust the temperature set point on the control panel of
the SMART TOUCH control module to the desired
water temperature so the appliance will call for heat.
17. Check burner performance by cycling the system while
you observe burner response. The burner should ignite
promptly. Flame pattern should be stable. Turn system
off and allow burner to cool, then cycle burner again to
ensure proper ignition and flame characteristics.
Figure 6-4 Inlet Gas Supply Check
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.
Gas valve replacement
The gas valve MUST NOT be replaced with a
conventional gas valve under any circumstances. As
an additional safety feature, the gas valves have flanged
connections to the venturi and the blower.
WARNING
WARNING
Failure to follow all precautions
could result in fire, explosion, or
death!
DO NOT adjust or attempt to
measure gas valve outlet pressure.
Attempting to alter or measure
the gas valve outlet pressure could
result in damage to the valve,
causing potential severe personal
injury, death, or substantial property
damage.
38
Page 39
7 Field wiring
PUMP
CON
TACTOR
LED
Installation & Operation Manual
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.
NOTICE
Wiring must be N.E.C. Class 1.
If original wiring as supplied with boiler
must be replaced, use only type 105°C
wire or equivalent.
Boiler must be electrically grounded as
required by National Electrical Code
ANSI/NFPA 70 – latest edition.
CAUTION
Label all wires prior to disconnection when
servicing controls. Wiring errors can
cause improper and dangerous operation.
Installation must comply with:
1. National Electrical Code and any other national, state,
provincial, or local codes, or regulations.
2. In Canada, CSA C22.1 Canadian Electrical Code Part 1,
and any local codes.
Line voltage connections
1. Connect 120 VAC power wiring to the line voltage terminal
strip in the junction box, as shown in FIG. 7-1.
2. Provide and install a fused disconnect or service switch
sized per the boiler amp draw (shown on the boiler rating
plate) as required by the code (see FIG. 7-1).
3. When connecting the boiler, system and hot water generator
pumps connect the wiring to the line voltage terminal strip
as shown in FIG. 7-1. Maximum current is 1.5 amps.
Install a field supplied contactor between the pump(s) and
the boiler connections.
4. For alternate voltages, consult factory.
Figure 7-1 Boiler Line Voltage Field Wiring Connections
NEUTRAL W
GROUND G
LINE BK
SYSTEM PUMP
DRY CONTACT
BOILER PUMP
DRY CONTACT
HWG PUMP
DRY CONTACT
SERVICE SWITCH
CONTACTOR
(FIELD SUPPLIED)
NL
FIELD SUPPLIED CON
BE INSTAL
MUST
SUPPLY
120V
SYSTEM PUMP
MAX. 1.5 AMPS PER
BOILER
NECTION
HWG PUMP
IMG00319
39
Page 40
Installation & Operation Manual
7 Field wiring (continued)
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.
Figure 7-2 Routing Field Wiring
LOW VOLTAGE
WIRING KNOCKOUTS
LOW VOLTAGE
J-BOX
LINE VOLTAGE
J-BOX
IMG01041
Enable
1. Connect the room thermostat or boiler enable contacts
(isolated contact only) to terminals 7 and 8, as shown in
FIG. 7-3.
2. If a thermostat is used, install the thermostat on the inside
wall away from influences of drafts, hot or cold water
pipes, lighting fixtures, television, sunlight, or fireplaces.
3. Thermostat anticipator (if applicable):
a. If connected directly to boiler, set for 0.1 amps.
b. If connected to relays or other devices, set to match
total electrical power requirements of connected
devices. See device manufacturers’ specifications
and thermostat instructions for details.
Outdoor temperature sensor
1. Connect the outdoor temperature sensor (FIG. 7-3) to
the Outdoor Sensor terminals on the connection board to
enable outdoor reset operation of the Crest.
2. Mount the sensor on an exterior wall, shielded from direct
sunlight or flow of heat or cooling from other sources.
3. Route sensor wires through a knockout at the rear of the
boiler (see FIG. 7-2).
Variable speed system pump
If a variable speed pump is used in the primary loop, and
a 0-10V signal is available from the pump speed control,
this signal can be used by the SMART TOUCH control to
anticipate changes in the building heat load. By connecting
this 0 - 10V signal to the 0 - 10V SYS PUMP IN terminals, the
boiler (or cascade) can modulate up and down as the primary
flow increases and decreases.
40
LINE VOLTAGE
WIRING KNOCKOUTS
ModBus / BACnet
The RS-485 ModBus / BACnet cable is connected to the
ModBus terminals. Use shielded, 2-wire twisted pair cable. If
desired, the shield can be connected to ground by installing a
jumper wire between terminals 1 and 3 on connector X5 on the
ModBus interface module.
Hot Water Generator (HW)
thermostat
1. Connect the HW tank thermostat to the Tank Thermostat
terminals on the connection board (FIG. 7-3).
Hot Water Generator (HW) tank
sensor
1. By installing a HW tank sensor, the SMART TOUCH
control can perform the tank thermostat function. The
SMART TOUCH control automatically detects the presence
of this sensor, and generates a HW call for heat when the
tank temperature drops 6°F (3°C) below the tank set point,
and finishes the call for heat when the tank temperature
reaches the tank set point.
2. A #100170544 / TST20015 sensor MUST be used with any
indirect tank. Failure to use the correct sensor will result
in the tank temperature being either above or below the
set point. Connect the correct sensor to the Tank Sensor
terminals (see FIG. 7-3).
NOTICE
See page 19 for special instructions when
common venting Crest boilers.
Louver relay
If louvers need to operate before the boiler fires, they can be
controlled by this output. Connect these terminals to a 24V
relay coil, which is wired to operate the louvers (FIG. 7-3).
Louver proving switch
Louvers are used to provide combustion air for the room air
option. A louver proving switch should be connected to the
appropriate terminals and are verified prior to operation (see
FIG. 7-3).
Boiler pump speed output
This 0 - 10V output is available to control the speed of a variable
speed boiler pump. The SMART TOUCH control will vary the
speed of this pump in order to maintain a minimum T (set
by the installer, see the Crest Service Manual) across the heat
exchanger, as well as prevent high limit lockouts when the flow
in the primary loop is extremely low. Connect this output to the
0 - 10V input on the boiler pump speed control.
NOTICE
The system supply temperature must be
provided for this feature to work. The
temperature can be sensed directly with
a system supply sensor, or sent through
ModBus/BACnet. This feature is to be used
with primary /secondary piping systems.
Rate output
This output provides a 0 - 10V signal that is proportional to the
firing rate of the boiler. This may be used by a BMS system to
monitor the actual rate of the boiler.
Page 41
7 Field wiring
Installation & Operation Manual
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. The SMART TOUCH control
automatically detects the presence of this sensor, and
controls the boiler firing rate to maintain the system
supply temperature to the set point.
NOTICE
2. For system supply sensor wiring information reference
(FIG. 7-3).
NOTICE
DO NOT INSTALL THE SYSTEM
SUPPLY SENSOR INTO THE SYSTEM
RETURN.
Unless a firing rate is being provided by
a BMS system, a system supply sensor
(factory supplied) MUST BE installed
with Primary/Secondary piping systems
for proper boiler operation.
Boiler management system
1. An external control may be connected to control either
the firing rate or the set point of the boiler. Connect the
0 - 10 VDC terminals to the 0 - 10 VDC output of the
external control. The SMART TOUCH control can be
enabled using the Enable output (see page 42) or using
the voltage applied to the 0 - 10 VDC input. Reference
the Crest Service Manual for more details.
2. Make sure terminal #34 on the Low Voltage Connection
Board is connected to the (-) or COM output terminal
of the external control, and 0 - 10 VDC terminal #33 is
connected to the 0 - 10 VDC terminal of the external
control.
Runtime contacts
The SMART TOUCH control closes a set of dry contacts
whenever the burner is running. This is typically used by
Building Management Systems to verify that the boiler is
responding to a call for heat.
Alarm contacts
The SMART TOUCH control closes another set of contacts
whenever the boiler is locked out or the power is turned off.
This can be used to turn on an alarm, or signal a Building
Management System that the boiler is down.
System return sensor
1. Install the system return sensor into the return of the
primary loop.
2. Connect the terminals to the system return sensor as
shown in FIG. 7-3.
Wiring of the cascade
When wiring the boilers for Cascade operation, select one boiler
as the Leader boiler. The remaining boilers will be designated
as Members. See page 52 “Configuration of the Cascade” for a
detailed explanation of this procedure.
Connect the system supply sensor and outdoor air sensor (if
used) to the Leader boiler. For the Cascade system to work
properly the system supply sensor must be installed. The
location of the system supply sensor should be downstream
of the boiler connections in the main system loop (FIG.’s 5-2
through 5-5). The system supply sensor should be wired to the
Low Voltage Connection Board at the terminals marked for the
system sensor (see FIG. 7-3). The Leader control will use the
water temperature at the system supply sensor to control the
operation of the Cascade.
If outdoor air reset is desired, the outdoor air sensor should be
wired to the Low Voltage Connection Board at the terminals
marked for the outdoor air sensor (FIG. 7-3). If the outdoor
air sensor is connected, the Leader control will calculate the
water temperature set point based on the programmed reset
curve parameters. If the outdoor air sensor is not connected,
the Leader control will maintain the fixed water temperature set
point that is programmed into the control.
If a Thermostat or Zone Control Enable output is available, it
should be wired to the Low Voltage Connection Board on the
Leader boiler at the terminals marked Enable (FIG. 7-3). If the
boilers are to run continuously, connect a jumper wire between
the R and W terminals for the Enable input. This will initiate a
call for heat on the Cascade.
Communication between the Leader boiler and the Member
boilers is accomplished by using shielded, 2-wire twisted pair
communication cable. Connect one of the twisted pair wires
to Cascade terminal A on each of the Low Voltage Connection
boards, and the other wire of the twisted pair to Cascade
terminal B on each of the Low Voltage Connection Boards.
Connect the shield wires to one of the shield terminals on
the Low Voltage Connection Boards (FIG. 7-3). If more than
two boilers are on the Cascade, daisy chain the wiring from
the Cascade terminals on the second boiler to the Cascade
terminals on the third boiler, then from the third to the forth,
and so on. The connections between boilers can be made in any
order, regardless of the addresses of the boilers. Try to keep
each cable as short as possible.
When the Member 1 boiler is programmed as an alternate
leader this allows the Member 1 boiler to automatically assume
control of the Cascade should it lose communication with the
Leader boiler. When programmed to YES, it is recommended
that the Member 1 boiler have its own set of external sensors
installed (such as the system supply sensor), to maintain the
same level of temperature control as with the Leader boiler.
Voltage signals (such as 0 - 10V system pump speed input) can
be connected to both boilers.
41
Page 42
7 Field wiring (continued)
Figure 7-3 Low Voltage Field Wiring Connections
Installation & Operation Manual
FROM PREVIOUS BOILER
TO NEXT BOILER
TANK SENSOR
SYSTEM SUPPLY SENSOR
TANK
SENSOR
302928
ENABLE
7
8
SYSTEM SUPPLY
LOUVER
9
SENSOR
SYSTEM RETURN
272625
PROVING
LOUVER
10
11
SYSTEM RETURN SENSOR
SENSOR
RELAY
12
BOILER PUMP
-
24
AUX
13
0-10V INPUT
SYSTEM PUMP
SHIELD
ABBASHIELD
B
A
SHIELD
CASCADE
SHIELD
40
393837
OUTDOOR SENSOR
IN
IN
BMS
SENSOR
OUTDOOR
SYSTEM PUMP
+
+
SHIELDBA
-
-
31
36
35
343332
CONTACTS
ALARM
1
THERMOSTAT
RUN TIME
CONTACTS
TANK
2
6
3
4
5
BAS
COMMUNICATION BUS
BOILER PUMP
0-10V OUTPUT
OUT
23
SWITCH 1
14
RATE
-++
22
AUX
15
OUT
21
SWITCH 2
16
SHIELD
B
201918
SHIELDAB
BAS
SHIELD
A
17
42
TANK
SYSTEM
BUILDING
MANAGEMENT
THERMOSTAT
*
DEVICE
ENABLING
LOUVER
PROVING
SWITCH
LOUVER
AUX
RELAY
AUX
SWITCH 1
SWITCH 2
* See page 19 for special instructions when common venting Crest boilers.
Page 43
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 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. Secure the hose to the condensate
trap and the boiler using the factory supplied hose clamps.
4. Connect the 3/8 inch (9.8 mm) fitting to the 3/8 inch (9.8
mm) fitting on the condensate trap (shipped loose) with
the factory supplied silicone hose. Secure the hose to the
condensate trap and the boiler using the factory supplied
hose clamps.
5. The condensate trap must be installed at the same level or
below the boiler base.
6. The condensate trap is sized for a 1" PVC outlet connection
pipe.
7. Plug the wiring connection from the condensate trap into
the connector located on the back of the unit.
8. Slope condensate tubing down and away from the boiler
into a drain or condensate neutralizing filter. Condensate
from the Crest will be slightly acidic (typically with a pH
from 3 to 5). Install a neutralizing filter if required by local
codes.
A neutralizer kit (FIG. 8-1) is available from the factory
(#100157652 / KIT30097). The neutralizer kit must be
placed on a surface that is a minimum of 3 inches lower
than the condensate trap with field supplied piping
(vacuum break) installed between the condensate trap and
the neutralizer kit.
Installation & Operation Manual
9. Do not expose condensate line to freezing temperatures.
NOTICE
NOTICE
10. A condensate removal pump is required if boiler is
below the drain. When installing a condensate pump,
select one approved for use with condensing boilers and
furnaces. The pump should have an overflow switch to
prevent property damage from condensate spillage. The
switch should be wired to the auxiliary device proving
switch terminals on the low voltage connection board.
Use materials approved by the authority
having jurisdiction. In the absence of
other authority, PVC and CPVC pipe
must comply with ASTM D1785 or
D2845. Cement and primer must comply
with ASME D2564 or F493. For Canada
use CSA or ULC certified PVC or CPVC
pipe, fittings, and cement.
To allow for proper drainage on large
horizontal runs, a second line vent may
be required and tubing size may need to
increase to 1 inch (25 mm).
The condensate line must remain
unobstructed, allowing free flow of
condensate. If condensate is allowed to
freeze in the line or if the line is obstructed
in any other manner, condensate can exit
from the boiler tee, resulting in potential
water damage to property.
Figure 8-1 Condensate Disposal
VACUUM
BREAK
DETAIL
FLOOR DRAIN
OR DRAIN PAN
NEUTRALIZER KIT
(OPTIONAL)
3" MINIMUM BELOW
CONDENSATE TRAP
CONDENSATE TRAP
IMG01042
SAME LEVEL OR BELOW
BOILER BASE
43
Page 44
9 Start-up
Installation & Operation Manual
Fill water
Check/control fill water chemistry
IMPORTANT
The manufacturer recommends the following for properly
filling your boiler with the appropriate water chemistry for
closed loop boilers. Good fill water quality will help extend
the life of the appliance by reducing the effects of lime scale
buildup and corrosion in closed loop systems.
Hardness between 5 and 15 grains per gallon
1. Consult local water treatment companies for hard water
areas (above 15 grains per gallon hardness).
2. Hardness levels that are above 15 grains/gallon can lead
to lime scale buildup throughout the boiler system. If the
fill water is below 5 grains/gallons, usually due to use of a
water softener, it is recommended to mix in some potable
water at the inlet to increase the hardness of the water to
above 5 grains/gallons.
pH between 6.5 and 9.5
1. pH levels below 6.5 can cause an increase in the rate of
corrosion. pH of 9.5 or higher can potentially cause lime
scale buildup.
Total Dissolved Solids (TDS) below 2,000 ppm
Conduct water quality testing prior to
installing the appliance. Various solutions
are available to adjust water quality.
Freeze protection
WARNING
1. Use glycol only if needed for freeze protection.
2. Propylene glycol is the recommended freeze protection.
3. Make sure to flush the boiler system before adding glycol.
4. Determine the freeze protection fluid quantity using
system water content, following the fluid manufacturer's
instructions. Boiler water content is listed on page 6.
Remember to include expansion tank water content.
5. Local codes may require a backflow preventer or actual
disconnect from city water supply.
6. When using freeze protection fluid with automatic fill, it is
suggested to install a water meter to monitor water makeup.
Freeze protection fluid may leak before the water begins to
leak, causing the concentration to drop, which reduces the
freeze protection level.
7. The freeze protection set points may be lowered when freeze
protection fluid is used (see the Crest Service Manual).
8. Consult the glycol manufacturer for details on the suggested
mix of glycol and water for the desired freeze protection
level and the de-rate effect it will have on the boiler output.
Ethylene glycol is toxic, DO NOT use as
your freeze protection. Ethylene glycol has a
sweet aroma which children and pets could
mistake as food and ingest; leading to death.
1. Total dissolved solids are all minerals, salts, metals, and
charged particles that are dissolved in water.
2. The greater the amounts of TDS present, the higher the
corrosion potential due to increased conductivity in the
water.
3. If using softened water to fill the boiler, it is still possible
to have high TDS. This water can be corrosive. It is
recommended to mix in some potable water with the
softened water to reduce this affect.
Chlorine concentration less than 200 ppm
1. Do not fill boiler or operate with water containing
chlorine in excess of 200 ppm.
2. Filling with fresh drinking water should be acceptable.
3. Do not use the boiler to directly heat swimming pool or
spa water.
Test / replace freeze protection fluid
1. For systems using freeze protection fluids, follow the fluid
manufacturer's instructions.
2. Freeze protection fluid must be replaced periodically due to
degradation of inhibitors over time.
3. It is recommended to test the glycol concentration annually
and adjust within the desired set points.
44
Page 45
9 Start-up (continued)
Installation & Operation Manual
Oxygen prevention
CAUTION
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 level
combined with oxygen further enhances its corrosive effects.
After boiler installation, check for air leaks in the following
areas:
• Suction gasket
• Pump
• Air valve
• O-ring gaskets
Precautions include installing a water meter to evaluate the
fresh water volume entering the system. Additional volumes
of fresh water could indicate that a leak is present.
Eliminate all system leaks. Continual
fresh makeup water will reduce boiler
life. Minerals can build up in the
heat exchanger, reducing heat transfer,
overheating the heat exchanger, and
causing heat exchanger failure.
Boiler water
CAUTION
• Monitoring pH, TDS and hardness levels can
prolong the life of the appliance by reducing lime
scale buildup, corrosion, and erosion. Check for
leaks to ensure that fresh water is not entering the
system.
• 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.
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 boiler, personnel, and/or
property may result.
Fill and test water system
1. Fill system only after ensuring the water meets the
requirements of this manual.
2. Close automatic and manual air vents and boiler drain
valve.
3. Fill to correct system pressure. Correct pressure will vary
with each application.
a. The minimum cold water fill pressure for a system is
12 psi.
b. Pressure will rise when the boiler is turned ON and
system water temperature increases.
4. At initial fill and during boiler startup and testing, check
the system thoroughly for any leaks. Repair all leaks before
proceeding further.
Purge air from water system
1. Purge air from system:
a. Connect a hose to the purge valve (see purge/drain
valve in the piping diagrams on pages 31 through 34).
Route the hose to an area where water can drain and be
seen.
b. Close the boiler or system isolation valve between the
purge valve and fill connection to the system.
c. Close zone isolation valves.
d. Open the quick-fill valve on the cold water makeup
line.
e. Open purge valve.
f. Open the isolation valves one zone at a time. Allow
water to run through the zone, pushing out the air.
Run until no noticeable air flow is present. Close
the zone isolation valves and proceed with the next
zone. Follow this procedure until all zones are purged.
g. Close the quick-fill water valve and purge valve and
remove the hose. Open all isolation valves. Watch that
system pressure rises to correct cold-fill pressure.
h. After the system has operated for a while, eliminate
any residual air by using the manual air vents located
throughout the system.
i. If purge valves are not installed in the system, open the
manual air vents in the system one at a time, beginning
with the lowest floor. Close the vent when water
squirts out. Repeat with remaining vents.
2. Open the automatic air vent (diaphragm-type or bladder
type expansion tank systems only) one turn.
• The addition of oxygen carried in by make-up water
can cause internal corrosion in system components.
• Leaks in the boiler or piping must be repaired at
once to prevent make-up water. It could be helpful
to install a water meter for this purpose to easily
check the amount of make-up water entering the
system.
3. Open other vents:
a. Starting on the lowest floor, open air vents one at a
time until water squirts out.
b. Repeat with remaining vents.
4. Refill to correct pressure.
45
Page 46
9 Start-up
Installation & Operation Manual
Check for gas leaks
WARNING
WARNING
Figure 9-1 Condensate Trap
TO FLOOR DRAIN
OR NEUTRALIZER KIT
1” PVC / CPVC CONNECTION
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.
DO NOT adjust or attempt to measure
gas valve outlet pressure. The gas valve is
factory set for the correct outlet pressure.
This setting is suitable for natural gas and
propane, requiring no field adjustment.
Attempting to alter or measure the gas
valve outlet pressure could result in
damage to the valve, causing potential
severe personal injury, death, or
substantial property damage.
FROM CONDENSATE
VENT ON BOILER
FROM CONDENSATE
DRAIN ON BOILER
WARNING
Propane boilers only – Your propane
supplier mixes an odorant with the propane
to make its presence detectable. In some
instances, the odorant can fade, and the
gas may no longer have an odor. Before
startup (and periodically thereafter), have
the propane supplier verify the correct
odorant level in the gas.
Check thermostat circuit(s)
1. Disconnect the two external wires connected to the
enable terminals on the connection board.
2. Connect a voltmeter across these two incoming wires.
Close each thermostat, zone valve, and relay in the
external circuit one at a time and check the voltmeter
reading across the incoming wires.
3. There should NEVER be a voltage reading.
4. If a voltage does occur under any condition, check and
correct the external wiring. (This is a common problem
when using 3-wire zone valves.)
5. Once the external boiler enable wiring is checked and
corrected if necessary, reconnect the external thermostat
circuit wires to the connection board. Allow the boiler to
cycle.
Inspect condensate system
Inspect/check condensate lines and fittings
1. Inspect the condensate drain line, condensate PVC
fittings and condensate trap.
46
Page 47
9 Start-up (continued)
Installation & Operation Manual
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 of water and all
system components are correctly set for operation.
Verify the preparation procedures of Section 9, pages 44
- 46 have been completed.
Verify electrical connections are correct and securely
attached.
Inspect vent piping and air piping for signs of deterioration
from corrosion, physical damage or sagging. Verify air
piping and vent piping are intact and correctly installed
per this manual.
Start the boiler
1. Read and follow the Operating instructions in FIG. 9-2,
page 48.
If boiler does not start correctly
1. Check for loose connections, blown fuse or service switch
off?
2. Is external limit control (if used) open? Is boiler water
temperature above 200°F (93°C)?
3. Is the boiler receiving a call for heat?
4. Is gas turned on at meter and boiler?
5. Is incoming gas pressure less than 4 inches w.c. (.99 kPa)?
6. Ignition problems are especially noticeable in new LP
installations and also in empty tank situations. This can
also occur when a utility company shuts off service to an
area to provide maintenance to their lines.
Check vent piping and air piping
1. Check for gastight seal at every connection, seam of air
piping, and vent piping.
WARNING
Check gas piping
1. Check around the boiler for gas odor following the
procedure on page 35 of this manual (connecting gas
supply piping).
WARNING
Venting system must be sealed gastight
to prevent flue gas spillage and carbon
monoxide emissions, which will result in
severe personal injury or death.
If you discover evidence of any gas leak,
shut down the boiler at once. Find the
leak source with a bubble test and repair
immediately. Do not start the boiler again
until corrected. Failure to comply could
result in severe personal injury, death, or
substantial property damage.
Check flame and combustion
NOTICE
1. Turn the main power off to the boiler by placing the
“On/Off” switch in the OFF position.
2. Remove the fitting from the flue collector. Note:
Combustion measurements will be made at this point.
3. Turn the main power on to the boiler by placing the “On/
Off” switch in the ON position.
For dual fuel models, reference the Crest
Dual Fuel Supplemental Manual.
If none of the above corrects the problem, refer to the
Troubleshooting Section of the Crest Service Manual.
Check system and boiler
Check water piping
1. Check system piping for leaks. If found, shut down the
boiler and repair immediately. (See WARNINGS on
pages 44 - 46 (startup) regarding failure to repair leaks.)
2. Vent any remaining air from the system using manual
vents. Air in the system will interfere with circulation
and cause heat distribution problems and noise.
47
Page 48
9 Start-up
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.
Installation & Operation Manual
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. B E FORE OPERATI NG sme ll a ll ar ound
the a pp liance are a fo r ga s. Be sure to
smell next to the floor because some gas
is heavier than air and will settle on the
floor.
WHAT T O DO IF YOU SMELL GAS
• D o not tr y to lig ht any ap pl ianc e.
• D o not touch any electric switch; do
not us e any ph on e i n your b ui lding.
OPERATING INSTRUCTIONS
1. STOP! Read the safety information
above on this label.
2. Set the thermostat to lowest setting.
3. Turn off all electric power to the
applia nc e.
4. T his appliance is equi pped with an
ign ition device w hich automatically lights
the burner. Do not try to light the burner
by ha nd .
5. Remove front door.
6. Turn gas shutoff valve counterclockwise
to “OFF”. H an dle wil l be perpendicu lar to
pipe. Do not force.
7. Wait five (5) minutes to clear out any gas.
If you then smell gas, ST OP! Follow “B”
in the safety information above this label.
If you don’t smell gas, go to next step.
• Immediately call your gas supplier from a
neig hbor ’s phone. Fol lo w t h e gas supplie r’s
instr uctions.
• If yo u cann ot re ach you r ga s sup pl ier, ca ll
the fire department.
C. Use only your hand to turn the gas control knob.
Never use tools. If the handle will not turn by
hand, do n’t t ry to repair i t, ca ll a qualifie d service
technician. Force or attempted repair may
result in a fire or expl osion.
D. Do n ot use t his applia nce if any part has be en
under wa ter. Immediately c all a qu al ified
ser vice technician to inspe ct th e a pp liance and
to replace any part of the control system and
any ga s co n tr ol w hich ha s been under water.
8. Tur n g as sh ut off val ve clo ckwise to “ O N”.
Handle will be parallel to pipe.
9. Instal l front door.
10. Turn on all electric power to appliance.
11. Se t thermostat to desire d setti ng .
12. If the appl iance w ill not op er ate, fol low the
instr uctions “T o Tu rn Off G a s T o Applia nce ” and
call your service technician or gas supplier.
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to lowest setting.
2. Turn off all e le ctric po wer to the ap pl iance
if se rvice i s t o be performe d.
3. Remove front door.
48
4. Turn gas shut off valve counterclockwise to
“OFF”. Handle will be perpendicular to pipe.
Do not force.
5. Instal l front door.
L BL2 005 3 REV B
Page 49
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 to the SERVICE
MAINTENANCE button as shown in FIG. 9-3.
5. On the Service Maintenance 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 fitting.
7. Once the boiler has modulated up to rate, measure the
combustion. The values should be in the range listed in
Table 9A (this page). CO levels should be less than 200
ppm for a properly installed unit. If the combustion is
not within range reference the Troubleshooting Section
in the Crest Service Manual for possible causes and
corrective actions.
Installation & Operation Manual
Table 9A Flue Products Chart
Flue Products
Gas Valve
Valve 1 High 9.2 4.6
Valve 1 Low 9.0 4.9
Valve 2 High 9.3 4.4
Valve 2 Low 8.7 5.5
Valve 1 High 11.0 4.1
Valve 1 Low 10.0 5.6
Valve 2 High 11.1 4.0
Valve 2 Low 10.7 4.6
**All set points should be within +/- 0.2%**
8. Once the heater analysis is complete, test the safety shutoff
device by turning the manual shutoff valve to the OFF
position and ensuring the heater shuts down and registers
an alarm. Open the manual shutoff valve and reset the
control.
9. Turn the main power off to the boiler and replace the
fitting into the flue pipe connection.
10. Ensure the boiler is placed back into normal operation.
Natural Gas
CO2 (%) O2 (%)
Propane
Figure 9-3 Service Maintenance Screen
SCROLLING
MENU FEATURE
SETUP BUTTON
WARNING
You must replace the fitting to prevent flue
gas spillage into the room. Failure to comply
could result in severe personal injury, death,
or substantial property damage.
SERVICE
MAINTENANCE
BUTTON
49
Page 50
9 Start-up
Installation & Operation Manual
Set space heating operation
Verify space heat circulator mode
The system pump output can be programmed to never run
(OFF), run only when a space heating demand is present
(ON), or run continuously except during warm weather
shutdown (WWSD). If the boiler is not heating an indirect
HW (Hot Water Generator) tank, it also turns on the boiler
pump. After the space heating call for heat ends, and the
system pump is programmed as ON, the system pump
continues to run for a short period of time. If the boiler
pump was running, it continues to run for a short period
of time as well. These pump delays are factory set to 30
seconds. If different delays are desired, the appropriate
parameters in the control must be changed. See the Crest
Service Manual for a detailed explanation of this procedure.
Figure 9-4 Set Point Screen
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 set point slider feature
or the PLUS (+) and MINUS (-) buttons
to adjust the set points as shown in FIG. 9-4.
2. Once the set point has been adjusted to the desired
setting, press the SAVE button to save changes to the set
point and return to the Home Screen.
Note: The SAVE button must be pressed to ensure proper
programming of the controls. Failure to press the SAVE
button will require all changes to be reprogrammed.
SET POINT SLIDER
DETAILS
BUTTON
SAVE BUTTON
50
Page 51
9 Start-up (continued)
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 off the boiler pump (if running), and
modulate to bring the outlet temperature to the HW boiler
set point. The maximum firing rate may be limited in this
mode if desired.
In Zone Mode it is assumed that the indirect HW tank is
piped as a zone on the primary loop. When a HW demand
begins, the control will turn on the HW pump output, and
raise the system temperature set point to the HW boiler set
point (if higher). The boiler pump will be turned on. The
system pump may be forced on, forced off, or not changed,
depending on the System Pump Mode selected (reference
the Crest Service Manual for details). In this mode, any
low temperature zones (such as radiant heating) may need
additional controls to limit the water temperature sent to
those zones.
Set HW boiler target temperature
When in the HW Mode, the control will modulate to maintain
the boiler outlet temperature or system supply temperature to
a set point. This set point is set at the factory to 180°F. If a
different set point is desired, the appropriate parameter in the
control must be changed. See the Crest Service Manual for a
detailed explanation of this procedure.
Set maximum HW fan speed
If the rated input of the indirect tank is less than the maximum
output of the boiler, change the maximum HW fan speed
setting to limit the boiler output accordingly, see the Crest
Service Manual for a detailed explanation of this procedure.
Set clock
The SMART TOUCH control has a built-in clock that it uses
for its night setback feature and for logging events. This clock
must be set when the boiler is installed, and anytime the boiler
has been powered off for more than one day. Use the following
procedure to set the clock:
1. Press the SETUP button (see FIG. 9-5).
2. Enter the installer password.
Figure 9-5 Rapid Setup Screen
SCROLLING
MENU FEATURE
RAPID SETUP
BUTTON
3. Press the RAPID SETUP button in the menu on the left.
4. Press the SET button next to the time and date on the
Rapid Setup Screen as shown in FIG. 9-5.
SET BUTTON
51
Page 52
9 Start-up
Configuration of the cascade
Note: For more detailed instructions, please refer to the Crest
Service Manual.
When installed in a Cascade system, the individual controls
must be programmed for cascade operation. Access the
Cascade Setup options as follows:
1. Press the SETUP button on the top of the display screen.
2. Enter the installer password.
3. Scroll through the scrolling menu feature to access the
Cascade option as shown in FIG. 9-6.
4. Press the CASCADE button.
5. Once all the updates are complete, press the SEND
UPDATE button at the top of the screen (FIG. 9-6) to save
changes.
Note: The SEND UPDATE button must be pressed to
ensure proper programming of the controls. Failure to press
the SEND UPDATE button will require all changes to be
reprogrammed.
Installation & Operation Manual
Figure 9-6 Cascade Screen
SCROLLING
MENU FEATURE
CASCADE
BUTTON
SEND UPDATE
BUTTON
SETUP
BUTTON
52
Page 53
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 blower pulls in air and pushes flue products
out of the boiler through the heat exchanger and flue piping.
The control module regulates blower speed to control the
boiler firing rate. The gas valves sense the amount of air
flowing into the boiler and allow only the right amount of
gas to flow.
How the control modules operate
The Crest boiler is equipped with a SMART TOUCH control
module. The SMART TOUCH control module receives
inputs from boiler sensors and external devices. The control
module activates and controls the blower and gas valves
to regulate heat input and switches the boiler, Hot Water
Generator (HW), and system pumps on and off as needed.
The user programs the control module to meet system needs
by adjusting control parameters. These parameters set
operating temperatures and boiler operating modes.
Control inputs and outputs
Enable
This input tells the boiler to provide water for space heating.
Hot Water Generator (HW) tank thermostat
This input tells the boiler to provide water for heating an
indirect HW tank.
0 - 10V BMS input (set point or power)
The Crest can be controlled by a Building Management
System (BMS) using a 0 - 10 VDC signal. The control can be
configured by the installer to use this signal to either control
set point or firing rate.
0 - 10V System Pump speed input
When a variable speed system pump is used, and there is a
0 - 10V signal available from the pump speed control, this
signal may be connected to the boiler. Doing so will allow
the boiler to anticipate changes in the BTU’s needed by the
system as the system flow changes, and therefore, help the
boiler to maintain the desired system temperature. Connect
the - input terminal to the COM or - output terminal on the
pump speed control, and the + input terminal to the 0 - 10V
or + output terminal on the pump speed control. Note that
the voltage on these inputs must never go below ground.
Installation & Operation Manual
HW priority
The SMART TOUCH control allows the connection of a HW
thermostat or tank sensor to the low voltage connection board.
When a tank sensor is connected, the HW thermostat input is
ignored. When a boiler is programmed for HW Normal Mode,
the maximum firing rate can be limited to match the input
rating of the indirect tank coil.
HW / space heating (SH) cycling
If a HW call for heat is received while a space heating call is in
progress, and the HW is in Normal Mode, the control will start
the HW pump and shut the boiler pump off. The system pump
will remain on. For stand-alone boilers, if the space heating call
is still active while the HW call is in operation, the control will
wait for 30 minutes (time adjustable by installer) then it will
switch back to the space heating demand. There is a timer to
switch from space heating to HW and a timer to switch from
HW to space heating. The control will switch back and forth
until one of the heat demands end. This function does not apply
to cascade systems.
Controlling sensor
The control module is programmed to use the outlet sensor
as the control sensor by default. If a system supply sensor
is connected, the control automatically uses it as the control
sensor. The control module may be programmed to use the inlet
sensor as the control sensor instead. In this case, the control
will use the system return sensor if it is connected.
Anti-cycling
After a space heating demand has been satisfied, the control will
delay the next space heating call for a set time period (time is
adjustable by the installer). The time delay will be bypassed if
the inlet water temperature drops too far during the delay.
Boiler, system, and HW pump control
When a space heating call for heat starts and no HW call is on,
the boiler pump is turned on. The system pump will turn on
also if it is programmed to do so. If a HW call for heat is on, the
boiler pump will wait to turn on until just before the HW pump
turns off. After the space heating call for heat ends, the boiler
pump will run for an additional period of time.
When a HW call for heat starts, the HW pump is turned on. If
a space heating call for heat is on, the boiler pump will turn off
a few seconds after the HW pump turns on.
Louver
When the boiler needs to control combustion air louvers,
connect a 24 VAC louver relay to the two (2) Louver Relay
terminals. Connect the Louver End Switch to the Louver
Proving Switch input on the Low Voltage Connection Board.
Temperature control
Modulation
The Crest is capable of modulating its firing rate from a
minimum of 4-6% (depending on model) to a maximum of
100%. The firing rate is dictated by the call for heat (i.e., space
heating or hot water generation), the heating load, ramp delay
(if enabled), and various other temperature limitations.
53
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10 Operating information
Gradient limiting
If during operation of the boiler the outlet water temperature
is rising too quickly, the control will reduce the firing rate to
its lowest setting.
Outdoor air reset
If an outdoor air sensor is connected, the control module
will calculate the set point based on the programmed reset
curve. The installer can change the slope of the reset curve
by several adjustable parameters. The user can limit the
maximum set point for the system using the space heating
set point.
Boost function
If outdoor air reset is active, the boost temperature is not
0, a space heating demand has been active continuously for
a set period of time (time adjustable by installer) and there
has been no HW demands, the control will increase the set
point by a fixed number of degrees (adjustable by installer).
This process will continue until the space heating demand
ends, the set point reaches the programmed set point or a
maximum of 20 increases has occurred. Once the system
heat demand is satisfied, the set point will revert to the value
determined by the reset curve.
Night setback
The controller may be programmed to reduce the space
heating set point and/or Hot Water Generator set point for
each demand during a certain time each day. A start and
stop time for each demand can be programmed for each day
of the week. The controller can be programmed to reduce
the tank set point as well. A different set of start and stop
times can be programmed each day of the week.
Flame current support
To prevent nuisance shutdowns when the boiler is firing at
minimum rates, the control will increase the firing rate when
the flame signal drops too low.
ModBus / BACnet
The Crest boiler can be connected to and controlled by a
Building Automation System through a ModBus or BACnet
interface. Connect the A and B wires to the A and B
terminals. If connecting another cable (in a daisy chain),
connect the shield wire of the first cable to one of the shield
terminals, and the shield wire of the second cable to the other
shield terminal. If it is desired to ground the cable shield
at the heater, connect the shield wire to one of the shield
terminals, and install a jumper across the two (2) terminals
in connector X5 on the ModBus / BACnet interface board.
Installation & Operation Manual
Ramp Delay
For systems with lower flow, the SMART TOUCH can limit
the firing rate (when enabled) when a space heating call for
heat starts, or when switching from a DHW call for heat to a
space heating call for heat. There are six (6) limits that can be
programmed, as well as six (6) time intervals corresponding to
each limit. The sixth limit will also limit the firing rate for the
rest of the call for heat.
Protection features
Outlet temperature, flue temperature, and temperature
rise limiting
The outlet water temperature is monitored by the boiler outlet
temperature sensor. When the outlet temperature exceeds
185°F, the unit will reduce the fan speed. If the outlet water
temperature exceeds 195°F (90°C) the control will shut the unit
down until the minimum off time has expired and the outlet
drops 10°F (5.5°C).
The control module monitors the flue temperature by a sensor
located in the flue exhaust. If the flue temperature exceeds
215°F (101°C) the control will reduce the maximum fan speed.
If the flue temperature exceeds 250°F (121°C) the control will
shut the unit down. The unit will restart automatically once
the flue temperature drops 50°F (27°C) and the minimum off
time has expired.
The control monitors the temperature difference between
the inlet and the outlet sensor. If this difference exceeds
70°F (21°C) the control will reduce the fan speed. If the
temperature difference exceeds 80°F (27°C) the control will
shut the unit down. The unit will restart automatically once
the temperature difference has dropped below 50°F (28°C) and
the minimum off time has expired.
Freeze protection
DO NOT install the boiler in a room likely to freeze.
The following integral feature of the SMART TOUCH control
module provides some protection for the boiler only -- not for
the system.
• The SMART TOUCH control module provides
freeze-up protection as follows when the boiler
water temperature drops below 45°F (7°C):
• Below 45°F (7°C), the boiler and system pumps (if
enabled) operate constantly.
• Below 37°F (3°C), the boiler turns on.
• Boiler and pumps turn off if boiler water
temperature rises above 43°F (6°C).
0-10V Rate output
A 0-10V signal which indicates the firing rate of the heater
is available. This output may be connected to a Building
Management System (BMS) to allow it to monitor the actual
firing rate. Connect the - terminal to the COM or - terminal
on the BMS, and connect the + terminal to the 0 - 10V or +
terminal on the BMS.
54
CAUTION
This feature of the SMART TOUCH control
module does not eliminate the possibility
of freezing. The installation must still
use recognized design, installation and
maintenance practice to prevent freeze
potential for the boiler and system.
Page 55
10 Operating information (continued)
Installation & Operation Manual
Monitor external limits
Connections are provided on the connection board for
external limits such as an additional high limit. The
SMART TOUCH control will shut off the burner and
inhibit relighting whenever any of these external limits
open.
Run-time and alarm outputs
The boiler provides dry contacts for indicating when the
boiler is running, and when it is unable to operate.
Run-time and cycle counting
The control uses four timers to monitor the total hours of
burner operation:
75 - 100% 50 - 75%
25 - 50% <25%
The control uses four (4) ignition counters to monitor
the amount of boiler cycles. The first counter counts all
ignitions of the control. The second counter counts only
ignition attempts that have failed. The third and fourth
counters are the same as the first and second respectively,
but can be reset by the installer.
Service reminder
The control can be programmed for service reminder
notification. This notification will become active when
either a set amount of time has expired, or a set amount of
running hours or cycles has expired (all adjustable by the
installer). The service reminder notification can be reset
by the installer. The service company’s name and phone
number can be programmed to display when service is due.
Error logging
The control will hold in memory the last 10 blocking faults
as well as the last 10 lockout faults. The date and time of
the occurrence will be recorded as well. Only the 10 most
recent occurrences will be held in memory.
High limit operations
The Crest SMART TOUCH control has two (2) integral limits,
one auto reset and one manual reset. The Crest also has one
auxiliary manual reset high limit. The integral and auxiliary
high limits are UL353 certified.
When the outlet temperature exceeds 195°F (90.6°C) (Installer
Adjustable Parameter), integral auto reset high limit action
occurs. The boiler will shut down until the outlet water cools
down and the timer expires.
If the outlet temperature exceeds 200°F (93.3°C) (User
Adjustable Dial), auxiliary manual reset high limit action
occurs. The boiler will shut down until the outlet water cools
down and the boiler is reset through the user interface.
If the outlet temperature exceeds 205°F (93.3°C) (Installer
Adjustable Parameter), integral manual reset high limit action
occurs. The boiler will shut down until the outlet water cools
down and the boiler is reset through the user interface.
Low water cutoff protection
A low water cutoff device with test and reset functionality is
provided in the boiler as standard equipment.
Flow sensing device
The SMART TOUCH control module uses temperature sensing
of both supply and return temperatures of the heat exchanger.
If the flow rate is too low or the outlet temperatures too high,
the control module modulates down and will shut the boiler
off. This ensures boiler shutdown in the event of low flow
conditions.
NOTICE
If a mechanical flow switch is required to
meet local code requirements the Crest
boiler can be equipped with a field supplied
outlet flow switch. Please wire to the Louver
Proving Switch terminals.
Outdoor reset operation, if used
Boiler temperature regulation
Operating temperature (target)
The SMART TOUCH control module senses water
temperature and regulates boiler firing and firing rate to
achieve a target temperature. The target temperature can
be set between 32°F (0°C) and 185°F (85°C).
• Target temperature is fixed when the outdoor
sensor is not installed.
• Target temperature is calculated as described
under “Outdoor Reset Operation” and “Target
Temperature Boost” when the outdoor sensor is
connected.
Target temperature with outdoor reset
This feature improves the system’s efficiency as the outdoor
temperature warms up.
See the Crest Service Manual to change the settings.
Reset curve
The reset curve looks at outdoor air temperature and adjusts
the set point.
55
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10 Operating information
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 and all others
would be designated as Member controls.
Once the Leader boiler receives a call for heat from the Enable
input, the 0 - 10 VDC input, ModBus or BACnet, the control
will determine what the set point will be. If outdoor air reset
is desired, connect the outdoor air sensor to the terminals on
the Low Voltage Connection Board on the Leader boiler. The
set point will be calculated based on the programmed reset
curve parameters. See the Crest Service Manual to program
the reset curve. If outdoor air reset is not desired, do not
connect the outdoor air sensor. A fixed temperature set point
can be programmed into the control, or provided through the
ModBus or BACnet interface.
If the water temperature at the controlling sensor is less than
the set point + the turn-off offset - the off-on differential, the
control will initiate a call for heat on the Cascade (see the
Crest Service Manual for an explanation of the offset and
differential). The Leader will energize the lead boiler on the
Cascade. For a new startup this will be the Leader boiler.
The two (2) types of Cascade control are listed below:
Efficiency optimization
Efficiency optimization is chosen when the application is such
that overall heating efficiency is most important. The Cascade
will fire the boilers in a way that is the most efficient. This
allows more boilers to fire at one time, at a lower rate, thus
more efficient. This Cascade is NOT allowed in a common
vent application.
Lead/Lag
The Lead/Lag method is chosen when the application requires
firing as few boilers at a time as possible. This method will not
bring on another boiler until the current number of boilers
cannot meet the demand. This Cascade is also required when
cascading boilers in a common vent application.
Sequence of the cascade
To equalize the run time of all boilers on the Cascade, the
firing sequence will automatically be changed at set intervals.
For the first 24 hours after initializing the Cascade, the
sequence will be changed every hour. After that the sequence
will be changed once every 24 hours.
HW operation with cascade
For normal mode HW operation any boiler(s) in the Cascade
can be selected to provide heat for a HW call. Select a boiler to
be designated as the HW boiler. Connect the HW thermostat
or sensor to the terminals on the Low Voltage Connection
Board marked for the corresponding device. When the boiler
receives a HW call, the Leader control will take that boiler
out of the Cascade sequence. If another boiler is available, the
Leader will start it up to take its place.
The HW boiler will adjust its set point to the programmed
HW boiler set point and will adjust its firing rate to maintain
this. Once the HW call has been satisfied, the Leader control
will place that boiler back into the Cascade sequence.
Switching of the boiler between HW operation and SH
operation when there is a call for both does not occur in
Cascade Mode.
When HW is programmed for Zone Mode, connect the HW
thermostat or tank sensor to the Leader boiler. When a HW
call is received, the Leader will modulate the entire Cascade
to bring the system supply temperature up to the HW boiler
set point (if higher).
Night Setback and Ramp Delay operations with
cascade
Night Setback and Ramp Delay operation of the boilers within
the Cascade are available. Programming will be done through
the Leader boiler. Refer to the Crest Service Manual for
information regarding Night Setback and Ramp Delay.
The parameters for both types of Cascade are adjustable.
Reference the Crest Service Manual for a more detailed
description of these adjustments.
56
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10 Operating information (continued)
Sequence of operation
Upon a call for heat, the control turns on the appropriate pumps (system and boiler pumps for a space heating call,
1.
HW pump for a hot water generator call).
The control confirms that the low water cutoff contacts are closed and energizes the louvers (optional) and damper
2.
(optional) relays.
The control confirms that the gas pressure switch, blocked drain switch, limits, louver proving switch (optional) and
3.
damper proving switch (optional) contacts close. The Pre-Purge cycle begins.
The control confirms the blower is up to the desired speed, and the air pressure switch is closed.
4.
Once the Pre-Purge cycle is complete, the control lowers the blower speed, closes the air metering valve, initiates
5.
sparking of the ignition electrode, and opens the gas valve.
After a short wait, the control stops sparking and checks for the presence of flame current through the flame sense
6.
electrodes.
Installation & Operation Manual
7.
8.
9.
10.
11.
12.
If flame is not detected after the sparking ends, the control will perform a postpurge, then start another prepurge cycle
and try to light the burner again.
If the control detects flame current, the control will hold the blower speed constant for a few seconds to allow the
flame to stabilize, then begin modulating the firing rate in order to maintain the controlling sensor to the desired set
point temperature.
If the current call for heat is for space heating and a HW call for heat becomes active, the control will turn on the HW
pump relay output, then turn off the boiler pump. It will then modulate the blower speed in order to maintain the
outlet temperature to the desired HW outlet set point temperature (Normal Mode Only).
If the small gas valve in the boiler is unable to maintain the desired set point temperature, the control will transition
to the large gas valve. The blower will modulate to a set speed, the air metering valve will be opened, the large gas
valve will be turned ON, the small gas valve will be turned OFF, and the spark igniter will be turned ON if the flame
current is low and the fan speed is held constant for a few seconds in order to re-establish the flame across the entire
burner surface. If the heat load should decrease sufficiently, this process is reversed, and the small gas valve is used.
Once both the space heating and HW calls for heat are satisfied, the control will turn off the gas valve and begin the
Post-Purge cycle. Any pumps that are running will begin their respective Pump Delay cycles. The air metering valve
will be opened.
At the end of the Post-Purge cycle, the louver relay contacts will de-energize.
13.
At the end of the Pump Delay cycle(s), the pump(s) will be turned off.
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Installation & Operation Manual
10 Operating information
w/Crest CON•X•US Interface (CCI)
The Home Screen displays the available basic system information. It is divided into the following sections: Status, System, Boiler,
Modulation, and Navigation.
Figure 10-1 Home Screen
• The System Section is located in the middle of the screen
and displays exterior sensor data. If hooked up it will
display the following: Outdoor Air, Hot Water Temp,
System Supply Temperature, and System Return
Temperature.
• The Boiler Section is located in the lower middle of the
screen and displays sensor data for those sensors installed
in the factory as follows: Inlet, Outlet and
Delta Water Temperature, Outlet Water Temperature,
Flue Temperature, Flame Currents, and Premix Air
Temperatures.
• The Modulation Section is located on the right of the
screen and displays the target modulation of the unit.
• The Status Section is located on the left of the screen and
displays how the unit is currently running (i.e. Off, Stand by, Blocking, and Lockout) including: the Power Button,
current driving demand (i.e. Space Heat or Hot Water),
the next Space Heat or Hot Water Setback scheduled, the
reason for any blocking or lockout, and the current set
point temperature with a button that allows you to
change the set points.
• 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 several screens that allows you to view sensor
data. The View Screens consists of Boiler, Modulation,
Pump, Cascade, BMS/BAS, Graph, History, and Service
Notes. The Setup Screen has several screens to aid in
setting up the boiler. The Setup Screens consist of Set
Points, Rapid Setup, Advance Setup, HW Night Setback,
Service Maintenance, Service Notification, and BAS. There
is also a HELP button located on the right side of the
screen along with an expanded HELP option (About, Save/
Load Parameters - also known as Loch’n Load, System
Update, and Wifi Setup).
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11 Maintenance
Maintenance and annual startup
Table 11A Service and Maintenance Schedules
Installation & Operation Manual
Service technician
(see the following pages for instructions)
General:
• Address reported problems, if any
• Inspect interior; clean and vacuum if
necessary;
• Clean condensate trap and fill with fresh
water
• Check for leaks (water, gas, flue,
condensate)
• Verify flue and air lines in good condition
and sealed tight
• Check system water pressure/system
piping/expansion tank
• Check control settings
• Check the ignition and both flame sense
electrodes (sand off any deposits; clean
and reposition)
• Check wiring and connections
Owner maintenance
(see the Crest User’s Information Manual for
instructions)
• Check boiler area
Daily
Monthly
• Check pressure/temperature
gauge
• Check vent piping
• Check air piping
• Check air and vent termination
screens
• Check relief valve
• Check condensate drain system
• Perform start-up checkout and
performance verification per Section 9.
ANNUAL START-UP
• Flame inspection (stable, uniform)
• Check both flame signals (at least 10
microamps at high fire)
• Clean the heat exchanger
• Test low water cutoff (reference the
Crest Service Manual).
If combustion or performance
indicate need:
• Clean heat exchanger
• Remove and clean burner using
compressed air only
• Clean the blower wheels
Every
6 months
End
of season
months
• Test low water cutoff
• Reset button (low water
cutoff)
• Check boiler piping (gas and
water) for leaks
• Operate relief valve
• Shut boiler down (unless boiler
used for domestic hot water)
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11 Maintenance
Installation & Operation Manual
WARNING
WARNING
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.
The boiler should be inspected annually only by a qualified service technician. In addition, the maintenance
and care of the boiler designated in Table 11A and explained on the following pages must be performed to
assure maximum boiler efficiency and reliability. Failure to service and maintain the boiler and system could
result in equipment failure.
Electrical shock hazard – Turn off power to the boiler before any service operation on the boiler except as
noted otherwise in this instruction manual. Failure to turn off electrical power could result in electrical shock,
causing severe personal injury or death.
Address reported problems
1. Inspect any problems reported by the owner and correct
before proceeding.
Inspect boiler area
1. Verify that boiler area is free of any combustible materials,
gasoline and other flammable vapors and liquids.
2. Verify that air intake area is free of any of the contaminants
listed in Section 1 of this manual. If any of these are
present in the boiler intake air vicinity, they must be
removed. If they cannot be removed, reinstall the air and
vent lines per this manual.
Inspect boiler interior
1. Remove the front access covers and inspect the interior
of the boiler.
2. Vacuum any sediment from inside the boiler and
components. Remove any obstructions.
Clean condensate trap
1. Inspect the condensate drain line, vent line, condensate
PVC fittings, and condensate trap.
Flush condensate trap with water
1. Remove the four (4) screws securing the top cover to the
condensate trap and remove the cover (FIG. 11-1).
2. Locate the plastic ball inside the float tube. Verify there
is nothing under the ball causing it to not seat properly.
3. Fill with fresh water until the water begins to pour out of
the drain.
4. Replace the top cover and the screws removed in Step 1.
Figure 11-1 Condensate Trap
Check all piping for leaks
WARNING
1. Inspect all water and gas piping and verify to be leak free.
2. Look for signs of leaking lines and correct any problems
found.
3. Check gas line using the procedure found in Section 6
- Gas Connections.
Eliminate all system or boiler leaks.
Continual fresh makeup water will
reduce boiler life. Minerals can build up,
reducing heat transfer, overheating heat
exchanger, and causing heat exchanger
failure. Leaking water may also cause
severe property damage.
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.
WARNING
Failure to inspect for the above conditions
and have them repaired can result in
severe personal injury or death.
Check water system
1. Verify all system components are correctly installed and
operational.
2. Check the cold fill pressure for the system. Verify it is
correct (must be a minimum of 12 psi (82.7 kPa)).
3. Watch the system pressure as the boiler heats up (during
testing) to ensure pressure does not rise too high.
Excessive pressure rise indicates expansion tank sizing
or performance problem.
TO FLOOR DRAIN
OR NEUTRALIZER KIT
1” PVC / CPVC CONNECTION
60
FROM CONDENSATE
VENT ON BOILER
FROM CONDENSATE
DRAIN ON BOILER
4. Inspect automatic air vents and air separators. Remove
air vent caps and briefly press push valve to flush vent.
Replace caps. Make sure vents do not leak. Replace any
leaking vents.
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11 Maintenance (continued)
Installation & Operation Manual
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. See Section 5 - Hydronic Piping for suggested best
location of expansion tanks and air eliminators.
Check boiler relief valve
1. Inspect the relief valve and lift the lever to verify flow.
Before operating any relief valve, ensure that it is piped
with its discharge in a safe area to avoid severe scald
potential. Read Section 5 - Hydronic Piping before
proceeding further.
WARNING
WARNING
Safety relief valves should be re-inspected
AT LEAST ONCE EVERY THREE
YEARS, by a licensed plumbing contractor
or authorized inspection agency, to ensure
that the product has not been affected
by corrosive water conditions and to
ensure that the valve and discharge line
have not been altered or tampered with
illegally. Certain naturally occurring
conditions may corrode the valve or its
components over time, rendering the
valve inoperative. Such conditions are
not detectable unless the valve and its
components are physically removed and
inspected. This inspection must only
be conducted by a plumbing contractor
or authorized inspection agency – not
by the owner. Failure to re-inspect the
boiler relief valve as directed could result
in unsafe pressure buildup, which can
result in severe personal injury, death, or
substantial property damage.
Following installation, the valve lever
must be operated AT LEAST ONCE
A YEAR to ensure that waterways
are clear. Certain naturally occurring
mineral deposits may adhere to the valve,
rendering it inoperative. When manually
operating the lever, water will discharge
and precautions must be taken to avoid
contact with hot water and to avoid water
damage. Before operating lever, check
to see that a discharge line is connected
to this valve directing the flow of hot
water from the valve to a proper place
of disposal. Otherwise severe personal
injury may result. If no water flows, valve
is inoperative. Shut down the boiler until
a new relief valve has been installed.
2. After following the above warning directions, if the relief
valve weeps or will not seat properly, replace the relief
valve. Ensure that the reason for relief valve weeping is
the valve and not over-pressurization of the system due
to expansion tank waterlogging or undersizing.
Inspect ignition and flame sense
electrodes
1. Remove the ignition and both flame sense electrodes
from the burner plate.
2. Remove any deposits accumulated on the ignition/
flame sense electrodes using sandpaper. If the electrodes
cannot be cleaned satisfactorily, replace with new ones.
3. Replace ignition/flame sense electrodes, making sure the
gaskets are in good condition and correctly positioned.
Check ignition ground wiring
1. Inspect boiler ground wire from the heat exchanger
access cover to ground terminal strip.
2. Verify all wiring is in good condition and securely
attached.
3. Check ground continuity of wiring using continuity
meter.
4. Replace ground wires if ground continuity is not
satisfactory.
Check all boiler wiring
1. Inspect all boiler wiring, making sure wires are in good
condition and securely attached.
Check control settings
1. Navigate to the Setup Screen and check all settings. See
Section 1 of the Crest Service Manual. Adjust settings if
necessary. See Section 1 of the Crest Service Manual for
adjustment procedures.
2. Check settings of external limit controls (if any) and
adjust if necessary.
Perform start-up and checks
1. Start boiler and perform checks and tests specified in
Section 9 - Start-up.
2. Verify cold fill pressure is correct and that operating
pressure does not go too high.
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11 Maintenance
Y
A
Installation & Operation Manual
Check burner flame
1. Inspect flame through observation windows.
2. If the flame is unsatisfactory at either high fire or low
fire, remove and clean the burner. Clean the burner
thoroughly using a vacuum cleaner or compressed
air. Do not use compressed air to clean the burner if
cleaning is performed inside a building.
• Shut down the boiler:
- Follow the “To Turn Off Gas to Appliance”
instructions for the boiler in Section 9 - Startup
of the Crest Installation and Operation Manual.
- Do not drain the boiler unless it will be
exposed to freezing temperatures. If using
freeze prevention fluid in system, do not drain.
3. Allow time for the boiler to cool to room temperature if
it has been firing.
4. Remove the top access panel(s) to gain access to the
gas/air manifold assembly.
5. Remove the gas/air manifold burner access cover (FIG.
11-2).
6. Remove the nuts/washers holding the burner to the gas/
air manifold assembly.
7. Remove the burner from the gas/air manifold assembly.
10. Re-install the gas/air manifold burner access cover.
Tighten 3/8" nuts to 8 ft.-lbs. using the star pattern
sequence.
11. After firing the unit, re-tighten the nuts to the torque
specifications.
WARNING
Failure to follow the torqueing specifications
listed in this manual could result in severe
personal injury or death.
Figure 11-2 Burner Assembly
NOTE: Be sure to pay close
attention to the Lochinvar logo.
lign the logo with the Lochinvar
logo on the gas/air manifold to
ensure proper assembly.
Pay close attention to the bolt
pattern, as the gas/air manifold
assembly can only be installed
one way.
LOCHINVAR LOGO
GAS/AIR MANIFOLD COVER
GAS/AIR MANIFOLD GASKET
BURNER
BURNER GASKET
GAS/AIR MANIFOLD
GAS/AIR MANIFOLD GASKET
BURNER TOP PLATE ASSEMBL
FIBERBOARD
NOTICE
8. When replacing the burner, ensure gaskets are in good
condition and positioned correctly (FIG. 11-2).
9. When securing the burner and manifold, be sure to
The burner gasket, burner, burner
baffle, and gas/air manifold access
cover can only be installed in one
orientation. All of these parts will
have to be re-installed correctly. To
ensure all of these parts are re-installed
correctly, align the logo on top of the
gas/air manifold cover with the logo on
the gas/air manifold as shown in FIG.
11-2. Be certain to pay close attention
to the bolt pattern when re-installing
the above parts.
DIR #2000508208
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 electrodes
does not improve, ground wiring is in good condition, and
ground continuity is satisfactory, replace the flame sense
electrode.
3. See Section 3 - Troubleshooting in the Crest Service Manual
for other procedures to deal with low flame signal.
tighten the nuts as follows:
a. Tighten the nuts in a star pattern sequence.
b. Tighten the 7/16" nuts, securing the
burner to the cast manifold to a torque of 8 ft.-lbs.
62
Page 63
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. Remind the owner to follow the proper shutdown procedure
and to schedule an annual start-up at the beginning of the
next heating season.
Cleaning boiler heat exchanger
1. Shut down boiler:
• Follow the “To Turn Off Gas to Appliance” instructions
for the boiler in Section 9 - Startup.
• Do not drain the boiler unless it will be exposed to
freezing temperatures. If using freeze prevention fluid
in system, do not drain.
2. Allow time for the boiler to cool to room temperature if it
has been firing.
3. Remove the top access panel to remove the gas/air manifold
assembly.
4. Remove the nuts securing the burner to the burner
mounting plate. Remove the burner (reference FIG. 11-2
and follow the steps in Check Burner Flame on page 62).
5. Remove the nuts securing the burner mounting plate from
the heat exchanger and set aside. Remove the entire burner
mounting plate assembly.
WARNING
6. Use a vacuum cleaner to remove any accumulation on the
tube sheet surfaces. Do not use any solvent.
7. Brush the heat exchanger (tube sheet, combustion chamber
walls, and tube entry) while dry using a nylon bristle brush.
Caution: DO NOT use a metal brush. Re-vacuum the heat
exchanger.
8. Finish cleaning using a clean cloth dampened with warm
water.
9. Temporarily remove the condensate drain line from the
condensate trap and route directly to a drain.
10. Rinse out debris with a low pressure water supply. The
water will drain through the condensate connection.
11. Allow the heat exchanger to thoroughly dry.
12. Reconnect the condensate drain line to the condensate trap.
13. Close isolation valves on piping to isolate boiler from
system. Attach a hose to the boiler drain and flush boiler
thoroughly with clean water by using purging valves to
allow water to flow through the water make-up line to the
boiler.
14. When securing the burner, be sure to tighten the nuts, but
DO NOT over-tighten. Tighten the nuts to a torque setting
of no more than 6.2 ft.-lbs. When securing the burner
mounting plate be sure to tighten the nuts, but DO NOT
over-tighten. Tighten the nuts to a torque setting of no
more than 15.5 ft.-lbs.
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.
Installation & Operation Manual
15. Replace the burner mounting plate assembly and gas/air
manifold assembly. Ensure gaskets are in good condition
and positioned properly. Restore boiler to operation.
16. Perform start-up and check-out procedures in the Check
Flame and Combustion - Section 9 - Startup on pages 47
and 49 of this manual.
Handling ceramic fiber materials
REMOVAL OF COMBUSTION CHAMBER
LINING
WARNING
The combustion chamber insulation in this
appliance contains ceramic fiber material.
Ceramic fibers can be converted to cristobalite
in very high temperature applications. The
International Agency for Research on Cancer
(IARC) has concluded, “Crystalline silica in the
form of quartz or cristobalite from occupational
sources is carcinogenic to humans (Group 1).”
Normal operating temperatures in this appliance
are below the level to convert ceramic fibers to
cristobalite. Abnormal operating conditions
would have to be created to convert the ceramic
fibers in this appliance to cristobalite.
The ceramic fiber material used in this appliance
is an irritant; when handling or replacing the
ceramic materials it is advisable that the installer
follow these safety guidelines.
Avoid breathing dust and contact with skin
and eyes.
• Use NIOSH certified dust respirator (N95).
This type of respirator is based on the OSHA
requirements for cristobalite at the
time this document was written.
Other types of respirators may
be needed depending on the job
site conditions. Current NIOSH
recommendations can be found on
the NIOSH website at http://
www.cdc.gov/niosh/homepage.
html. NIOSH approved respirators,
manufacturers, and phone numbers are
also listed on this website.
• Wear long-sleeved, loose fitting clothing,
gloves, and eye protection.
Apply enough water to the combustion
chamber lining to prevent airborne dust.
Remove the combustion chamber lining
from the boiler and place it in a plastic bag
for disposal.
Wash potentially contaminated clothes
separately from other clothing. Rinse
clothes washer thoroughly.
NIOSH stated First Aid.
Eye: Irrigate immediately.
Breathing: Fresh air.
63
Page 64
12 Diagrams
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)
GAS
VALVE
(SMALL)
CONTACTOR
BOLIER PUMP
CONTACTOR
DHW PUMP
CONTACTOR
BLOWER
BLOWER
12
3
BAS
FLUE DAMPER
TRANSFORMER
12
3
TRANSFORMER
FLUE DAMPER
TEST
SWITCH
LWCO
PROBE
LWCO RESET
GPS1 GPS2
BLOCKED FLUE
SWITCH
BLOCKED DRAIN
SWITCH
ALARM
CONTACTS
CONTACTS
TANK
THERMOSTAT
LOUVER
PROVING
AUX
SWITCH 1
AUX
SWITCH 2
ENABLE
R
W
FLAME
SENSE 1
FLAME
SENSE 2
SPARK
GENERATOR
SPARK
ROD
SHIELD
SHIELD
A
B
BAS
OPTION
RATE
OUT
BOILER
PUMP OUT
SENSOR
SENSOR
TANK
SENSOR
OUTDOOR
SENSOR
BMS
IN
PUMP IN
SHIELD
SHIELD
A
B
CASCADE
INLET SENSOR
GROUND
1
2
5
BLOWER
BOX DEPICTS
OPTIONAL ITEMS
BOX DEPICTS
DUAL SENSOR
SINGLE HOUSING
HIGH VOLTAGE
LOW VOLTAGE
120 VAC
Notes:
C.S.A. in Canada.
locations when using diagrams to troubleshoot unit.
"X5"
BLOCK WIRING
IS MODEL
DEPENDENT
AIR VALVE
PRESS. SWITCH
BLOWER
AIR VALVE
HIGH LIMIT
SWITCH
RIBBON CABLE
M
M
DISCONNECT POWER
BEFORE SERVICING
BOILER PUMP
DHW PUMP
5.0 A
3.15 A
F2
LARGE GAS
LARGE GAS
SMALL GAS
SMALL GAS
USB
INTERFACE
X11
WIFI
DONGLE
USB CABLE
SW1
LG CON BRD
OPTIONAL
ETHERNET CABLE
OPTIONAL USB/WIFI
EXTENSION CABLE
BAS
E
GND
Figure 12-1 Ladder Diagram
Installation & Operation Manual
64
Page 65
12 Diagrams (continued)
Figure 12-2 Wiring Diagram
SHIELD
A
BAS
OPTION
B
A
B
COMMUNICATION
CONTROL BOARD
SW1
R
W
LWCO
PROBE
19
20
21
22
23
25
26
29
30
31
32
33
35
36
39
USB CABLE
OPTIONAL USB/WIFI
EXTENSION CABLE
OPTIONAL
ETHERNET CABLE
1
2
3
5
6
9
10
11
12
13
15
16
OR/BK
GPS1
DONGLE
TEST
SWITCH
LWCO RESET
OR
WIFI
LG CON BRD
PUMP OUT
BAS
R
PR
THERMOSTAT
BOILER
OUTDOOR
PUMP IN
CASCADE
CONTACTS
CONTACTS
PROVING
SWITCH 1
SWITCH 2
RATE
OUT
SENSOR
SENSOR
SENSOR
SENSOR
BMS
ALARM
ENABLE
LOUVER
GND
SHIELD
TANK
IN
SHIELD
SHIELD
E
TANK
AUX
AUX
R
PR
INLET SENSOR
OUTLET SENSOR (S9)
OUTLET SENSOR (S1)
FLUE SENSOR
FLUE SENSOR (S10)
HIGH LIMIT
R
OR/BK
OR
OR
GPS2
SWITCH
Installation & Operation Manual
BOX DEPICTS
OPTIONAL ITEMS
BOX DEPICTS
DUAL SENSOR
SINGLE HOUSING
BK
T
BL
R
BL
R
BR
W
OR
OR/W
P
W
BL
BK
BL
R/W
R
W
BR
BL
R
R
OR
OR
BL
BK
BR
R
BL
BL
R
OR
OR
BR
PR
T
OR
OR
BL
R
BL
R
BK
BLOWER
W
T
R
R
R
P
FLUE DAMPER
TRANSFORMER
BK
SPARK
GENERATOR
SWITCH
ON/OFF
BK
W
G
DISCONNECT POWER
BEFORE SERVICING
LOW VOLTAGE
120 VAC
HIGH VOLTAGE
120V
GND
L
N
BK
BK
FLAME SENSE 2
SPARK ROD
FLAME SENSE 1
FLUE DAMPER
BL
OR
GAS VALVE
(SMALL)
GAS VALVE
(LARGE)
BLOWER
1
1
2
3
1
23
M
CONTACTOR
BOILER PUMP
CONTACTOR
DHW PUMP
CONTACTOR
GND
Notes:
diagrams to troubleshoot unit.
BLOCKED FLUE
SWITCH
BLOCKED DRAIN
SWITCH
"X5"
BLOCK WIRING
IS MODEL
DEPENDENT
PR
BK
X11
USB
INTERFACE
OR/W
OR/BK
OR
BL
TRANSFORMER
BL
OR/R
AIR VALVE
PRESSURE SWITCH
AIR VALVE
M
65
Page 66
Notes
Installation & Operation Manual
66
Page 67
Notes
Installation & Operation Manual
67
Page 68
Revision Notes: Revision A (ECO #C17106) initial release.
Revision B (ECO C17419) reflects the addition of the large Crest
models (1501 - 2001).
Revision C (Change #500000695) reflects the addition of ICC venting
options on page 17 (R06799), add PVC to SS adapter and 6" starter
piece on page 20 (R08066), along with edits made to the Gas
Connections Section, and the addition of the California contaminant
warning on page 3 (R07228).
Revision D (Change #500000938) reflects the removal of the balancing
valves notice on page 34.
Revision E (Change #500001029) reflects the addition of the Crest
CON•X•US Interface, along with the addition of the re-spark ignition
option.
FBII-I-O_MM #100208043_DIR #2000004587 Rev E
11/15
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