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6

Table 1A First Stage Piping at High Pressure_10 PSI

The gas piping must be sized for the proper flow and length of 
pipe, to avoid excessive pressure drop.  Both the gas meter and 
the gas regulator must be properly sized for the total gas load.  

If you experience a pressure drop greater than 1 inch w.c.       
(249 Pa), the meter, regulator, or gas line is 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.’s 1-1 and 1-2.

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 10 of this manual.

7.  Observe the gas supply pressure as the burner fires at 
 

100% of rated input.  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.

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.

 WARNING

Check inlet gas supply

1  

Gas connections 

        

Dual Fuel Supplemental Manual

The Dual Fuel Crest is equipped with 
two (2) inlet gas connections.  Each 
connection must be checked to ensure 
proper operation.

 NOTICE

Table 1B Second Stage Piping at Low Pressure_1/2 PSI

10

20

30

40

50

60

70

80

90

100

125

150

1/2

2442

1885

1580

1382

1240

1133

1048

979

921

872

775

703

Pipe

3/4

4831

3812

3230

2842

2561

2346

2175

2035

1917

1816

1618

1470

Size

1

8531

6916

5939

5270

4776

4392

4083

3829

3614

3429

3063

2789

(I.D.)

1 1/4

16626 13771 11963 10691

9736

8987

8378

7872

7443

7074

6336

5779

1 1/2

23670 19957 17510 15749 14407 13341 12470 11740 11119 10581

9501

8682

2

42521 36514 32398 29359 27001 25104 23538 22216 21082 20097 18104 16580

Nominal Iron Pipe 

Size Inches

                                           

Length of pipe or tubing, feet

                                   Maximum Capacities of Pipe in KBTUH/Hr

Notice:  Capacities show n are for Natural Gas.  Please consult supplier for proper gas pipe sizing for propane.

10

20

30

40

50

60

70

80

90

100

125

150

1 1/4

2205

1496

1212

1039

913

834

771

724

677

630

567

511

Pipe

1 1/2

3307

2299

1858

1559

1417

1275

1181

1086

1023

976

866

787

Size

2

6221

4331

3465

2992

2646

2394

2205

2047

1921

1811

1606

1496

(I.D.)

2 1/2

10140 7046

5695

4778

4343

3908

3618

3329

3160

2991

2654

2412

3

17990 12510 10110 8481

7708

6936

6422

5908

5608

5309

4711

4281

4

36710 25520 20620 17300 15730 14150 13100 12050 11440 10830 9613

8736

Nominal Iron Pipe 

Size Inches

                                    Length of pipe or tubing, feet

                           Maximum Capacities of Pipe in KBTUH/Hr

Notice:  Capacities show n are f or Natural Gas.  Please consult supplier f or proper gas pipe sizing f or propane.

Summary of Contents for CREST 2.5

Page 1: ...Crest Installation and Operation 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 WARNING Save this manual for future reference FBD SUP_100161023_2000004585 Rev D Dual Fuel Supplemental Manual Models FBD 2 5 5 0 ...

Page 2: ...us 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 HAZARD DEFINITIONS 2 PLEASE READ BE...

Page 3: ...ternal 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 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 ...

Page 4: ...s flowing 8 Large natural gas valve Valve 2 Natural The large natural gas valve senses the negative pressure created by the blowers allowing gas to flow only if the gas valves are powered and combustion air is flowing 9 Large propane gas valve Valve 2 Propane The large propane gas valve senses the negative pressure created bytheblowers allowinggastoflowonlyifthegasvalvesarepowered and combustion a...

Page 5: ...and high altitude Crest Models 4 0 and 5 0 boilers are equipped to operate from 3 000 to 5 500 feet High altitude models are manufactured with different control parameters for high altitude operation but the sequence of operation given in this manual remains the same as the standard boilers A high altitude label as shown in FIG A is also affixed to the unit 6 Standard Crest boilers will de rate by...

Page 6: ...g 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 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 p...

Page 7: ...es 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 venturis and blowers Figure 1 1 Inlet Gas Supply Check_Natural DO NOT adjust or attempt to measure gas valve outlet pressure Attempting to alter or measure the gas valve outlet pressure could result in damag...

Page 8: ...coming gas pressure less than 4 inches w c 99 kPa 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 in the Crest Installation and Operation Manual startup regarding failure to repair leaks 2 Vent any re...

Page 9: ...o inspect the appliance and to replace any part of the control system and any gas control which has been under water 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 appliance 4 This appliance is equipped with an ignition device which automatically lights the burner Do not try to light the burn...

Page 10: ...ice 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 flue temperature sensor 7 Once the heat exchanger has modulated up to rate measure the combustion The values should be in the range listed in Table 2A CO levels should be less than 200 ppm for ...

Page 11: ...on the ball valves for the ones in use 3 total 5 Turn the main power ON 6 Using the Touch Screen accept the appropriate personality identification as shown in FIG 2 4 Figure 2 4 Personality Plug Screen Figure 2 2B Fuel Selector Switch Models 4 0 5 0 IMG00063 NATURAL PROPANE DETAIL MAIN POWER SWITCH NATURAL PERSONALITY I D PROPANE PERSONALITY I D FUEL SELECTION SWITCH IMG00555 ...

Page 12: ...J3 6 LWCO BOARD J3 3 J3 2 J2 1 J2 2 X6 3 R O K B R O K B R O TEST SWITCH LWCO PROBE R O R O LWCO RESET X6 5 X6 15 BLOWER PROVING SWITCH LARGE R O X6 12 BLOWER PROVING SWITCH SMALL T X13 1 BLOCKED FLUE SWITCH R P X6 6 BLOCKED DRAIN SWITCH K B ENABLE X8 3 X8 8 X8 2 X8 4 X8 9 X7 1 X7 5 X7 2 X7 6 INLET SENSOR OUTLET SENSOR S9 OUTLET SENSOR S1 FLUE SENSOR FLUE SENSOR S10 PRE MIX SENSOR 1 S11 PRE MIX SE...

Page 13: ...0V TANK SENSOR OUTDOOR SENSOR 0 10V 0 10V BMS IN SYSTEM PUMP IN SHIELD SHIELD A B CASCADE LARGE CONNECTION BOARD CN6 1 CN3 6 CN3 7 CN3 14 CN3 13 CN3 11 CN3 9 CN3 8 CN3 1 CN3 2 CN3 3 CN3 4 CN6 2 CN6 3 CN3 10 CN3 12 BAS X4 1 X4 2 X4 3 X6 3 X6 1 X6 2 X8 20 X8 10 X7 8 X8 13 X8 14 X8 12 INTEGRATED CONTROL X8 5 X8 15 X7 7 X8 11 X8 6 X8 16 X8 7 X8 17 X8 1 T INLET SENSOR X8 3 X8 8 X8 2 X8 4 X8 9 X7 1 X7 5...

Page 14: ...0 5 X10 3 X10 6 X1 6 ON OFF SWITCH GND BK W PR T OR X6 18 X6 8 X1 8 G X6 9 X6 17 X2 4 X13 2 X13 3 BLOWER SMALL BLOWER LARGE R BK GY W W BK T M T GN R W BK W X2 3 X1 7 X1 10 X1 5 FLAME SENSE 2 FLAME SENSE 1 SPARK GENERATOR SPARK ROD X2 5 FLUE DAMPER TRANSFORMER X13 4 FLUE DAMPER 24V TRANSFORMER BL R R R P BK BL Y OR BL Y BK X1 2 X1 3 X1 1 INTEGRATED CONTROL LARGE CONNECTION BOARD SMALL CONNECTION B...

Page 15: ...0 10V 0 10V BMS IN SYSTEM PUMP IN SHIELD SHIELD A B CASCADE LARGE CONNECTION BOARD CN6 1 CN3 6 CN3 7 CN3 14 CN3 13 CN3 11 CN3 9 CN3 8 CN3 1 CN3 2 CN3 3 CN3 4 CN6 2 CN6 3 CN3 10 CN3 12 BAS X4 1 X4 2 X4 3 X6 3 X6 1 X6 2 X8 20 X8 10 X7 8 X8 13 X8 14 X8 12 INTEGRATED CONTROL X8 5 X8 15 X7 7 X8 11 X8 6 X8 16 X8 7 X8 17 X8 18 T INLET SENSOR X8 3 X8 8 X8 2 X8 4 X8 9 X7 1 X7 5 X7 2 X7 6 GROUND X6 18 X6 9 ...

Page 16: ... R O K B R O K B R O TEST SWITCH LWCO PROBE R O R O LWCO RESET X6 5 X6 15 BLOWER PROVING SWITCH LARGE R O X6 12 BLOWER PROVING SWITCH SMALL T X13 1 BLOCKED FLUE SWITCH R P X6 6 BLOCKED DRAIN SWITCH K B ENABLE X8 3 X8 8 X8 2 X8 4 X8 9 X7 1 X7 5 X7 2 X7 6 INLET SENSOR OUTLET SENSOR S9 OUTLET SENSOR S1 FLUE SENSOR FLUE SENSOR S10 PRE MIX SENSOR 1 S11 PRE MIX SENSOR 1 S13 PRE MIX SENSOR 2 S12 PRE MIX ...

Page 17: ...NSOR 0 10V 0 10V BMS IN SYSTEM PUMP IN SHIELD SHIELD A B CASCADE LARGE CONNECTION BOARD CN6 1 CN3 6 CN3 7 CN3 14 CN3 13 CN3 11 CN3 9 CN3 8 CN3 1 CN3 2 CN3 3 CN3 4 CN6 2 CN6 3 CN3 10 CN3 12 BAS X4 1 X4 2 X4 3 X6 3 X6 1 X6 2 X8 20 X8 10 X7 8 X8 13 X8 14 X8 12 INTEGRATED CONTROL X8 5 X8 15 X7 7 X8 11 X8 6 X8 16 X8 7 X8 17 X8 18 T INLET SENSOR X8 3 X8 8 X8 2 X8 4 X8 9 X7 1 X7 5 X7 2 X7 6 GROUND X6 18 ...

Page 18: ...Dual Fuel Supplemental Manual Notes 18 ...

Page 19: ...19 Dual Fuel Supplemental Manual Notes ...

Page 20: ...ts the update of wiring and ladder diagrams on pages 12 and 13 Revision C ECO C11685 reflects the addition of models 4 0 and 5 0 Revision D Change 500001029 reflects the removal of Models 1 5 and 2 0 along with updates to the control FBD SUP_MM 100161023_DIR 2000004585 Rev D 10 15 ...

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