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35

        

Installation & Operation Manual

7  

Field wiring 

ELECTRICAL SHOCK HAZARD – For 
your safety, turn off electrical power supply 
before making any electrical connections 
to avoid possible electric shock hazard.  
Failure to do so can cause severe personal 
injury or death.

Wiring must be N.E.C. Class 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.

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 - Models 

1.5 - 3.5

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.

Line voltage connections - Models 

4.0 - 5.0

1.  Connect 208 VAC 3



wye 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

Label all wires prior to disconnection when 
servicing controls.  Wiring errors can 
cause improper and dangerous operation.

 WARNING

 NOTICE

 CAUTION

12
0V

SU
PPLY

SY
STEM

 PU

M

P

BOI

L

ER

 PU

M

P

HWG P

U

MP

M

AX.

 1

.5 AMPS P

ER 

CO

NNECT
IO

N

NL

F

IEL
D

 SU

PPL

IED
 C
O

N

TA
C

TOR

 MUS

T

BE I

N

ST
A

L

LE
D

GROUND   G

NEUTRAL   W

LINE   BK

SYSTEM PUMP

DRY CONTACT

BOILER PUMP

DRY CONTACT

HWG PUMP

DRY CONTACT

SERVICE SWITCH

CONTACTOR

(FIELD SUPPLIED)

MODELS 1.5 - 3.5

NEUTRAL  W

SERVICE SWITCH

CONTACTOR

(FIELD SUPPLIED)

L1 BK

L2 R

L3 BL

BOILER PUMP
DRY CONTACT

SYSTEM PUMP
DRY CONTACT

DHW PUMP
DRY CONTACT

IMG00319

GROUND  G

MODELS 4.0 - 5.0

 

Summary of Contents for Crest 2500 Series

Page 1: ...g 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 WARNING Save...

Page 2: ...ing 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 Requi...

Page 3: ...p water can cause internal corrosion in system components Leaks in boiler or piping must be repaired at once to prevent the need for makeup water Freeze protection fluids NEVER use automotive antifree...

Page 4: ...on air is flowing 18 Blower proving switches Prove adequate airflow during prepurge 19 High limit devices primary and backup The high limit devices are used to monitor the outlet water temperature if...

Page 5: ...llation Operation Manual Models 1 5 5 0 2 11 1 39 Front View 7 36 6 35 9 29 5 19 10 Rear View 33 12 13 17 34 3 37 25 26 21 22 29 20 12 27 14 32 4 IMG00318 16 15 23 18 34 19 30 31 28 40 MODELS 4 0 5 0...

Page 6: ...ded 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 I...

Page 7: ...able liquids 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 monoxid...

Page 8: ...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 r...

Page 9: ...tion 2 General Venting Tables 2A 1 and 2A 2 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 pla...

Page 10: ...st fan Close fireplace dampers 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 pl...

Page 11: ...xtend at least half way under the boiler heat exchanger to assure proper lifting technique with no damage to the boiler d If lifting by crane is desired remove the top access panels to gain access to...

Page 12: ...T 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...

Page 13: ...ANS 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 syst...

Page 14: ...14 Installation Operation Manual Vertical 2 General venting Sidewall Direct venting Vertical Vent Sidewall Air Sidewall Vertical Optional room air...

Page 15: ...s instructions can result in personal injury death or property damage Mixing of venting materials will void the warranty and certification of the appliance NOTICE The use of double wall vent or insula...

Page 16: ...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 The Crest uses model...

Page 17: ...7 810003369 2SVDSA08 2SVEE890 CCA08MM CCK08TM 9890 9892 2500 810003982 810003397 810003409 2SVDSA09 2SVEE990 CCA09MM CCK09TM 9890 9992 3000 3500 810003984 810003435 810003447 2SVDSA10 2SVEE1090 CCA10M...

Page 18: ...ve 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 TO...

Page 19: ...ith 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 WARNING NOTICE WARNING Do...

Page 20: ...ction It is not classified as a forced air intake with regard to spacing from adjacent boiler vents 36 914 MM 36 914 MM 12 305 MM 12 305 MM 12 305 MM 12 305 MM 12 305 MM 12 305 MM Figure 3 3 Vertical...

Page 21: ...r substantial property damage 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 De...

Page 22: ...air connection as described in this manual FIG 4 4 WARNING 22 Installation Operation Manual 4 Sidewall direct venting Vent air termination sidewall 4 4 Figure 4 2 Clearance to Doors and Windows VENT T...

Page 23: ...tered 23 Elbow Figure 4 5 Direct Vent Terminations ROOM AIR DIRECT EXHAUST TERMINATIONS Vent Termination 23 Elbow 45 Elbow 90 Elbow Figure 4 6 Room Air Direct Exhaust Terminations Room air AIR INLET C...

Page 24: ...of the Crest 5 2 thru 5 5 1 Connect the system return to the 4 flanged connection marked Inlet make sure to install with a suitable gasket between flanges 2 Connect the system supply to the 4 flanged...

Page 25: ...00 4 184 4 1 92 1 2 61 0 6 FB 2500 4 230 4 6 115 1 4 77 0 7 FB 3000 4 276 5 6 138 1 7 92 0 8 FB 3500 4 322 7 5 161 2 2 107 1 1 FB 4000 4 248 4 2 186 1 8 124 0 9 FB 5000 4 310 4 5 233 0 9 155 0 5 0 00...

Page 26: ...estic 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...

Page 27: ...rimary Secondary Piping with a Hot Water Generator HOT WATER GENERATOR WATER GENERATOR CIRCULATOR BOILER PUMP FLOW CHECK VALVE TYPICAL Y STRAINER RECOMMENDED RELIEF VALVE BALL VALVE TYPICAL AIR SEPERA...

Page 28: ...MAKE UP WATER BOILER DRAIN TYPICAL SYSTEM RETURN SENSOR SYSTEM SUPPLY SENSOR Figure 5 3 Multiple Boilers Common Header Recommended Primary Secondary Flow Model Number of Units 2 3 4 5 6 7 8 Recommende...

Page 29: ...acturer s instructions for each system component The installer is responsible for compliance with local codes NOTICE Y STRAINER RECOMMENDED RELIEF VALVE BALL VALVE TYPICAL AIR SEPERATOR DRAIN PORT TYP...

Page 30: ...te Common Header Fixed or Variable Flow Primary When installing multiple Crest boilers in fixed or variable flow primary applications utilize a reverse return or other piping method to ensure balanced...

Page 31: ...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 fro...

Page 32: ...E 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 propert...

Page 33: ...ure 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 dete...

Page 34: ...he 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 Gas valve replaceme...

Page 35: ...Install a field supplied contactor between the pump s and the boiler connections 4 For alternate voltages consult factory Line voltage connections Models 4 0 5 0 1 Connect 208 VAC 3 wye power wiring...

Page 36: ...able 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 HWG thermostat 1 Connect...

Page 37: ...IG s 5 5 and 5 6 The system supply sensor should be wired to the Low Voltage Connection Board at the terminals marked for the system supply sensor see FIG 7 3 The Leader control will use the water tem...

Page 38: ...PPLY SYSTEM RETURN BOILER PUMP OUT OUT RATE MODBUS SHIELD SHIELD B A SHIELD SHIELD B A BUILDING MANAGEMENT SYSTEM TANK THERMOSTAT ENABLING DEVICE LOUVER PROVING SWITCH LOUVER RELAY AUX SWITCH 1 AUX SW...

Page 39: ...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 neutrali...

Page 40: ...uire a backflow preventer or actual disconnect from city water supply 3 When using freeze protection fluid with automatic fill install a water meter to monitor water makeup Freeze protection fluid may...

Page 41: ...nd 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 e...

Page 42: ...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 immediatel...

Page 43: ...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...

Page 44: ...ll Installer Level adjustable parameters Press ENTER without a password to access the User Level parameters 1 To change a set point use the arrows to highlight a user set point parameter and press the...

Page 45: ...rd Screen will appear Entering the correct password will allow access to all Installer Level adjustable parameters Press ENTER without a password to access the User Level parameters The SMART TOUCH co...

Page 46: ...rate can be limited to match the input rating of the indirect tank coil HWG space heating SH cycling If a HWG call for heat is received while a space heating call is in progress and the HWG is in Nor...

Page 47: ...ilable 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...

Page 48: ...r is not installed Target temperature is calculated as described under Outdoor Reset Operation and Target Temperature Boost when the outdoor sensor is connected High limit operations The Crest SMART T...

Page 49: ...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 The p...

Page 50: ...the desired set point temperature 9 If the current call for heat is for space heating and a HWG call for heat becomes active the control will turn on the HWG pump relay output then turn off the boiler...

Page 51: ...this screen Main Menu button Pressing this button brings up the Main Menu Screen From this screen navigation to nine 9 other screens is possible Reference the Main Menu Screen section on page 52 of t...

Page 52: ...2 other screens for the adjustment of the control parameters Cascade Shows the status of multiple boilers connected together in a cascade arrangement Leader only Modulation Shows the status of the two...

Page 53: ...ut and performance verification per Section 9 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 C...

Page 54: ...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 cau...

Page 55: ...ust 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 val...

Page 56: ...ing the burner mounting plate to the heat exchanger be sure to tighten the nuts but DO NOTover tighten Tightenthe3 8 nuts toatorque setting of 25 ft lbs c For Models 1 5 2 0 2 5 3 0 and 3 5 tighten th...

Page 57: ...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...

Page 58: ...UPPLY SENSOR 0 10V 0 10V 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 CN...

Page 59: ...2 SHIELD SHIELD A B MODBUS OPTION RATE OUT BOILER PUMP OUT SYSTEM RETURN SENSOR SYSTEM SUPPLY SENSOR 0 10V 0 10V TANK SENSOR OUTDOOR SENSOR 0 10V 0 10V BMS IN SYSTEM PUMP IN SHIELD SHIELD A B CASCADE...

Page 60: ...0 10V 0 10V 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 CN...

Page 61: ...MODBUS OPTION RATE OUT BOILER PUMP OUT SYSTEM RETURN SENSOR SYSTEM SUPPLY SENSOR 0 10V 0 10V TANK SENSOR OUTDOOR SENSOR 0 10V 0 10V BMS IN SYSTEM PUMP IN SHIELD SHIELD A B CASCADE R R R O R O L B K B...

Page 62: ...OR 0 10V 0 10V 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...

Page 63: ...TE OUT BOILER PUMP OUT SYSTEM RETURN SENSOR SYSTEM SUPPLY SENSOR 0 10V 0 10V TANK SENSOR OUTDOOR SENSOR 0 10V 0 10V BMS IN SYSTEM PUMP IN SHIELD SHIELD A B CASCADE R R R O R O L B K B R B R Y R O HIGH...

Page 64: ...ade to Table 5A on page 25 an updated Low Voltage Field Wiring Connections diagram in FIG 7 3 on page 38 and a note added to the Flow sensing device section on page 48 Revision M ECO C13628 reflects t...

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