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Installation & Operation Manual

Diagrams

Figure 12-1 Ladder Diagram

TERMINAL STRIP

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

BAS

FLUE DAMPER

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

FLAME

SENSE 1

FLAME

SENSE 2

SPARK

GENERATOR

SPARK

ROD

SHIELD

BAS
OPTION

RATE
OUT

BOILER
PUMP OUT

SENSOR

TANK
SENSOR

OUTDOOR
SENSOR

BMS
IN

PUMP IN

SHIELD

CASCADE

INLET SENSOR

GROUND

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

DISCONNECT POWER

BEFORE SERVICING

BOILER PUMP

DHW PUMP

5.0 A

3.15 A

LARGE GAS

SMALL GAS

USB

INTERFACE

X11

WIFI

DONGLE

USB CABLE

SW1

LG CON BRD

OPTIONAL

ETHERNET CABLE

OPTIONAL USB/WIFI
EXTENSION CABLE

BAS

GND

Содержание Crest FBL0751

Страница 1: ...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 t...

Страница 2: ...l 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 Pi...

Страница 3: ...ic and can attack gaskets and seals used in hydronic systems When calling or writing about the boiler Please have the boiler model and serial number from the boiler rating plate Consider piping and in...

Страница 4: ...s are used to monitor the outlet water temperature if either device senses the water temperature exceeding the predetermined setting the boiler will shut down 20 Ignition electrode An electrical spark...

Страница 5: ...t works continued 5 Installation Operation Manual IMG01025 2 39 1 11 Front View IMG01128 36 7 19 12 29 20 6 5 35 3 18 Rear View IMG01130 33 17 16 34 37 9 41 IMG01129 25 26 21 22 15 4 30 31 28 14 32 10...

Страница 6: ...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 allowan...

Страница 7: ...flammable 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 m...

Страница 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...

Страница 9: ...pliance 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 i...

Страница 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...

Страница 11: ...d 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 the...

Страница 12: ...truction 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 do...

Страница 13: ...ve 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 a...

Страница 14: ...14 Installation Operation Manual Vertical IMG01033 2 General venting IMG01059 IMG01056 Sidewall Direct venting Vertical Vent Sidewall Air Sidewall IMG01057 Vertical IMG01058 Optional room air...

Страница 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...

Страница 16: ...erly 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...

Страница 17: ...dapters Category IV Model ProTech Z Flex Heat Fab Adapter Intake Adapter Intake Adapter Flue Intake 751 1001 810003974 810003269 2SVDSA06 2SVEE0690 9601MAD CCK06TM 9690 9692 1251 810003980 810003281 2...

Страница 18: ...ial 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 perman...

Страница 19: ...1751 8 100141561 FB2001 8 100141561 NOTICE 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 I...

Страница 20: ...M D2466 PVC Schedule 80 ANSI ASTM D2467 CPVC Schedule 80 ANSI ASTM F439 Pipe Cement Primer PVC ANSI ASTM D2564 CPVC ANSI ASTM F493 NOTICE DO NOT USE CELLULAR FOAM CORE PIPE NOTE In Canada CPVC and PVC...

Страница 21: ...r substantial property damage WARNING Installations must comply with applicable national state and local codes For Canadian installation polypropylene vent must be listed as a ULC S636 approved system...

Страница 22: ...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 no...

Страница 23: ...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...

Страница 24: ...or 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 D...

Страница 25: ...CONNECTION 36 914 MM MIN 48 1219 MM MAX 12 305 MM MIN GRADE OR SNOW LINE Figure 4 2B Stainless Steel Sidewall Termination w Field Supplied Fittings 36 914 MM MIN 48 1219 MM MAX 12 305 MM MIN FROM BOIL...

Страница 26: ...eration Manual 4 Sidewall direct venting continued Vent air termination sidewall 4 4 Figure 4 3 Clearance to Doors and Windows VENT TERMINATION IF LESS THAN 10 36 MIN FORCED AIR INLET AIR TERMINATION...

Страница 27: ...Elbow Figure 4 6 Direct Vent Terminations ROOM AIR DIRECT EXHAUST TERMINATIONS Vent Termination 23 Elbow 45 Elbow 90 Elbow Figure 4 7 Room Air Direct Exhaust Terminations Room air IMG01036 AIR INLET C...

Страница 28: ...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...

Страница 29: ...60 F 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 200...

Страница 30: ...ded 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...

Страница 31: ...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 SEPERATOR DR...

Страница 32: ...SYSTEM TO SYSTEM MAKE UP WATER BOILER DRAIN TYPICAL SYSTEM RETURN SENSOR SYSTEM SUPPLY SENSOR IMG01037 Figure 5 3 Multiple Boilers Common Header Recommended Primary Secondary Flow Model Number of Unit...

Страница 33: ...each system component The installer is responsible for compliance with local codes NOTICE RELIEF VALVE BALL VALVE TYPICAL AIR SEPERATOR DRAIN PORT TYPICAL SYSTEM CIRCULATOR BACK FLOW PREVENTER PRESSU...

Страница 34: ...PICAL RELIEF VALVE TYPICAL AIR SEPERATOR DRAIN PORT TYPICAL SYSTEM CIRCULATOR BACK FLOW PREVENTER PRESSURE REDUCING VALVE PRESSURE GAUGE EXPANSION TANK FROM SYSTEM TO SYSTEM MAKE UP WATER BOILER DRAIN...

Страница 35: ...tor 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...

Страница 36: ...NOTICE 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 p...

Страница 37: ...um 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...

Страница 38: ...ner 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 replacement The...

Страница 39: ...ge 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 c...

Страница 40: ...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 connecti...

Страница 41: ...ply 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 t...

Страница 42: ...YSTEM SUPPLY SYSTEM RETURN BOILER PUMP OUT OUT RATE BAS SHIELD SHIELD B A SHIELD SHIELD B A BUILDING MANAGEMENT SYSTEM TANK THERMOSTAT ENABLING DEVICE LOUVER PROVING SWITCH LOUVER RELAY AUX SWITCH 1 A...

Страница 43: ...7 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 neu...

Страница 44: ...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...

Страница 45: ...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...

Страница 46: ...e 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 extern...

Страница 47: ...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 repa...

Страница 48: ...an to 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...

Страница 49: ...ing Section in the Crest Service Manual for possible causes and corrective actions Table 9A Flue Products Chart 8 Once the heater analysis is complete test the safety shutoff device by turning the man...

Страница 50: ...es to be reprogrammed 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...

Страница 51: ...nued 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 f...

Страница 52: ...on 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 Cascad...

Страница 53: ...g 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 Norma...

Страница 54: ...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 termi...

Страница 55: ...sensor 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 SM...

Страница 56: ...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 applic...

Страница 57: ...to stabilize then begin modulating the firing rate in order to maintain the controlling sensor to the desired set point temperature 9 If the current call for heat is for space heating and a HW call f...

Страница 58: ...basic system information It is divided into the following sections Status System Boiler Modulation and Navigation The System Section is located in the middle of the screen and displays exterior senso...

Страница 59: ...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...

Страница 60: ...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...

Страница 61: ...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...

Страница 62: ...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...

Страница 63: ...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 Resea...

Страница 64: ...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 SH...

Страница 65: ...RESET GPS1 GPS2 BR OR BLOCKED FLUE SWITCH PR BLOCKED DRAIN SWITCH BK ENABLE INLET SENSOR R W X5 BLOCK WIRING IS MODEL DEPENDENT BK T BL R W R W BR L N GND 120V ON OFF SWITCH GND GAS VALVE SMALL GAS V...

Страница 66: ...Notes Installation Operation Manual 66...

Страница 67: ...Notes Installation Operation Manual 67...

Страница 68: ...er 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 reflec...

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