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Crestron electronic 2.5 manual

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Table of contents for the manual

  • Page 1

    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.  WARNING Save this manual for future [...]

  • Page 2

    2 Contents Hazard definitions The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product.  DANGER  WARNING  CAUTION CAUTION NOTICE DANGER indicates an imminently hazardous situation which, if not avoided, wil[...]

  • Page 3

    Installation & Operation Manual Please read before proceeding 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 r[...]

  • Page 4

    Installation & Operation Manual 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. Blowers The blowers pull in air and gas through the venturis (ite[...]

  • Page 5

    Left Side (inside unit) Right Side (inside unit) The Crest - How it works... (continued) 5 Installation & Operation Manual Models 1.5 - 2.0 - 2.5 - 3.0 - 3.5 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 15 16 23 19 28 31 30 34 18[...]

  • Page 6

    6 Installation & Operation Manual Ratings Crest AHRI Rating Model Number Note: Change “N” to “L” for L.P. gas models. Input MBH (Note 4) Min Max Gross Output MBH (Note 1) Net AHRI Ratings Water, MBH (Note 2) FB(N,L)1500 60 1500 1380 1200 FB(N,L)2000 80 2000 1840 1600 FB(N,L)2500 125 2500 2300 2000 FB(N,L)3000 150 3000 2760 2400 FB(N,L)3[...]

  • Page 7

    7 Installation & Operation Manual Installation must comply with: • Local, state, provincial, and national codes, laws, regulations, and ordinances. • National Fuel Gas Code, NFPA 54 / ANSI Z223.1 – latest edition. • Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1 - latest edition, when required.[...]

  • Page 8

    Installation & Operation Manual 8 1 Determine boiler location 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 openi[...]

  • Page 9

    Installation & Operation Manual 9 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 [...]

  • Page 10

    Installation & Operation Manual 1 Determine boiler location 10 When removing a boiler from existing common vent system: Do not install the Crest into a common vent with any other appliance except as noted in Section 2 on page 18. This will cause flue gas spillage or appliance malfunction, resulting in possible severe personal injury, death, or [...]

  • Page 11

    Installation & Operation Manual 1 Determine boiler location (continued) 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. Re[...]

  • Page 12

    1 Determine boiler location Installation & Operation Manual 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 Can[...]

  • Page 13

    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 cm 2 per kW). This opening must be located within 12” (30 cm) of the top of the enclosure (see FIG. 1-7). TABLE - [...]

  • Page 14

    14 Installation & Operation Manual Vertical 2 General venting Sidewall Direct venting Vertical Vent, Sidewall Air Sidewall Vertical Optional room air[...]

  • Page 15

    15 Installation & Operation Manual 2 General venting (continued) Install vent and combustion air piping  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, [...]

  • Page 16

    16 Installation & Operation Manual 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, Ta[...]

  • Page 17

    17 Installation & Operation Manual 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 pro[...]

  • Page 18

    Installation & Operation Manual 18 2 General venting Common venting Crest boilers may be common vented; however, the following criteria MUST BE followed: 1. Only Crest boilers may be connected to the common vent. DO NOT mix other manufacturer’s appliances or other Lochinvar models. 2. Crest boilers connected to the common vent must all be of [...]

  • Page 19

    Installation & Operation Manual 19 3 Vertical direct venting Vent/air termination – vertical 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 noncom[...]

  • Page 20

    20 Installation & Operation Manual 3 Vertical direct venting Multiple vent/air terminations 1. When terminating multiple Crest boilers, terminate each vent/air connection as described in this manual (FIG. 3-3). Terminate all vent pipes at the same height and all air pipes at the same height to avoid recirculation of flue products and the possib[...]

  • Page 21

    Installation & Operation Manual 3. Maintain clearances as shown in FIG.’s 4-1 thru 4-3, pages 21 and 22. 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 les[...]

  • Page 22

    Termination and fittings 1. The air termination must be oriented at least 12 inches above grade or snow line as shown in FIG. 4-1, page 21. 2. Maintain the required dimensions of the finished termination piping as shown in FIG. 4-1, page 21. 3. Do not extend exposed vent pipe outside of the building more than what is shown in this document. Condens[...]

  • Page 23

    Installation & Operation Manual 4 Sidewall direct venting (continued) 2. Place wall penetrations to obtain minimum clearance of 12 inches (305 mm) between vent pipe and adjacent air inlet, as shown in FIG. 4-4 for U.S. installations. For Canadian installations, provide clearances required by CSA B149.1 Installation Code. 3. The air inlet of a C[...]

  • Page 24

    24 Installation & Operation Manual 5 Hydronic piping 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 t[...]

  • Page 25

    Installation & Operation Manual 5 Hydronic piping (continued) 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 [...]

  • Page 26

    Installation & Operation Manual 5 Hydronic piping 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 Genera[...]

  • Page 27

    27 Installation & Operation Manual 5 Hydronic piping (continued) 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. NOTICE Figure 5-2 Single Boiler - Recommended - Primary / Secondary Piping with a Hot Water Generator HOT W ATER[...]

  • Page 28

    28 Installation & Operation Manual 5 Hydronic piping 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. NOTICE HOT W ATER GENERATOR WA T E R GENERATOR CIRCULATOR BOILER PUMP (TYPICAL) FLOW CHECK VALVE (TYPICAL) Y-ST RA INE R (RE[...]

  • Page 29

    29 Installation & Operation Manual 5 Hydronic piping (continued) 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. NOTICE Y-ST RA INE R (RECOMMENDED) RELIEF VALVE BALL VALVE (TYPICAL) AIR SEPERATOR DRAIN PORT (TYPICAL) SYSTEM C[...]

  • Page 30

    30 Installation & Operation Manual 5 Hydronic piping 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. NOTICE Y-ST RA INER (RECOMMENDED) (TYPICAL) RELIEF VALVE (TYPICAL) BALL VALVE (TYPICAL) AIR SEPERATOR DRAIN PORT (TYPICAL) S[...]

  • Page 31

    31 Installation & Operation Manual 6 Gas connections Connecting gas supply piping 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. Figure 6-1 Gas Supply Piping 2. Support piping with hangers,[...]

  • Page 32

    32 Installation & Operation Manual 6 Gas connections 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. USE BACK UP WRENCH TO PREVENT PIPE FROM R O[...]

  • Page 33

    33 Table 6B Natural Gas Pipe Size Chart 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[...]

  • Page 34

    34 Installation & Operation Manual  WARNING 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. 14. Turn on the gas supply at the manual gas valve. 15. Turn the power switch to the “ON” position[...]

  • Page 35

    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 mu[...]

  • Page 36

    Installation & Operation Manual 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 38 of this manual and the boiler wiring diagram. LINE VOLTAGE J-BOX LOW VOLTAGE J-BOX LOW VOLTAGE[...]

  • Page 37

    37 Installation & Operation Manual 7 Field wiring (continued) 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 [...]

  • Page 38

    38 Installation & Operation Manual 7 Field wiring 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 ALAR M CONTA CTS RUN TIME CONTA CTS TANK THER MOSTAT ENAB L E LO U VE R PROVING L OUVER REL AY AUX SWITCH 1 AUX SWITCH 2 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 CASCA DE SYSTEM PUMP IN BMS IN OUTDOOR SENSOR SENSOR SENSOR SENS[...]

  • Page 39

    Installation & Operation Manual 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) fitti[...]

  • Page 40

    40 Installation & Operation Manual 9 Start-up Check/control water chemistry Do not use petroleum-based cleaning or sealing compounds in the boiler system. Damage to elastomer seals and gaskets in the system could occur, resulting in substantial property damage. Hardness less than 7 grains 1. Consult local water treatment companies for hard wate[...]

  • Page 41

    41 Installation & Operation Manual 9 Start-up (continued) Check for gas leaks 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[...]

  • Page 42

    42 Installation & Operation Manual 9 Start-up Final checks before starting the boiler  Read the Crest Service Manual to familiarize yourself with SMART TOUCH control module operation. Read this manual, page 43 for proper steps to start boiler.  Verify the boiler and system are full of water and all system components are correctly set for [...]

  • Page 43

    43 Installation & Operation Manual F O R YOUR S AF ET Y RE AD BE F ORE OP ERAT ING W A RNI NG : I f y ou do no t f oll ow t hes e i nstr uc t ions ex a c t l y, a f ir e or ex plos i on m ay r esult caus i ng pro per t y dam a ge, pers o nal i njury , or los s of lif e. A. T h i s ap p l i a n ce d o e s no t h a ve a p i l o t. It i s eq ui pp[...]

  • Page 44

    44 Installation & Operation Manual 9 Start-up Check flame and combustion (continued) 4. Navigate to the Service Screen from the Home Screen by pressing the MAIN MENU button and then the SERVICE button. 5. On the Service Screen place heater into Service Mode by selecting the START button, then selecting Set Gas Valve 1 - High . 6. Insert the pro[...]

  • Page 45

    45 Installation & Operation Manual Set Hot Water Generator (HWG) operation Verify HWG circulator mode The HWG Mode is programmed to heat an indirect hot water tank. When a tank thermostat or a tank sensor initiates a call for heat, the SMART TOUCH control will turn on the HW pump and turn off the boiler pump (if running). If the system pump is [...]

  • Page 46

    46 Installation & Operation Manual General How the boiler operates The Crest uses an advanced stainless steel heat exchanger and electronic control module that allows fully condensing operation. The blowers pull in air and push flue products out of the boiler through the heat exchanger and flue piping. The control module regulates blower speeds[...]

  • Page 47

    10 Operating information (continued) 47 Installation & Operation Manual 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 ba[...]

  • Page 48

    48 Installation & Operation Manual 10 Operating information 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 provi[...]

  • Page 49

    10 Operating information (continued) 49 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 [...]

  • Page 50

    10 Operating information 50 Installation & Operation Manual Sequence of operation 1. Upon a call for heat, the control turns on the appropriate pumps (system and boiler pumps for a space heating call, HW pump for a domestic hot water call). 2. The control confirms that the low water cutoff contacts are closed and energizes the louvers (optional[...]

  • Page 51

    10 Operating information (continued) 51 Installation & Operation Manual Outlet Water Temperature - This is the boiler outlet temperature. Inlet Water Temperature - This is the boiler inlet temperature. System Supply Temperature - This is the water temperature as measured by the system supply sensor located in the downstream piping (if connected[...]

  • Page 52

    52 Installation & Operation Manual 10 Operating information Figure 10-2 Main Menu Screen Use the Main Menu Screen (FIG. 10-2) to access the screens necessary to set temperatures, operating conditions, and monitor boiler operation. The Crest is equipped with a SMART TOUCH control system. All menu options are accessed by touching the screen with [...]

  • Page 53

    53 Installation & Operation Manual 11 Maintenance Maintenance and annual startup Table 11A Service and Maintenance Schedules 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 • Che[...]

  • Page 54

    54 Installation & Operation Manual 11 Maintenance 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 [...]

  • Page 55

    55 Installation & Operation Manual 11 Maintenance (continued) 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 discharg[...]

  • Page 56

    56 Installation & Operation Manual 11 Maintenance 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. Repl[...]

  • Page 57

    57 Installation & Operation Manual 11 Maintenance (continued) 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.  WARNING Cleaning boiler heat exchanger 1. Shut down boiler: • Follow the “To Turn Off Gas to Appliance?[...]

  • Page 58

    58 Installation & Operation Manual JUNCTION BOX TERMIN AL STRIP 120V SU PPLY "L" TERMINAL STR IP 120V SUPPLY "N" 120VAC NEUTRAL INTEGRA TED CONTROL ON/OFF SWITCH F2 3.15 A F4 5 .0 A SYSTEM PU MP R ELAY BO ILER PUMP RE LAY DH W PU MP RELAY X1-1 X1-2 X 1 - 4 X1-8 X 2-4 SMA L L B L OW ER RELA Y LAR G E BLO W ER RELAY SMALL G A [...]

  • Page 59

    59 Installation & Operation Manual 12 Diagrams (continued) Figure 12-2 Wiring Diagram -T -T -T -T -T -T - T - T -T 23 1 1 2 4 5 3 23 1 1 2 45 3 M 1 2 3 Notes : 1. All w i ring m u s t be inst alled i n ac c ordanc e with: lo cal, stat e, provincia l and na t ion al code req uir ements per either N.E. C . in USA or C . S.A. in Canada. 2. If any [...]

  • Page 60

    Revision Notes: Revision A (ECO #C07970) initial release. Revision B (ECO #C08023) reflects changes made to FIG. 6-3 on page 32 for Mass approval and changes made to FIG. 5-3 on page 28. Revision C (ECO #C08179) reflects the addition of three (3) new vent manufacturers (pg. 16 - Table 2A). Revision D (ECO #C08585) reflects edits made to FIG. 4-4 an[...]