Lochinvar Crest 5.0 Installation & Operation Manual
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Lochinvar Crest 5.0 Installation & Operation Manual

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See also: User's Information Manual
FB-I-O Rev V_2000004593_100161011
Installation & Operation Manual
Models: 1.5 - 5.0
This manual must only be used by
WARNING
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.
Save this manual for future reference.

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  • Page 1 FB-I-O Rev V_2000004593_100161011 Installation & Operation Manual Models: 1.5 - 5.0 This manual must only be used by WARNING 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: Table Of Contents

    Contents HAZARD DEFINITIONS ............ 2 5. HYDRONIC PIPING PLEASE READ BEFORE PROCEEDING ......3 System Water Piping Methods ......... 24 THE CREST -- HOW IT WORKS ........4-5 Low Water Cutoff Device ..........24 RATINGS ................6 Chilled Water System ............24 Freeze Protection .............

  • Page 3: Please Read Before Proceeding

    Installation & Operation Manual Please read before proceeding The California Safe Drinking Water and Installer – Read all instructions, including WARNING WARNING Toxic Enforcement Act requires the this manual and the Crest Service Manual, Governor of California to publish a list of before installing.

  • Page 4: The Crest - How It Works

    Installation & Operation Manual The Crest - How it works... 19. High limit devices (primary and backup) 1. Front access panels The high limit devices are used to monitor the outlet water Provides access to the controls compartment. temperature - if either device senses the water temperature 2.
  • Page 5 Installation & Operation Manual The Crest - How it works... (continued) Models 1.5 - 5.0 Front View Rear View MODELS 4.0 - 5.0 IMG00318 MODELS 1.5 - 3.5 Right Side (inside unit) Left Side (inside unit)

  • Page 6: Ratings

    Installation & Operation Manual Ratings Crest Other Specifications AHRI Rating Vent Weight AHRI Model Number Gross Input Appliance Size w/Water Pipe Pipe Ratings Output Water Gas Inlet (lbs.) Size Size Size Water, Content Size Outlet Inlet Note: Change “N” to (Notes 4 - 6) Gallons “L”...

  • Page 7: Determine Boiler Location

    Installation & Operation Manual Determine boiler location Installation must comply with: Check around the boiler for any potential air contaminants • Local, state, provincial, and national codes, laws, that could risk corrosion to the boiler or the boiler combustion regulations, and ordinances. air supply (see Table 1A on page 9).

  • Page 8: Provide Air Openings To Room

    Installation & Operation Manual Determine boiler location Flooring and foundation If you do not provide the recommended NOTICE service clearances shown, it may not be Flooring possible to service the boiler without removing it from the space. The Crest is approved for installation on combustible flooring, but must never be installed on carpeting.

  • Page 9: Using An Existing Vent System To Install A New Boiler

    Installation & Operation Manual Determine boiler location (continued) When using an existing vent system to install a new boiler: Table 1A Corrosive Contaminants and Sources Failure to follow all instructions can result Products to avoid: WARNING in flue gas spillage and carbon monoxide Spray cans containing chloro/fluorocarbons emissions, causing severe personal injury Permanent wave solutions...

  • Page 10: Removing A Boiler From Existing Common Vent

    Installation & Operation Manual Determine boiler location When removing a boiler from existing common vent system: Do not install the Crest into a common d. Place in operation the appliance being inspected. DANGER vent with any other appliance except Follow the lighting instructions. Adjust thermostat so as noted in Section 2 on page 18.

  • Page 11: Remove Boiler From Wood Pallet

    Installation & Operation Manual Determine boiler location (continued) Remove boiler from wood pallet Figure 1-3 Boiler Removed from Shipping Pallet 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).

  • Page 12: Combustion And Ventilation Air Requirements

    Installation & Operation Manual Determine boiler location Combustion ventilation 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.
  • Page 13 Installation & Operation Manual Determine boiler location (continued) Under no circumstances should the If a single combustion air opening is provided to bring CAUTION equipment room ever be under negative combustion air in directly from the outdoors, the pressure. Particular care should be taken opening must be sized based on a minimum free area where exhaust fans, attic fans, clothes dryers, of one square inch per 3000 Btu/hr (7 cm...

  • Page 14: General Venting

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

  • Page 15: Install Vent And Combustion Air Piping

    Installation & Operation Manual General venting (continued) Install vent and combustion air piping The Crest must be vented and supplied Sealing of Type “B” double-wall vent material or galvanized DANGER with combustion and ventilation air as vent pipe material used for air inlet piping on a sidewall or described in this section.

  • Page 16: Vent And Air Piping

    Installation & Operation Manual General venting Air intake/vent connections When a sidewall or vertical rooftop combustion air supply system is disconnected for any reason, the air inlet pipe Combustion Air Intake Connector (FIG. 2-1) - Used to must be resealed to ensure that combustion air will be free of provide combustion air directly to the unit from outdoors.

  • Page 17: Min./Max. Combustion Air & Vent Piping Lengths

    Installation & Operation Manual General venting (continued) Table 2A-2 Approved Stainless Steel Terminations and Adapters - Category IV ProTech Z Flex Heat Fab Model Adapter Intake Adapter Intake Adapter Flue Intake 810003315 9790 1500 810003977 2SVDSA07 2SVEE0790 CCA07MM CCK07TM 810003327 9792 810003357 9890...

  • Page 18: Common Venting

    Vent and air piping Each Crest boiler must have a Lochinvar supplied flue Vent and air system: damper installed (see Table 2D). Installation must comply with local...

  • Page 19: Vertical Direct Venting

    Installation & Operation Manual Vertical direct venting Vent/air termination – vertical Follow instructions below when determining WARNING Figure 3-2 Vertical Termination of Air and Vent w/Rain vent location to avoid possibility of severe personal injury, death or substantial property damage. Do not connect any other appliance to the WARNING vent pipe or multiple boilers to a common...

  • Page 20: Multiple Vent/Air Terminations

    Installation & Operation Manual Vertical direct venting 3. The vent piping must terminate in an up-turned coupling Figure 3-4 Alternate Vertical Terminations with Multiple as shown in FIG. 3-1. The top of the coupling or the Boilers rain cap must be at least 36" (914 mm) above the air intake.

  • Page 21: Sidewall Direct Venting

    Installation & Operation Manual Sidewall direct venting Vent/air termination – sidewall Follow instructions below when Sidewall vent and air inlet terminations WARNING WARNING determining vent location to avoid must terminate in the same pressure possibility of severe personal injury, death, zone.

  • Page 22: Prepare Wall Penetrations

    Installation & Operation Manual Sidewall direct venting Vent/air termination – sidewall Prepare wall penetrations Figure 4-2 Clearance to Doors and Windows Air pipe penetration: Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter.

  • Page 23: Room Air

    Installation & Operation Manual Sidewall direct venting (continued) 2. Place wall penetrations to obtain minimum clearance Figure 4-6 Room Air (Direct Exhaust Terminations) of 12 inches (305 mm) between vent pipe and adjacent air inlet, as shown in FIG. 4-4 for U.S. installations. For ROOM AIR (DIRECT EXHAUST TERMINATIONS) Canadian installations, provide clearances required by Vent Termination...

  • Page 24: Hydronic Piping

    Installation & Operation Manual Hydronic piping System water piping methods General piping information The Crest is designed to function in a closed loop pressurized Basic steps are listed below along with illustrations on the system not less than 12 psi (83 kPa). A temperature and following pages, which will guide you through the installation pressure gauge is included to monitor system pressure and of the Crest (5-2 thru 5-5).

  • Page 25: Circulator Sizing

    Installation & Operation Manual Hydronic piping (continued) 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.

  • Page 26: Near Boiler Piping Components

    ASME specifications. ABSOLUTE MINIMUM FLOW RATE 9. System temperature sensor: MODEL FLOW RATE (GPM) Lochinvar supplies a system temperature sensor. FB(N,L)1500 The sensor is to be installed in the heating loop downstream from the boiler hot water piping and FB(N,L)2000 heating loop junction.
  • Page 27 Installation & Operation Manual Hydronic piping (continued) Figure 5-2 Single Boiler - Recommended - Primary / Secondary Piping with a Hot Water Generator FROM SYSTEM SYSTEM RETURN SENSOR 12" BALL VALVE RELIEF HOT WATER (TYPICAL) VALVE GENERATOR AIR SEPERATOR DRAIN PORT (TYPICAL) SYSTEM SUPPLY SENSOR...
  • Page 28 Installation & Operation Manual Hydronic piping Table 5C Multiple Boilers - Common Header - Primary / Secondary Flow Number of Units Model Recommended Common Header Pipe Sizes in Inches FB 1500 FB 2000 FB 2500 FB 3000 FB 3500 FB 4000 FB 5000 [Based on a boiler ΔT of 30°F.] A system supply sensor (factory supplied) MUST BE installed for proper boiler operation.
  • Page 29 Installation & Operation Manual Hydronic piping (continued) Figure 5-4 Single Boiler - Alternate - Fixed or Variable Flow Primary System Piping RELIEF VALVE BALL VALVE (TYPICAL) FROM SYSTEM AIR SEPERATOR BOILER DRAIN DRAIN PORT (TYPICAL) SYSTEM CIRCULATOR Y-STRAINER (RECOMMENDED) EXPANSION TANK TO SYSTEM PRESSURE...
  • Page 30 Installation & Operation Manual Hydronic piping Figure 5-5 Multiple Boilers - Alternate - Common Header - Fixed or Variable Flow Primary RELIEF VALVE (TYPICAL) BALLVALVE (TYPICAL) 2-WAY MOTORIZED VALVE (OPTIONAL) FROM SYSTEM BOILER DRAIN (TYPICAL) SYSTEM RETURN AIR SEPERATOR SENSOR DRAIN PORT (TYPICAL) SYSTEM SUPPLY...

  • Page 31: Gas Connections

    Installation & Operation Manual Gas connections Gas supply Figure 6-1 Gas Supply Piping GAS SUPPLY Ensure that the high gas pressure regulator NOTICE is at least 10 feet (3 m) upstream of the appliance. UNION It is recommended to install one (1) gas regulator for each (FACTORY SUPPLIED) MANUAL SHUTOFF Crest boiler.

  • Page 32: Natural Gas

    Installation & Operation Manual Gas connections 3. Install 100% lockup gas pressure regulator in supply line for Use two wrenches when tightening gas WARNING each boiler if inlet pressure exceeds 14 inches w.c. (3.5 kPa). piping at boiler (FIG. 6-2), using one wrench to prevent the boiler gas line Gas valves used on Crest boilers are rated for at least 27 connection from turning.

  • Page 33: Check Inlet Gas Supply

    Installation & Operation Manual Gas connections (continued) Table 6B Natural Gas Pipe Size Chart TABLE - 6B 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) Length of Pipe in Straight Feet Pipe Size...

  • Page 34: Gas Valve Replacement

    Installation & Operation Manual Gas connections Gas valve replacement Do not check for gas leaks with an open WARNING flame -- use the bubble test. Failure to The gas valve MUST NOT be replaced with a use the bubble test or check for gas leaks conventional gas valve under any circumstances.

  • Page 35: Field Wiring

    Installation & Operation Manual Field wiring Line voltage connections - Models ELECTRICAL SHOCK HAZARD – For WARNING 1.5 - 3.5 your safety, turn off electrical power supply before making any electrical connections to avoid possible electric shock hazard. 1. Connect 120 VAC power wiring to the line voltage terminal strip in the junction box, as shown in FIG.

  • Page 36: Low Voltage Connections

    Installation & Operation Manual Field wiring ModBus Low voltage connections The RS-485 ModBus cable is connected to the ModBus 1. Route all low voltage wires through the knockouts in the terminals. Use shielded, 2-wire twisted pair cable. If desired, rear of the boiler, as shown in FIG. 7-2. the shield can be connected to ground by installing a jumper wire between terminals 1 and 3 on connector X5 on the 2.

  • Page 37: Wiring Of The Cascade

    Installation & Operation Manual Field wiring (continued) Auxiliary switch 1 & 2 Wiring of the cascade Additional field supplied limit controls may be connected to When wiring the boilers for Cascade operation, select one boiler the auxiliary switch inputs. If additional limit controls fail or as the Leader boiler.
  • Page 38 Installation & Operation Manual Field wiring Figure 7-3 Low Voltage Field Wiring Connections...

  • Page 39: Condensate Disposal

    Installation & Operation Manual Condensate disposal Condensate drain 9. Do not expose condensate line to freezing temperatures. 1. The Crest is a high efficiency appliance that produces Use materials approved by the authority condensate. NOTICE having jurisdiction. In the absence of 2.

  • Page 40: Startup

    Installation & Operation Manual Start-up Check/control water chemistry Fill and test water system Do not use petroleum-based cleaning or CAUTION sealing compounds in the boiler system. 1. Fill system only after ensuring the water meets the Damage to elastomer seals and gaskets requirements of this manual.

  • Page 41: Check For Gas Leaks

    Installation & Operation Manual Start-up (continued) Check for gas leaks Propane boilers only – Your propane WARNING supplier mixes an odorant with the propane Before starting the boiler, and during to make its presence detectable. In some WARNING initial operation, smell near the floor and instances, the odorant can fade, and the around the boiler for gas odorant or any gas may no longer have an odor.

  • Page 42: Start The Boiler

    Installation & Operation Manual Start-up Final checks before starting the boiler  Check vent piping and air piping 1. Check for gastight seal at every connection, seam of air  Read the Crest Service Manual to familiarize yourself piping, and vent piping. with SMART TOUCH control module operation.

  • Page 43: For Your Safety Read Before Operating

    Installation & Operation Manual Start-up (continued) 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. •...

  • Page 44: Set Space Heating Operation

    Installation & Operation Manual Start-up Check flame and combustion Set space heating operation (continued) 4. Navigate to the Service Screen from the Home Screen Verify space heat circulator mode by pressing the MAIN MENU button and then the SERVICE button. The system pump output can be programmed to never 5.
  • Page 45 Installation & Operation Manual Start-up (continued) Set Hot Water Generator (HWG) operation Verify HWG mode There are two (2) modes of operation for HWG. In Normal The internal clock does not adjust for NOTICE Mode, when a HWG demand begins, the control will start Daylight Savings Time and therefore, will the HWG pump, turn off the boiler pump (if running), and require a manual adjustment.

  • Page 46: Operating Information

    Installation & Operation Manual Operating information General HWG priority The SMART TOUCH control allows the connection of a HWG How the boiler operates thermostat or tank sensor to the low voltage connection board. When a tank sensor is connected, the HWG thermostat input The Crest uses an advanced stainless steel heat exchanger is ignored.
  • Page 47 Installation & Operation Manual Operating information (continued) Gradient limiting Ramp Delay If during operation of the boiler the outlet water temperature For systems with lower flow, the SMART TOUCH can limit is rising too quickly, the control will reduce the firing rate to the firing rate (when enabled) when a space heating call for its lowest setting.
  • Page 48 Installation & Operation Manual Operating information Monitor external limits High limit operations Connections are provided on the connection board for The Crest SMART TOUCH control has two (2) integral limits, external limits such as an additional high limit. one auto reset and one manual reset. The Crest also has one SMART TOUCH control will shut off the burner and auxiliary manual reset high limit.

  • Page 49: Cascade

    Installation & Operation Manual Operating information (continued) Cascade Sequence of the cascade When multiple boilers are installed, they can be wired together To equalize the run time of all boilers on the Cascade, the in a cascade sequence. A maximum of eight boilers can be firing sequence will automatically be changed at set intervals.

  • Page 50: Sequence Of Operation

    Installation & Operation Manual Operating information Sequence of operation Note: This unit is equipped with two (2) gas train systems. Gas Train 1 will fire first. If the demand cannot be met by the first gas train, the second gas train (Gas Train 2) will fire. Upon a call for heat, the control turns on the appropriate pumps (system and boiler pumps for a space heating call, HWG pump for a hot water generator call).

  • Page 51: Status Screen

    Installation & Operation Manual Operating information (continued) Crest control module The Home Screen displays status, modulation rate, outlet water temperature, inlet water temperature, flue temperature, system supply temperature, system return temperature, outdoor air temperature, and domestic hot water tank temperature. The boiler can be started and stopped by pressing the ON/OFF button.

  • Page 52: Main Screen

    Installation & Operation Manual Operating information 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 your finger or a stylus from a PDA.

  • Page 53: Maintenance

    Installation & Operation Manual Maintenance Maintenance and annual startup Table 11A Service and Maintenance Schedules Owner maintenance Service technician (see the Crest User’s Information Manual for (see the following pages for instructions) instructions) General: • Address reported problems, if any •...

  • Page 54: Address Reported Problems

    Installation & Operation Manual Maintenance Follow the service and maintenance procedures given throughout this manual and in component literature WARNING 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.

  • Page 55: Check Expansion Tank

    Installation & Operation Manual Maintenance (continued) Check expansion tank 2. After following the above warning directions, if the relief valve weeps or will not seat properly, replace the relief 1. Expansion tanks provide space for water to move in valve. Ensure that the reason for relief valve weeping is and out as the heating system water expands due to the valve and not over-pressurization of the system due temperature increase or contracts as the water cools.

  • Page 56: Check Burner Flame

    Installation & Operation Manual Maintenance Check burner flame Figure 11-2 Burner Assembly 1. Inspect flame through observation windows. 2. If the flame is unsatisfactory at either high fire or low INSULATION fire, remove and clean the burner. Clean the burner thoroughly using a vacuum cleaner or compressed AIR/GAS air.

  • Page 57: Review With Owner

    Installation & Operation Manual Maintenance (continued) Review with owner 15. Replace the burner mounting plate assembly and gas/air manifold assembly. Ensure gaskets are in good condition 1. Review the Crest User’s Information Manual with the and positioned properly. Restore boiler to operation. owner.

  • Page 58: Diagrams

    Installation & Operation Manual Diagrams Figure 12-1 Ladder Diagram_ 1.5 - 3.5 Models...
  • Page 59 Installation & Operation Manual Diagrams (continued) Figure 12-2 Wiring Diagram_ 1.5 - 3.5 Models BOX DEPICTS OPTIONAL ITEMS BOX DEPICTS DUAL SENSOR SINGLE HOUSING MODBUS BOARD X1-1 LARGE CONNECTION BOARD X1-2 LOW VOLTAGE X1-3 120 VAC SHIELD CN6-3 X6-3 INTEGRATED CONTROL CN6-2 X6-1 MODBUS...

  • Page 60: Ladder Diagrams

    Installation & Operation Manual Diagrams (continued) Figure 12-3 Ladder Diagram_ 4.0 Model NEUTRAL JUNCTION BOX BOX DEPICTS L1 L2 L3 TERMINAL STRIP TERMINAL STRIP OPTIONAL ITEMS 208V 3 SUPPLY 208V SUPPLY "N" BOX DEPICTS DUAL SENSOR SINGLE HOUSING INTEGRATED CONTROL X1-3 MODBUS 1.5A EACH MAX...
  • Page 61 Installation & Operation Manual Diagrams (continued) Figure 12-4 Wiring Diagram_ 4.0 Model BOX DEPICTS OPTIONAL ITEMS BOX DEPICTS DUAL SENSOR SINGLE HOUSING MODBUS BOARD X1-1 LARGE CONNECTION BOARD X1-2 LOW VOLTAGE X1-3 120 VAC CN6-3 X6-3 SHIELD INTEGRATED CONTROL CN6-2 X6-1 MODBUS HIGH VOLTAGE...
  • Page 62 Installation & Operation Manual Diagrams (continued) Figure 12-5 Ladder Diagram_5.0 Model NEUTRAL JUNCTION BOX BOX DEPICTS L1 L2 L3 TERMINAL STRIP TERMINAL STRIP OPTIONAL ITEMS 208V 3 SUPPLY 208V SUPPLY "N" BOX DEPICTS DUAL SENSOR SINGLE HOUSING INTEGRATED CONTROL X1-3 MODBUS 1.5A EACH MAX ON/OFF...
  • Page 63 Installation & Operation Manual Diagrams (continued) Figure 12-6 Wiring Diagram_5.0 Model BOX DEPICTS OPTIONAL ITEMS BOX DEPICTS DUAL SENSOR SINGLE HOUSING MODBUS BOARD X1-1 LARGE CONNECTION BOARD X1-2 LOW VOLTAGE X1-3 120 VAC CN6-3 X6-3 SHIELD INTEGRATED CONTROL CN6-2 X6-1 MODBUS HIGH VOLTAGE OPTION...

  • Page 64: Wiring Diagrams

    Revision K (ECO C12612) reflects edits made to Table 5A on page 25 (R05939), note added to FIG. 5-5 on page 30, the addition of the Lead/Lag statement on page 18, along with edits made to Table 9A - Flue Products Chart. Revision Notes: Revision A (ECO #C07970) initial release.

This manual is also suitable for:

Crest 2500 seriesCrest 3000 seriesCrest 5000 seriesCrest 3500 seriesCrest 4000 series

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