Lochinvar Crest FBL0751 Installation & Operation Manual
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Lochinvar Crest FBL0751 Installation & Operation Manual

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FBII-I-O_100208043_2000004587 Rev E
Installation & Operation Manual
Models: 751 - 2001
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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Summary of Contents for Lochinvar Crest FBL0751

  • Page 1 FBII-I-O_100208043_2000004587 Rev E Installation & Operation Manual Models: 751 - 2001 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 Termination and Fittings ..........26 PLEASE READ BEFORE PROCEEDING ......3 Multiple Vent/Air Terminations ....... 26-27 THE CREST -- HOW IT WORKS ........4-5 Room Air ..............27 RATINGS ................6 5. HYDRONIC PIPING System Water Piping Methods ......... 28 1.

  • Page 3: Please Read Before Proceeding

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

  • Page 4: The Crest - How It Works

    Installation & Operation Manual The Crest - How it works... 1. Front access panels 20. Ignition electrode Provides access to the controls compartment. An electrical spark across the electrodes will ignite the burner. 2. Top access panel 21. Line voltage junction box Provides access to the burner compartment.
  • Page 5 Installation & Operation Manual The Crest - How it works... (continued) IMG01128 IMG01025 Front View Rear View IMG01130 IMG01129 Left Side (inside unit) Right 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 19.

  • 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 IMG01057 IMG01033 IMG01056 Sidewall Vertical Vent, Sidewall Air Vertical Optional room air IMG01059 IMG01058 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 Table 2A-2 Approved Stainless Steel Terminations and Adapters - Category IV ProTech Z Flex Heat Fab Model Adapter Intake Adapter Intake Adapter Flue Intake 9690 751-1001 810003974 810003269 2SVDSA06 2SVEE0690 9601MAD CCK06TM 9692 9690 1251 810003980 810003281...
  • Page 18 Installation & Operation Manual General venting (continued) When determining equivalent combustion air and vent Vent, air piping and termination: length, add 5 feet (1.5m) for each 90° elbow and 3 feet (.9 m) The Crest vent and air piping can be installed through the roof for each 45°...

  • Page 19: Common Venting

    Crest boilers connected to the common vent must all be FB1251 8" 100141561 of the same size. FB1501 8" 100141561 Each Crest boiler must have a Lochinvar supplied flue FB1751 8" 100141561 damper installed (see Table 2D). FB2001 8" 100141561...
  • Page 20 Installation & Operation Manual General venting (continued) Table 2E PVC/CPVC Vent Pipe, and Fittings Dry fit vent or air piping to ensure proper fit up before assembling any joint. The pipe should go Approved PVC/CPVC Vent Pipe and Fittings a third to two-thirds into the fitting to ensure Item Material Standard...

  • Page 21: Polypropylene

    Installation & Operation Manual General venting Polypropylene Use only the adapters and vent system listed WARNING in Tables 2F and 2G. DO NOT mix vent This product has been approved for use with polypropylene systems of different types or manufacturers. vent with the manufacturers listed in Table 2F.

  • Page 22: Vertical Direct Venting

    Installation & Operation Manual Vertical direct venting Vent/air termination – vertical Follow instructions below when determining Figure 3-2 Vertical Termination of Air and Vent w/Rain WARNING 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 23: 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 24: 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 25 Installation & Operation Manual Sidewall direct venting Vent/air termination – sidewall Figure 4-2A PVC/CPVC/ Polypropylene Sidewall Termination w/Field Supplied Fittings Figure 4-1B PVC/CPVC/ Polypropylene Sidewall Termination of Air and Vent w/Field Supplied Fittings BIRD SCREEN TO BOILER INTAKE AIR CONNECTION 36"...

  • Page 26: Prepare Wall Penetrations

    Installation & Operation Manual Sidewall direct venting (continued) Vent/air termination – sidewall Prepare wall penetrations 6. Locate terminations so they are not likely to be damaged by foreign objects, such as stones or balls, or subject to buildup Air pipe penetration: of leaves or sediment.

  • Page 27: Room Air

    Installation & Operation Manual Sidewall direct venting 2. Place wall penetrations to obtain minimum clearance Figure 4-7 Room Air (Direct Exhaust Terminations) of 12 inches (305 mm) between vent pipe and adjacent air inlet, as shown in FIG. 4-5 for U.S. installations. For ROOM AIR (DIRECT EXHAUST TERMINATIONS) Canadian installations, provide clearances required by Vent Termination...

  • Page 28: Hydronic Piping

    Installation & Operation Manual Hydronic piping System water piping methods General piping information All boiler piping must contain an oxygen IMPORTANT The Crest is designed to function in a closed loop pressurized barrier. This will help prevent any excess system not less than 12 psi (83 kPa). A temperature and oxygen from entering the system.

  • Page 29: Circulator Sizing

    Installation & Operation Manual Hydronic piping 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 30: Near Boiler Piping Components

    ASME specifications. MODEL FLOW RATE (GPM) 9. System temperature sensor: FB(N,L)0751 Lochinvar supplies a system temperature sensor. The sensor is to be installed in the heating loop FB(N,L)1001 downstream from the boiler hot water piping and FB(N,L)1251 heating loop junction.
  • Page 31 Installation & Operation Manual Hydronic piping Figure 5-2 Single Boiler - Recommended - Primary / Secondary Piping with a Hot Water Generator FROM SYSTEM SYSTEM RETURN SENSOR HOT WATER GENERATOR 12" BALL VALVE (TYPICAL) RELIEF AIR SEPERATOR VALVE DRAIN PORT (TYPICAL) SYSTEM SUPPLY SENSOR...
  • Page 32 Installation & Operation Manual Hydronic piping (continued) Table 5C Multiple Boilers - Common Header - Primary / Secondary Flow Number of Units Model Recommended Common Header Pipe Sizes in Inches FB 0751 FB 1001 FB 1251 FB 1501 FB 1751 FB 2001 [Based on a boiler ΔT of 30°F.] A system supply sensor (factory supplied) MUST BE installed for proper boiler operation.
  • Page 33 Installation & Operation Manual Hydronic piping 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) Y-STRAINER (RECOMMENDED) SYSTEM CIRCULATOR PRESSURE REDUCING VALVE (OPTIONAL) BYPASS EXPANSION...
  • Page 34 Installation & Operation Manual Hydronic piping (continued) Figure 5-5 Multiple Boilers - Alternate - Common Header - Fixed or Variable Flow Primary RELIEF VALVE (TYPICAL) ISOLATION VALVE 2-WAY MOTORIZED VALVE (OPTIONAL) FROM SYSTEM BOILER DRAIN (TYPICAL) AIR SEPERATOR DRAIN PORT SYSTEM RETURN (TYPICAL) SENSOR...

  • Page 35: Gas Connections

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

  • Page 36: Natural Gas

    Installation & Operation Manual Gas connections (continued) 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 37: Check Inlet Gas Supply

    Installation & Operation Manual Gas connections 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 (Inches)

  • Page 38: Gas Valve Replacement

    Installation & Operation Manual Gas connections (continued) 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 39: Field Wiring

    Installation & Operation Manual Field wiring Line voltage connections ELECTRICAL SHOCK HAZARD – For WARNING your safety, turn off electrical power supply 1. Connect 120 VAC power wiring to the line voltage terminal before making any electrical connections strip in the junction box, as shown in FIG. 7-1. to avoid possible electric shock hazard.

  • Page 40: Low Voltage Connections

    Installation & Operation Manual Field wiring ModBus / BACnet (continued) Low voltage connections The RS-485 ModBus / BACnet cable is connected to the ModBus terminals. Use shielded, 2-wire twisted pair cable. If 1. Route all low voltage wires through the knockouts in the desired, the shield can be connected to ground by installing a rear of the boiler, as shown in FIG.

  • Page 41: Wiring Of The Cascade

    Installation & Operation Manual Field wiring Auxiliary switch 1 & 2 Wiring of the cascade When wiring the boilers for Cascade operation, select one boiler Additional field supplied limit controls may be connected to as the Leader boiler. The remaining boilers will be designated the auxiliary switch inputs.
  • Page 42 Installation & Operation Manual Field wiring (continued) Figure 7-3 Low Voltage Field Wiring Connections...

  • Page 43: Condensate Disposal

    Installation & Operation Manual Condensate disposal Condensate drain 1. The Crest is a high efficiency appliance that produces 9. Do not expose condensate line to freezing temperatures. condensate. Use materials approved by the authority 2. The rear of the boiler has a 1 inch (25.4 mm) stainless steel NOTICE having jurisdiction.

  • Page 44: Startup

    Installation & Operation Manual Start-up Freeze protection Fill water Check/control fill water chemistry Ethylene glycol is toxic, DO NOT use as WARNING your freeze protection. Ethylene glycol has a Conduct water quality testing prior to IMPORTANT sweet aroma which children and pets could installing the appliance.
  • Page 45 Installation & Operation Manual Start-up (continued) Oxygen prevention Fill and test water system 1. Fill system only after ensuring the water meets the Eliminate all system leaks. Continual CAUTION requirements of this manual. fresh makeup water will reduce boiler life. Minerals can build up in the 2.

  • Page 46: Check For Gas Leaks

    Installation & Operation Manual Start-up 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 47: Start The Boiler

    Installation & Operation Manual Start-up (continued) 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 48: For Your Safety Read Before Operating

    Installation & Operation Manual Start-up 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. • A.
  • Page 49 Installation & Operation Manual Start-up (continued) Check flame and combustion Table 9A Flue Products Chart (continued) 4. Navigate to the Service Maintenance Screen from the Natural Gas Flue Products Home Screen by pressing the SETUP button, enter the Gas Valve CO 2 (%) O 2 (%) installer password, and then using the scrolling menu...
  • Page 50 Installation & Operation Manual Start-up Set space heating operation Set space heating set point temperature During normal operation, space heating set point Verify space heat circulator mode temperatures can be adjusted from the Home Screen by The system pump output can be programmed to never run pressing the DETAILS button on the bottom of the screen (OFF), run only when a space heating demand is present (see FIG.
  • Page 51 Installation & Operation Manual Start-up (continued) Set Hot Water Generator (HW) operation Set HW boiler target temperature When in the HW Mode, the control will modulate to maintain Note: For more detailed instructions, please refer to the the boiler outlet temperature or system supply temperature to Crest Service Manual.
  • Page 52 Installation & Operation Manual Start-up Configuration of the cascade Note: For more detailed instructions, please refer to the Crest Service Manual. When installed in a Cascade system, the individual controls must be programmed for cascade operation. Access the Cascade Setup options as follows: 1.

  • Page 53: Operating Information General

    Installation & Operation Manual Operating information General HW priority The SMART TOUCH control allows the connection of a HW How the boiler operates thermostat or tank sensor to the low voltage connection board. When a tank sensor is connected, the HW thermostat input is The Crest uses an advanced stainless steel heat exchanger ignored.
  • Page 54 Installation & Operation Manual Operating information 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 55 Installation & Operation Manual Operating information (continued) 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 56: Cascade

    Installation & Operation Manual Operating information 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 57: Sequence Of Operation

    Installation & Operation Manual Operating information (continued) Sequence of operation 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 hot water generator call). The control confirms that the low water cutoff contacts are closed and energizes the louvers (optional) and damper (optional) relays.

  • Page 58: Home Screen

    There are three (3) main sections located next display the following: Outdoor Air, Hot Water Temp, to the Lochinvar icon: Home, View, and Setup. The Home System Supply Temperature, and System Return Section is the screen shown above. The View Section Temperature.

  • Page 59: 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 60: 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 61 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 62: Check Burner Flame

    Crest Installation and Operation Manual. NOTE: Be sure to pay close attention to the Lochinvar logo. - Do not drain the boiler unless it will be Align the logo with the Lochinvar exposed to freezing temperatures. If using GAS/AIR MANIFOLD COVER logo on the gas/air manifold to ensure proper assembly.

  • Page 63: Handling Ceramic Fiber Materials

    Installation & Operation Manual Maintenance (continued) Review with owner 15. Replace the burner mounting plate assembly and gas/air 1. Review the Crest User’s Information Manual with the manifold assembly. Ensure gaskets are in good condition owner. and positioned properly. Restore boiler to operation. 2.

  • Page 64: Diagrams

    Installation & Operation Manual Diagrams Figure 12-1 Ladder Diagram...

  • Page 65: Wiring Diagram

    Installation & Operation Manual Diagrams (continued) Figure 12-2 Wiring Diagram BOX DEPICTS OPTIONAL ITEMS DISCONNECT POWER BOX DEPICTS BEFORE SERVICING DUAL SENSOR SINGLE HOUSING LOW VOLTAGE 120 VAC SHIELD HIGH VOLTAGE OPTION SHIELD RATE BOILER PUMP OUT SENSOR SENSOR TANK SENSOR OR/W OUTDOOR...
  • Page 66 Installation & Operation Manual Notes...
  • Page 67 Installation & Operation Manual Notes...

  • Page 68: Revision Notes

    Revision Notes: Revision A (ECO #C17106) initial release. Revision B (ECO C17419) reflects the addition of the large Crest models (1501 - 2001). Revision C (Change #500000695) reflects the addition of ICC venting options on page 17 (R06799), add PVC to SS adapter 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).

This manual is also suitable for:

Crest fbn0751Crest fbl1251Crest fbn1001Crest fbl1001Crest fbn1251Crest fbl1751 ... Show all

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