Crest Dual Fuel Sup Manual - Models 1500
Contents
1. LCD DISPLAY DU941 SMALL CONNECTION BOARD ALARM 3d E CONTACTS _2 RUN TIME CONTACTS _ 4 4 TANK s THERMOSTAT ENABLE 1 CN1 4 L 1 CN1 5 CN1 6 OR CN1 12 OR CN1 10 BL CN1 11 BK 2 oun 1 1 Insti ERIS CN1 9 BR PROVING 104 CN1 8 _ 24 VAC LOUVER MN CN1 7 Y RELAY COIL 124 CN1 1 OR HIGH LIMIT CN1 2 SWITCH CN1 3 R d EN 1 i 0 134 SWITCH 1 AUX 155 SWITCH 2 2m en OOOOOODOODOOOOOO LWCO TEST PROBE SWITCH CF OR BK o Lo OR BK LWCO RESET R OR CAM PROPANE LGPS SWITCH _ o o BK GPS2 GPS3 OR o o OR o o BR e o o NATURAL LGPS 9 OR BLOWER PROVING SWITCH LARGE o T BLOWER PROVING SWITCH SMALL BLOCKED FLUE SWITCH BK BLOCKED DRAIN CAM SWITCH CAM SWITCH SWITCH PROPANE LIGHT NATURAL LIGHT Notes SPARK GENERATOR FLUE DAMPER TRANSFORMER Dual Fuel Supplemental Manual OX DEPICTS 1 DISCONNECT BK R BL aw 7 7 BK Ww G 9 OR BK2. 7 Revision Notes Back Cover 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 A DANGER EE indicates an imminently hazardous situation which if not avoided will result in death or serious A WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious A CAUTION i indicates a potentially hazardous situation which if not avoided may result in minor or moderate CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not CAUTION avoided may result in property damage NOTICE NOTICE indicates special instructions on installation operation or maintenance that are important but not related to personal injury or property damage CREST Dual Fuel Supplemental Manual TRAE PED Please read before proceeding A WARNING Installer Read all instructions including When servicing boiler this manual the Crest Installation and Operation Manual and the Crest Service To avoid electric shock disconnect electrical supply Manual before installing Perform steps before performing maintenance in the order given To avoid severe burns allow boiler to cool before Use
3. X6 11 CNT9 ad BR X4 T 0 m R H 6 14 s CN1 7 m Y X6 10 3 BILL TT ERN HIGH LIMIT CN1 2 FL SWITCH CN1 3 0 0 BL X6 4 BLOWER Exil o R LARGE oooooooooooooooQO ALARM CONTACTS 24 RUN TIME 34 CONTACTS 44 TANK CL 5 THERMOSTAT ENABLE WwW LOUVER o0 B PROVING 24 VAC LOUVER RELAY COIL ARI o 154 SWITCH 2 16 BLOWER SMALL 1 1 1 cA 1 114 Sm X13 2 W BK X13 3 R li FLAME SENSE 2 R LWCO TEST R T GENERATOR SPARK ROD PROBE SWITCH X6 3 OR BK a Lo OR BK P FLAME SENSE 1 LWCO RESET TRANSFORMER OR TRANSFORMER lt CAM X2 5 BK FAAS GND SWITCH PROPANE GPS2 GPS3 FLUE DAMPER NATURAL LGPS E oTt OR X6 15 Y BLOWER PROVING SWITCH LARGE X13 4 OR oLo _ _ _ _ H X6 12 BLOWER PROVING SWITCH SMALL O O PR X13 1 24V BLOCKED FLUE SWITCH TRANSFORMER Oo BK X6 6 BLOCKED DRAIN SWITCH CAM CAM SWITCH SWITCH is BL PROPANE LIGHT X11 e R Y NATURAL LIGHT x5 X5 9 BLOCK WIRING IS MODEL DEPENDANT Ke Notes 1 All wiring must be installed in accordance with local state pro
4. GND LIN ies OR HIGH LIMIT SWITCH R 05 0 BL FLAME SENSE 2 SPARK ROD SPARK GENERATOR FLUE DAMPER TRANSFORMER K FLUE DAMPER GND GPS2 GPS3 OR oo OR o o BR LI FLAME SENSE 1 PR 24V TRANSFORMER BK CAM SWITCH O Q BL E Y HEN SUE INTERFACE BLOCK WIRING IS MODEL DEPENDANT local state provincial and national code requirements per either N E C in USA or C S A in Canada 2 If any original equipment wire as supplied with the appliance must be replaced it must be replaced with wire having same wire gauge AWG and rated for a minimum of 105 C Exceptions Replacement high vo Itage spark lead and ribbon cables must be purchased from the factory Use of a non approved spark lead or ribbon cables can lead to operational problems 3 Actual connector block locations may vary from diagrams to troubleshoot unit which could result in non repairable damage to the integrated controller or other components those shown on diagrams Refer to actual components for proper connector block locations when using WIRING DIAGRAM LBL20282 REV A COA Ae Dual Fuel Supplemental Manual 3 Dia grams continued Figure 3 2 Ladder Diagram_1 5 3 5 Models 120VAC JUNCTION BOX NEUTRAL 09 DISCO
5. 1 LWCO TEST PROBE SWITCH 3 3 LWCO RESET 2 1 CAM J2 2 SWITCH 24V TRANSFORMER C SMALL BLOWER RELAY C LARGE BLOWER CONTACTOR FLAME SENSE 2 GENERATOR SPARK ROD LAME SENSE 1 T PROPANE PROPANE LIGHT e NATURAL LIGHT FROPARE LGPS BLOWER PROVING SWITCH LARGE BLOWER PROVING SWITCH SMALL BLOCKED FLUE SWITCH BLOCKED DRAIN SWITCH X5 BLOCK WIRING IS MODEL DEPENDANT GPS2 GPS3 CAM SWITCH NRTURALLGPS X6 15 INTEGRATED CONTROL Notes HIGH LIMIT SWITCH OPTIONAL ITEMS GROUND INTEGRATED CONTROL INLET SENSOR X8 8 RIBBON CABLE SMALL CONNECTION BOARD CN1 4 CN1 5 CN6 2 LARGE CONNECTION BOARD CN6 3 DISCONNECT POWER BEFORE SERVICING LOW VOLTAGE 120 VAC HIGH VOLTAGE CN6 1 OS OSA SO ON SY OO OY OV SHIELD MODBUS B OPTION SHIELD RATE OUT BOILER PUMP OUT SYSTEM RETURN SENSOR SYSTEM SUPPLY SENSOR TANK SENSOR OUTDOOR SENSOR BMS IN SYSTEM PUMP IN SHIELD CASCADE SHIELD DU941 CN1 6 CN1 12 i CN1 10 CN1 11 CN1 9 CN1 8
6. Size Inches 10 20 30 40 50 60 70 80 90 100 125 150_ Maximum Capacities of Pipe in KBTUH Hr _ Maximum Capacities of Pipe in KBTUH Hr 3230 2842 2175 2035 5939 5270 4776 4392 4083 3829 3614 3429 11963 10691 9736 8987 8378 7872 7443 7074 17510 15749 14407 13341 12470 11740 11119 10581 2 42521 36514 32398 29359 27001 25104 23538 22216 21082 20097 Notice Capacities show n are for Natural Gas Please consult supplier for proper gas pipe sizing for propane Table 1B Second Stage Piping at Low Pressure 1 2 PSI Nominal Iron Pipe Length of pipe or tubing feet Size Inches 10 20 30 40 50 60 70 80 90 100 125 150_ Maximum Capacities of Pipe in KBTUH Hr Check inlet gas supply DO NOT adjust or attempt to measure gas 4 Slowly turn on the gas supply at the factory installed valve outlet pressure Attempting to alter manual gas valve or measure the gas valve outlet pressure could result in damage to the valve causing potential severe personal injury death or 6 Adjust the temperature set point on the control panel of substantial property damage the SMART TOUCH control module to call for heat or utilize Service Mode see page 10 of this manual NOTICE The Dual Fuel Crest is equipped with two 2 inlet gas connections Each 7 Observe the gas supply pressure as the burner fires at connection must be checked
7. OR W CAM SWITCH SMALL VALVE e R BK e R W CAM SWITCH NATURAL VALVE R1 li li 11273 BLOWER SMALL Y2l3l4 1 BLOWER LARGE 1121314 FLAME SENSE SPARK ROD FLAME SENSE BEFORE SERVICING NATURAL PROPANE POWER 1 3 LOW VOLTAGE SHIELD 17 CN6 3 X6 3 INTEGRATED CONTROL 120 VAC MODBUS 4 1849 CN62 X6 1 eee HIGH VOLTAGE OPTION 1949 CN6 1 X6 2 SHIELD 2039 X4 1 X8 20 RATE 2149 X4 2 X8 10 OUT 224 X4 3 BOILER 2359 X7 8 PUMP OUT 244 xn SYSTEM RETURN 2549 a 208V 38 SENSOR 2649 aa N L1 L2 L3 A EA SYSTEM SUPPLY 2749 X8 12 SYSTEM PUMP SENSOR 284 CONTACTOR TANK 29 55 X8 5 BOILER PUMP SENSOR 3049 ner CONTACTOR OUTDOOR 3149 X8 6 DHW PUMP SENSOR 32419 exis CONTACTOR BMS 3349 X8 7 Ju gt HB JUNCTION X8 17 BOX SYSTEM 3549 X8 18 PUMP IN 3649 xd SHIELD 3749 Jj 3849 CASCADE INLET SENSOR B 39549 SHIELD 4049 SMALL VALVE VALVE 2 1 FLUE DAMPER 24V TRANSFORMER 16 1 All wiring must be installed in accordance with local state provincial and national code requirements per either N E C in USA or C S A in Canada 2 If any original equipment wire as supplied with the appliance must be replaced it must be replaced with wire having same wire gauge AWG and rated for a minimum
8. allowing gastoflowonlyifthe gasvalvesare powered and combustion air is flowing Small propane valve Valve 1 Propane The small propane gas valve senses the negative pressure created bytheblowers allowing gastoflowonlyifthe gas valvesare powered and combustion air is flowing Models FBD 1 5 5 0 IMG00062 Front View 4 Dual Fuel Supplemental Manual COME Ae Mi RE The Crest Dual Fuel How it works 8 10 11 12 13 14 15 Large natural gas valve Valve 2 Natural The large natural gas valve senses the negative pressure created by the blowers allowing gas to flow only if the gas valves are powered and combustion air is flowing Large propane gas valve Valve 2 Propane Thelarge propane gasvalvesensesthenegative pressurecreatedbythe blowers allowing gas to flow only if the gas valves are powered and combustion air is flowing Natural shutoff valve The natural shutoff valve is used to isolate the boiler gas train from the gas supply Propane shutoff valve The propane shutoff valve is used to isolate the boiler gas train from the gas supply Natural ball valve Valve 1 The ball valve for natural valve 1 is used to isolate natural valve 1 from the propane gas supply Propane ball valve Valve 1 The ball valve for propane valve 1 is used to isolate propane valve 1 from the natural gas supply Natural ball valve Valve 2 The ball valve for natural valve 2 is used to isolate natural va
9. 6 7 1 19 4 11 0 4 1 6 6 8 After Gas Valve 1 is set repeat the same procedure for the second gas train by selecting Set Gas Valve 2 High on the Service Screen FUEL SELECTION SWITCH IMG00063 DETAIL 9 Once the heater analysis is complete test the safety shutoff device by turning the manual shutoff valve to the OFF position and ensuring that the heater shuts down and registers an alarm Open the manual shutoff valve and reset the control 10 CRES Dual Fuel Supplemental Manual CAR Ae 2 Start u D continued 3 Turn off all ball valves 3 total for the fuel not i FIG Figure 2 2B Fuel Selector Switch Models 4 0 5 0 23 off all ball valves 3 total for the fuel not in use PROPANE PERSONALITY I D Figure 2 3 Ball Valves NATURAL PERSONALITY I D IMG00555 MAIN POWER SWITCH FUEL SELECTION SWITCH PROPANE IMG00063 DETAIL IMG00061 4 Turn on the ball valves for the ones in use 3 total 5 Turn the main power ON 6 Using the Touch Screen FIG 2 4 accept the appropriate personality identification as shown in FIG s 2 2A and 2 2B password required 5309 Figure 2 4 Personality Plug and Passcode Screens a j cos T A 12 45pm coo Sa M o n 3 Diagrams CREST Dual Fuel Supplemental Manual Aa Ae EP PT Figure 3 1 Wiring Diagram_1 5 3 5 Models 12 LARGE C
10. Tum gas shutoff valve counterclockwise mA mS m to OFF Handle will be perpendicular to to CLOSE E to OPEN pipe Do not force 7 Waitfive 5 minutes to clear out any gas If you then smell gas STOP Follow B in the safety information above this label If you dont smell gas go to next step TO TURN OFF GAS TO APPLIANCE Set the thermostat to lowest setting 4 Turn gas shut off valve counterclockwise to Turn off all electric power to the appliance OFF Handle will be perpendicular to pipe if service isto be performed Do not force Remove front door 5 Install front door LBL20053 REV B 2 Start up Check flame and combustion NOTICE A flame and combustion check must be performed on natural gas and then repeated on propane 1 Turn the main power off to the boiler by placing the On Off switch in the OFF position 2 Remove the flue temperature sensor from the flue collector Note Combustion measurements will be made at this point 3 Turn the main power on to the boiler by placing the On Off switch in the ON position 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 probe from a combustion analyzer into the hole left by the removal of the flue temperature sensor 7 Once the
11. heat exchanger has modulated up to rate measure the combustion The values should be in the range listed in Table 2A levels should be less than 200 ppm for a properly installed unit If the combustion is not within range reference the Troubleshooting Section in the Crest Service Manual for possible causes and corrective actions Table 2A Flue Products Chart CREST Dual Fuel Supplemental Manual ee MN SP 10 Repeat the same procedure for propane gas Reference the Dual Fuel Switching Instructions on pages 10 and 11 of this manual 11 Turn the main power off to the boiler and replace the flue temperature sensor into the flue pipe connection 12 Place the boiler back into normal operation A WARNING You must replace the flue gas temperature sensor to prevent flue gas spillage into the room Failure to comply could result in severe personal injury death or substantial property damage Dual fuel switching instructions 1 Turn the main power off to the boiler by placing the On Off switch in the OFF position FIG s 2 2A and 2 2B 2 Using the fuel selector switch FIG s 2 2A and 2 2B select the desired fuel Figure 2 2A Fuel Selector Switch Models 1 5 3 5 MAIN POWER SWITCH NS IMG00064 PROPANE PERSONALITY I D Pro ane NATURAL PERSONALITY I D Gas a ROTER 1 High 3 5 5 5 11 11 2 14 8 14 8 5 1 6 8 10 5 13 2 5 13 2 2 High 7 8 8 6 5
12. to ensure 10096 of rated input Percent of burner input will be proper operation displayed on the Modulation Screen 5 Turn the power switch to the ON position 8 Ensure inlet pressure is within specified range Minimum and maximum gas supply pressures are specified in this section of the manual 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 9 If gas supply pressure is within normal range and no If you experience a pressure drop greater than 1 inch w c 8 adjustments are needed proceed on to Step 11 249 Pa the meter regulator or gas line is undersized or in need of service Perform the steps below when checking inlet 10 Ifthe gas pressure is out of range contact the gas utility gas supply gas supplier qualified installer or service agency to l l determine the necessary steps to provide proper gas 1 Turn the main power switch to the OFF position pressure to the control 2 Shut off gas supply at the manual gas valve in the gas Turn the power switch to the OFF position piping to the appliance 12 Shut off the gas supply at the manual gas valve in the gas 3 Remove the 1 8 pipe plug on the flange to the factory piping to the appliance supplied gas shutoff valve and install a suitable 1 8 fitting field supplied for the manometer tubing Plac
13. CN1 7 CN1 1 cem TE 2 ALARM CONTACTS r3 TE 4 RUN TIME CONTACTS EN TANK THERMOSTAT LE8 W ENABLE LOUVER PROVING 24 VAC LOUVER RELAY COIL EN 7 AUX SWITCH 1 AUX SWITCH 2 CN1 2 CN1 3 SMALL BLOWER LARGE BLOWER LCD DISPLAY 1 All wiring must be installed in accordance with local state provincial and national code requirements per either N E C in USA or C S A in Canada 2 If any original equipment wire as supplied with the appliance must be replaced it must be replaced with wire having same wire gauge AWG and rated for a minimum of 105 C Exceptions Replacement high voltage spark lead and ribbon cables must be purchased from the factory Use of a non approved spark lead or ribbon cables can lead to operational problems which could result in non repairable damage to the integrated controller or other components 3 Actual connector block locations may vary from those shown on diagrams Refer to actual components for proper connector block locations when using diagrams to troubleshoot unit LADDER DIAGRAM LBL20345 REV A EH um CREST CPE M eee DO 3 Dia grams continued Figure 3 5 Wiring Diagram_5 0 Model JE OPTIONAL ITEMS MODBUS BOARD X1 1 1 2 LARGE CONNECTION BOARD
14. FBD SUP Rev LS CONDENSING BOILER Dual Fuel Supplemental Manual Models FBD 1 5 5 0 This manual must only be used by a qualified heating installer service technician Read all instructions including this manual along witk the Crest Installation and Operatior Manual and the Crest Service Manual before installing Perform steps in the order given Failure to comply coulc result in severe personal injury death or substantial property damage lt Lochiny High Efficiency Water Heaters Boilers and Pool Heaters Save this manual for future reference 5 HAZARD DEFINITIONS 2 2 START UP PLEASE READ BEFORE PROCEEDING 3 ota DOI BE ee cee eens eee 8 THE CREST HOW IT WORKS 4 Check System and 8 RATINGS A 5 Operating Instructions aisexaccccese peace bat 9 1 GAS CONNECTIONS Check Flame and 10 Check Inlet Gas Supply 6 Dual Fuel Switching Instructions 11 Gas Pressure man VID y 3 DIAGRAMS oerein 12 17 Gas Valve
15. G If the information in this manual is not followed exactly a fire or explosion may result causing property damage personal injury or loss of life This appliance MUST NOT be installed in any location where gasoline or flammable vapors are likely to be present WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building e Immediately call your gas supplier from a near by phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier 1 Propane gas connection The propane gas connection pipe is a threaded black iron pipe connection This pipe should be connected to the incoming gas supply to deliver propane gas to the boiler Natural gas connection The natural gas connection pipe is a threaded black iron pipe connection This pipe should be connected to the incoming gas supply to deliver natural gas to the boiler Fuel selection switch Switches the unit between natural and propane gas Natural gas indicator light green Indicates that natural gas operation has been selected Propane gas indicator light red Indicates that propane gas operation has been selected Small natural gas valve Valve 1 Natural The small natural gas valve senses the negative pressure created bytheblowers
16. HERMOSTAT ENABLE LOUVER PROVING 24 VAC LOUVER RELAY COIL 13 o EM AUX SWITCH 1 15 3 o EN 1 AUX SWITCH 2 SMALL BLOWER LARGE BLOWER 1 All wiring must be installed in accordance with local state provincial and national code requirements per either N E C in USA or C S A in Canada 2 If any original equipment wire as supplied with the appliance must be replaced it must be replaced with wire having same wire gauge AWG and rated for a minimum of 105 C Exceptions Replacement high voltage spark lead and ribbon cables must be purchased from the factory Use of a non approved spark lead or ribbon cables can lead to operational problems which could result in non repairable damage to the integrated controller or other components 3 Actual connector block locations may vary from those shown on diagrams Refer to actual components for proper connector block locations when using diagrams to troubleshoot unit LADDER DIAGRAM LBL20347 REV A EM 77 CREST Dual Fuel Supplemental Manual Notes 18 CREST Dual Fuel Supplemental Manual Notes 19 Revision Notes Revision A ECO C08841 initial release Revision B EC 010391 reflects the update of wiring and _ C r ladder diagrams on pages 12 and 13 W High Efficiency Water Heaters Boilers and Pool Heaters Revision C ECO C1 1685 reflects the addition of models 300 Maddox Simps
17. HIELD H 204G X4 1 BK X8 20 RATE S X4 2 T X8 10 OUT 220 m X4 3 BOILER 2349 naire Des fs SYSTEM RETURN 2916 Neda Bh 208V SENSOR 2648 ie a ay N L1 L2 L3 1 5 EACH MAX SYSTEM SUPPLY T 2719 BR eae eer SYSTEM PUMP SENSOR 2849 CONTACTOR B CN3 11 H w ET X8 11 CN3 10 X8 5 2 BOILER PUMP SENSOR 3049 CN3 9 ORW X8 15 OUTDOOR r n OS cn3 8 H P DHW PUMP SENSOR 3249 EE Q CONTACTOR ES CN3 1 H w 1 X8 16 BMS 10 2 L X8 7 JUNCTION 2 3449 BOX zi CN3 3 4 BK X8 17 SYSTEM oTov 3519 CN3 5 H L xo 18 PUMPIN CV sel T a X8 1 SHIELD 37 i A X BL X8 3 SOooogggg VJ CASCADE INLET SENSOR B 3949 A amp 4 SHIELD 404 X8 8 X8 2 X8 4 8 X1 6 ws EI LCD xt 12 DISPLAY X10 1 4 X141 PR xt2 F CT X4 4 OR a G 10 2 OR W CAM pes LL Sith ZX SMALL SMALL x10 3 NATURAL PROPANE VALVE VALVE I x10 3 cue CM CAM x LARGE LARGE NATURAL PROPAN VALVE VALVE SMALL CONNECTION BOARD i7 X6 18 R s ek L 4 R X3 3 X1 8 GY Kj 5 R X3 4 R1 CN1 6 oR X3 1 CN1 12 4 OR X3 2 X6 9 ul Pt F nr qm CN1 11
18. HIGH LIMIT SWITCH Notes 1 All wiring must be installed in accordance with local state provincial and national code requirements per either N E C in USA or C S A in Canada 2 If any original equipment wire as supplied with the appliance must be replaced it must be replaced with wire having same wire gauge AWG and rated for a minimum of 105 C Exceptions Replacement high voltage spark lead and ribbon cables must be purchased from the factory Use of a non approved spark lead or ribbon cables can lead to operational problems which could result in non repairable damage to the integrated controller or other components 3 Actual connector block locations may vary from those shown on diagrams Refer to actual components for proper connector block locations when using diagrams to troubleshoot unit LADDER DIAGRAM LBL20283 REV A EH CREST Dual Fuel Supplemental Manual PPP AP Ae EC amp 3 Dia grams continued Figure 3 3 Wiring Diagram_4 0 Model OPTIONAL ITEMS DISCONNECT POWER MODBUS BOARD X14 LARGE CONNECTION BOARD X12 X1 3 LOW VOLTAGE SHIELD S X63 j INTEGRATED CONTROL 120 VAC S HIGH VOLTAGE OPTION 19418 CN6 1 H PR X6 2 f UN S
19. ING SWITCH LARGE BLOWER PROVING SWITCH SMALL BLOCKED FLUE SWITCH BLOCKED DRAIN SWITCH m x5 xg BLOCK WIRING IS MODEL 4 DEPENDANT e SWITCH NATURAL LGPS CONTROL GPS2 GPS3 X6 15 CN1 4 CN1 5 CN1 6 CN1 12 CN1 10 CN1 11 CN1 9 CN1 1 CN1 1 N CN1 1 HIGH LIMIT SWITCH CN1 2 O O CN1 3 Notes SN E GROUND INTEGRATED CONTROL INLET SENSOR X8 8 OPTIONAL ITEMS CN34 CN3 9 SMALL CONNECTION BOARD Dual Fuel Supplemental Manual CN6 2 A WARNING DISCONNECT POWER BEFORE SERVICING LARGE CONNECTION BOARD CN6 3 LOW VOLTAGE 120 HIGH VOLTAGE CN6 1 CN3 6 CN3 7 CN3 14 CN3 13 CN3 12 CN3 11 ire CN3 10 CN3 8 SSP SOP CN3 1 CN3 2 H17 SHIELD F18 A MODBUS H19 B OPTION 20 SHIELD r21 RATE MEN OUT r23 BOILER L EE PUMP OUT B mae r26 SYSTEM RETURN SENSOR BE 28 SYSTEM SUPPLY SENSOR TANK SENSOR OUTDOOR SENSOR 0 10V BMS IN 0 10V SYSTEM PUMP IN SHIELD CASCADE SHIELD VSO ALARM CONTACTS RUN TIME CONTACTS TANK T
20. NNECT POWER INTEGRATED CONTROL ON OFF 1 5A EACH MAX g SWITCH TERMINAL STRIP END xe e HIGH VOLTAGE SYSTEM PUMP CONTACTOR INTEGRATED LARGE CONTROL CONNECTION BOARD BOLIER PUMP CONTACTOR Q DHW PUMP CONTACTOR SHIELD A MODBUS B OPTION X1 8 mom SHIELD _ 4 RATE SMALL BLOWER RELAY X2 4 LARGE BLOWER RELAY C OUT BOILER 2 PUMP OUT N SYSTEM RETUR SENSOR _ VIO SOO OO OPO OY OV POV OOOO TANK SENSOR OUTDOOR SENSOR FLAME Bus 4 SENSE 2 NS SYSTEM SPARK PUMP IN ROD SHIELD CASCADE SHIELD A X11 BA INLET SENSOR USB INTERFACE SMALL BLOWER SMALL BLOWER T 1 LARGE BLOWER RELAY LARGE BLOWER 5 X1 2 X1 3 FLUE DAMPER ee SMALL BLOWER TRANSFORMER LARGE BLOWER LWCO TEST PROBE SWITCH LWCO RESET J2 1 CAM J2 2 SWITCH net RIBBON CABLE D IGHT INTEGRATED CN1 CN3 L CONTROL NATURAL LIGHT te PROPA E LGPS Lt Rea GPS2 GPS3 SMALL DU941 CAM switcH NATU X6 15 CONNECTION BOARD BLOWER SWITCH LARGE BLOWER PROVING SWITCH SMALL ALARM CONTACTS RUN TIME CONTACTS THERMOSTAT BLOCKED FLUE SWITCH BLOCKED DRAIN SWITCH ENABLE LOUVER PROVING 24 VAC LOUVER RELAY COIL AUX SWITCH 1 AUX SWITCH 2 x5 BLOCK WIRING IS MODEL DEPENDANT
21. ONNECTION BOARD SHIELD MODBUS 4 OPTION SHIELD RATE OUT BOILER PUMP OUT SYSTEM RETURN SENSOR SYSTEM SUPPLY sensor TANK sensor OUTDOOR SENSOR LX lt BMS IN SYSTEM PUMP IN SHIELD 0 10V A CASCADE SHIELD DU941 CN1 SMALL CONNECTION BOARD ALARM CONTACTS RUN TIME CONTACTS TANK THERMOSTAT amp oooooooooooooooQo ENABLE M LOUVER PROVING 24 VAC LOUVER RELAY COIL LWCO TEST PROBE SWITCH C OR BK aLo ORB LWCO RESET OR SWITCH ofo _ T SWITCH PROPANE LIGHT gd L NATURAL LIGHT Notes 1 All wiring must be installed in accordance with Co CAM PROPANE LGPS e o c NATURAL LGPS o OR BLOWER PROVING SWITCH LARGE BLOWER PROVING SWITCH SMALL BLOCKED FLUE SWITCH BLOCKED DRAIN SWITCH BOX DEPICTS E LOPTIONAL ITEMS DISCONNECT POWER BEFORE SERVICING MODBUS BOARD LOW VOLTAGE 120 VAC m HIGH VOLTAGE GY R PR INTEGRATED CONTROL 1 5 EACH SYSTEM PUMP CONTACTOR 120V SUPPLY BOILER PUMP CONTACTOR A DHW PUMP CONTACTOR E JUNCTION BOX y s oO S NI INLET SENSOR BK ON OFF l SWITCH Qo LI
22. and nothing need be added for normal piping and pickup 9 For Crest Models 4 0 and 5 0 installations above 5 500 feet Ratings are based on a piping and pickup allowance of contact the factory 1 15 10 Ratings have been confirmed by the Hydronics Section of 3 Crest boilers require special gas venting Use only AHRI the vent materials and methods specified in the Crest Installation and Operation Manual P dli Standard Crest boilers equipped to operate from sea level to 4 500 feet only with no adjustments UNIT EQUIPPED FOR High altitude Crest Models 1 5 2 0 2 5 3 0 and 3 5 HIGH ALTITUDE boilers are equipped to operate from 3 000 to 12 000 feet and high altitude Crest Models 4 0 and 5 0 boilers 3000 FT TO 12 000 FT are equipped to operate from 3 000 to 5 500 feet High altitude models are manufactured with different control parameters for high altitude operation but the sequence of operation given in this manual remains the same as the standard boilers A high altitude label as shown in FIG A is also affixed to the unit Standard Crest boilers will de rate by 2 2 for each 1 000 feet above sea level up to 4 500 feet when combustion calibration is performed are adjusted to the recommended levels d n Figure A High Altitude Label Location 5 CREST Dual Fuel Supplemental Manual 1 Gas connections Table 1A First Stage Piping at High Pressure_10 PSI Nominal Iron Pipe Length of pipe or tubing feet
23. e 9 for proper steps to start boiler LI Verify the boiler and system are full of water and all system components are correctly set for operation LI Verify the preparation procedures of Section 9 of the Crest Installation and Operation Manual have been completed Verify electrical connections are correct and securely attached LI Inspect vent piping and air piping for signs of deterioration from corrosion physical damage or sagging Verify air piping and vent piping are intact and correctly installed per this manual Start the boiler 1 Read and follow the Operating instructions in FIG 2 1 page 9 If boiler does not start correctly 1 Check for loose connections blown fuse or service switch off 2 Is external limit control if used open Is boiler water temperature above 200 F 93 C 3 Is the boiler receiving a call for heat 4 Is gas turned on at meter and boiler 5 Is incoming gas pressure less than 4 inches w c 99 kPa If none of the above 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 repair immediately See WARNINGS in the Crest Installation and Operation Manual startup regarding failure to repair leaks 2 Vent any remaining air from the system using manual vents Air in the system will interfere with circulation and cause heat d
24. e the 13 Remove the manometer from the pressure tap on top of tubing of the manometer over the tap once the 1 8 the gas valve Remove the 1 8 3 mm field supplied fitting is installed as shown in FIG s 1 1 and 1 2 fitting and reinstall the pipe plug removed in Step 3 6 1 Gas connections continued not check for gas leaks with an open A WARNING flame use the bubble test Failure to 14 15 16 17 18 use the bubble test or check for gas leaks can cause severe personal injury death or substantial property damage Turn on the gas supply at the manual gas valve Turn the power switch to the position Adjust the temperature set point on the control panel of the SMART TOUCH control module to the desired water temperature so the appliance will call for heat Check burner performance by cycling the system while you observe burner response The 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 Repeat Steps 1 17 for both natural and LP gas supply Gas Pressure The gas pressure must remain between 4 inches w c 99 kPa minimum and 14 inches w c 3 5 kPa maximum for Natural gas and between 4 inches w c 99 kPa minimum and 14 inches w c 3 5 kPa maximum for LP gas during standby static mode and while in operating dynamic mode If an in line regulator is us
25. ed it must be a minimum of 10 feet 3 m from the Crest boiler It is very important that the gas line is properly purged by the gas supplier or utility company Failure to properly purge the lines or improper line sizing will result in ignition failure CREST GADEA Gir Niii 4 Dual Fuel Supplemental Manual Ignition problems are especially noticeable in NEW LP installations and also in empty tank situations This can also occur when a utility company shuts off service to an area to provide maintenance to their lines Gas valve replacement The gas valve MUST NOT be replaced with a conventional gas valve under any circumstances As an additional safety feature the gas valves have flanged connections to the venturis and blowers Failure to follow all precautions J could result in fire explosion or death A WARNING DO NOT adjust or attempt to measure gas valve outlet pressure Attempting to alter or measure the gas valve outlet pressure could result in damage to the valve causing potential severe personal injury death or substantial property damage Figure 1 1 Inlet Gas Supply Check Natural ips ttl X Al AAAA AAA P9 a Figure 1 2 Inlet Gas Supply Check Propane IMG00065 2 Start up Final checks before starting the boiler Q Read the Crest Service Manual to familiarize yourself with SMART TOUCH control module operation Read this manual pag
26. istribution problems and noise Dual Fuel Supplemental Manual CEN PAE Check vent piping and air piping 1 Check for gastight seal at every connection seam of air piping and vent piping A WARNING Venting system must be sealed gastight to prevent flue gas spillage and carbon monoxide emissions which will result in severe personal injury or death Check gas piping 1 Check around the boiler for gas odor following the procedure in the Crest Installation and Operation Manual connecting gas supply piping If you discover evidence of any gas leak shut down the boiler at once Find the leak source with a bubble test and repair immediately Do not start the boiler again until corrected Failure to comply could result in severe personal injury death or substantial property damage CREST Dual Fuel Supplemental Manual TRAE te PAE 2 Start u D continued Figure 2 1 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 This appliance does not have a pilot It is e Immediately call your gas supplier from a equipped with an ignition device which neighbor s phone Follow the gas suppliers automatically lights the burner Do not try instructions to lightthe burner by hand If you cannot reach your gas supplier call BEFORE OPERATING
27. lve 2 from the propane gas supply Propane ball valve Valve 2 The ball valve for propane valve 2 is used to isolate propane valve 2 from the natural gas supply Left Side inside unit 6 CREST Dual Fuel Supplemental Manual 6 Ch IDEE Aer Ratings DOE CERTIFIED AMPH CERTIFIED Crest x poeta AHRI Rating LIE Net Model Number Input AHRI Wishes MBH Ratings PpP Pipe Air Water Gas Inlet Note Ch N Water Content Size Size Size ote Change N to _ L for L P gas models PIS Gallons sulle Note 2 i FB NLD 500 60 1500 9 4 1 7 250 FBINLD 2000 80 200 184 16 a aie e 3055 FB N L D 2500 168 a 4a 2 amp o 3650 FB N L b 3000 N L D Other Specifications FB N L D 3500 FB N L D 4000 FB N L D 5000 For LP models the minimum input is 420 MBH NOTICE Maximum allowed working pressure is located on the rating plate Notes 7 High altitude Crest Models 1 5 2 0 2 5 3 0 and 3 5 will 1 The ratings are based on standard test procedures de rate by 1 4 for each 1 000 feet above sea level up to 5 500 prescribed by the United States Department of Energy feet and 1 8 for each 1 000 feet above 5 500 feet 2 Net AHRI ratings are based on net installed radiation of 9 High altitude Crest Models 4 0 and 5 0 will not de rate up to sufficient quantity for the requirements of the building 5 500 feet
28. of 105 C Exceptions Replacement high vo Itage spark lead and ribbon cables must be purchased from the factory Use of a non approved spark lead or ribbon cables can lead to operational problems which could result in non repairable damage to the integrated controller or other components 3 Actual connector block locations may vary from those shown on diagrams Refer to actual components for proper connector block locations when using diagrams to troubleshoot unit WIRING DIAGRAM LBL20346 REV A O ON OFF SWITCH z SMALL BLOWER CONTACTOR 1 2 3 4 LARGE BLOWER ARGE BLOWER x14 LWCO TEST PROBE SWITCH LWCO RESET CAM SWITCH e 3 Dia grams continued Figure 3 6 Ladder Diagram 5 0 Model INTEGRATED CONTROL x11 JUNCTION BOX SYSTEM PUMP CONTACTOR BOILER PUMP CONTACTOR DHW PUMP CONTACTOR MN itir NEUTRAL gt X1 8 O x2 4 SMALL BLOWER CONTACTOR LARGE BLOWER CONTACTOR FLAME SENSE 2 SPARK SPARK GENERATOR ROD USB INTERFACE SMALL BLOWER CONTACTOR FLUE DAMPER TRANSFORMER FLUE DAMPER 1 24V TRANSFORMER J3 3 J2 1 J2 2 PROPANE LIGHT 1 2 3 4 FLAME SENSE 1 INTEGRATED R NATURAL LIGHT pROPARELGPS BLOWER PROV
29. on Parkway 4 0 and 5 0 Lebanon TN 37090 n 615 889 8900 Fax 615 547 1000 FBD SUP Rev C www Lochinvar com 11 12
30. r This manual is for use only performing maintenance by a qualified heating installer service technician Refer to the User s Boiler operation Information Manual for your reference Do not block flow of combustion or ventilation air to Have this boiler serviced inspected by the boiler a qualified service technician at least BODIE Should overheating occur or gas supply fail to shut off Failure to comply with the above could do not turn off or disconnect electrical supply to result in severe personal injury death or circulator Instead shut off the gas supply at a location substantial property damage external to the appliance NOTICE When calling or WTE about the boiler Do not use this boiler if any part has been under water Please have the boiler model and serial The possible damage to a flooded appliance can be extensive and present numerous safety hazards Any Consider piping and installation when appliance that has been under water must be replaced number from the boiler rating plate determining boiler location Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee Factory warranty shipped with unit does not apply to units improperly installed or improperly operated A WARNING Failure to adhere to the guidelines on this page can result in severe personal injury death or substantial property damage A WARNIN
31. smell all around the fire department the appliance area for gas Be sure to C Use onl hand to turn th rol knob smell next to the floor because some gas a AT i Never use tools If the handle will not turn by is heavier than air and will sette on the hand don t try to repair it call a qualified service floor technician Force or attempted repair may WHAT TO DO IF YOU SMELL GAS result in a fire or explosion Do not try to light any appliance Do not use this appliance if any part has been under water Immediately call a qualified Do not touch any electric switch do service technician to inspect the appliance and not use any phone in your building 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 8 Turn gas shutoff valve clockwise to ON above on this label Handle will be parallel to pipe 2 Setthe thermostat to lowest setting 9 Install front door 3 Turn off all electric power to the 10 Turn on all electric power to appliance appliance 11 Set thermostat to desired setting 4 This appliance is equipped with an 12 If the appliance will not operate follow the ignition device which automatically lights instructions To Tum Off Gas To Appliance and Do nottry to light the burner call your service technician or gas supplier pes Gas Valve Gas Valve o Remove front door OPEN CLOSED 6
32. vincial and national code requirements per either N E C in USA or C S A in Canada 2 If any original equipment wire as supplied with the appliance must be replaced it must be replaced with wire having same wire gauge AWG and rated for a minimum of 105 C Exceptions Replacement high vo Itage spark lead and ribbon cables must be purchased from the factory Use of a non approved spark lead or ribbon cables can lead to operational problems which could result in non repairable damage to the integrated controller or other components 3 Actual connector block locations may vary from those shown on diagrams Refer to actual components for proper connector block locations when using diagrams to troubleshoot unit WIRING DIAGRAM LBL20344 REV A 14 CA A oe J Dia grams continued Dual Fuel Supplemental Manual Figure 3 4 Ladder Diagram 4 0 Model x x SWITCH 1 L DID 2 ey 5 5 3 4 X1 2 FLUE DAMPER TRANSFORMER X11 USB INTERFACE INTEGRATED CONTROL JUNCTION BOX X1 3 SYSTEM PUM DHW PUMP TERMINAL STRIP CONTACTOR BOILER PUMP CONTACTOR CONTACTOR NEUTRAL EACH MAX P X1 8 X2 4 X10 2 X10 3 X10 6 SPARK gt L SMALL BLOWER SMALL BLOWER RELAY 1 X1 1 X1 3 IK LARGE BLOWER CONTACTOR LARGE BLOWER FLUE DAMPER
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