Crestron 1.5 Installation & Operation Manual

Text of Crestron 1.5 User Guide:

• Crestron 1.5, 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. Condensate could freeze and block vent pipe. 4. Stainless steel terminations are designed to penetrate walls with a thickness up to 9.25 inches of standard construction. All vent pipes and air inlets must terminate at the same heigh

• 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:

• Crestron 1.5, 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 Member controls. Once the Leader boiler receives a call for heat from the Enable input, the 0 - 10 VDC input, or ModBus, the control will determine what the set point will be. If outdoor air reset is desired, connect the outdoor air sensor to the terminals on the Low Voltage Connection Board on the

• Crestron 1.5, 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 products and common household and hobby products often contain fluorine or chlorine compounds. When these chemicals pass through the boiler, they can form strong acids. The acid can eat through the boiler wall, causing serious damage and

• Crestron 1.5, 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 (item 34). Air and gas mix inside the blowers and are pushed into the burner, where they burn inside the combustion chamber. 5. Boiler drain connection Location from which the heat exchanger can be drained. 6. Boiler inlet temperature sensor The boiler inlet temperature sensor monito

• Crestron 1.5, 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 Generator circulating pump: Field supplied. When installed in a Primary/Secondary arrangement, the Crest requires an additional pump for the Hot Water Generator Loop. The pump should be sized per Table 5A. Consult the indirect water heater operating guide to determine flow characteristics for t

• 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-STRAINER (RECOMMENDED) (TYPICAL) RELIEF VALVE (TYPICAL) BALL VALVE (TYPICAL) AIR SEPERATOR DRAIN PORT (TYPICAL) SYSTEM CIRCULATOR BACK FLOW P

• Crestron 1.5, 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 must be replaced, use only type 105°C wire or equivalent. Boiler must be electrically grounded as required by National Electrical Code ANSI/NFPA 70 – latest edition. Installation must comply with

• 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 to contro

• Crestron 1.5, 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 high limit shutdowns and poor system performance. NOTICE The pressure drop reflected in FIG. 5-1 is for the boiler only. Additional allowances must be made for piping, especially if sizing pumps for Primary/Secondary applications. NOT

• Crestron 1.5, 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). System Return Temperature - This is the water temperature measured by the system return sensor located in the upstream piping (if connected). Outside Air Temperature - This

• Crestron 1.5, 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 ROTATING Figure 6-2 Inlet Pipe with Backup Wrench Natural gas supply pressure requirements 1. Pressure required at the gas valve inlet pressure port: • Maximum 14 in

• Crestron 1.5, 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 provides dry contacts for indicating when the boiler is running, and when it is unable to operate. Run-time and cycle counting The control uses four timers to monitor the total hours of burner operation: 75 - 100% 50 - 75% 25 - 50% <25% The control uses four (4) ignition counters to monito

• Crestron 1.5, 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 that the boiler has a pressure drop which must be figured in when sizing the circulators. Each boiler installation must have an air elimination device, which will remove air from the system. Install the boiler so the gas ignition system components are protected from water (dripping, spraying, etc.) during a

• Crestron 1.5, 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, Table 305.4 or as local codes dictate. 2. Vent Connector (FIG. 2-1) - Used to provide a passageway for conveying combustion

• Crestron 1.5, 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, and combustion air quality. See also Section 1 of this manual. Inspect finished vent and air piping thoroughly to ensure all are airtight and comply with the instructions provided and with all requirements of applicable codes. Failure to provide a properly installed vent and air system will cause severe personal in

• 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 subs

• Crestron 1.5, 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 discharge and air intake are clean and free of obstructions. Failure to inspect for the above conditions and have them repaired can result in severe personal injury or death. Check water system 1. Verify all system components are correctly installed and operational. 2. Check the cold fill pressure for the

• Crestron 1.5, 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 noncombustible construction, size the vent pipe hole per the vent manufacturer’s instructions. b. Insert a galvanized metal thimble in the vent pipe hole (when required by local codes). 3. Space the air and vent holes to provide the minimum spacing shown in FIG. 3-1. 4.

• Crestron 1.5, 59 Installation & Operation Manual 12 Diagrams (continued) Figure 12-2 Wiring Diagram -T -T -T -T -T -T - T - T -T 231 1 2 4 5 3 231 1 2 45 3 M 1 2 3 Notes : 1. All w i ring mu s t be installed in acc ordanc e with: lo cal, state, 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 o riginal equ ipmen t wire a s supplied w ith the ap pliance must be re placed, it must be rep l a ced w ith wir e ha ving same w ire gauge ( A WG) and rated fo r a mi n im um of 105°C. Exceptions: R eplacement hi g h vo ltage spark l e ad and ribb on cables must b

• Crestron 1.5, 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 reference. Have this boiler serviced/inspected by a qualified service technician, at least annually. Failure to comply with the above could result in severe personal injury, death or substantial property damage. Failure to adhere to the guidelines on this page can result in severe personal injury, death, o

• Crestron 1.5, 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-STRAINER (RECOMMENDED) RELIEF VALVE BALL VALVE (TYPICAL) AIR SEPERATOR DRAIN PORT (TYPICAL) SYSTEM CIRCULATOR BACK FLOW PREVENTER PRESSURE REDUCING VALVE PRESSURE GAUGE EXPANSION TANK FROM SYSTEM TO SYSTEM MAKE UP WATER BOILER DRAIN Figure 5-4 Single Boiler - Alternate - Fixed or Variable Flow Prim

• Crestron 1.5, 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, will result in death or serious injury. WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. CAUTION used without the safety alert symbol indicates a potentially hazar

• Crestron 1.5, 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 of a gas leak. Use an approved leak detection solution. Repair any leaks at once. DO NOT adjust or attempt to measure gas valve outlet pressure. The gas valve is factory set for the correct outlet pressure. This setting is suitable for natural gas and propane, requiring no field adjustm

• 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 in need of service. Perf

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