Crest Audio FBN0751 Service Manual Download Page 54

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Troubleshooting

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Summary of Contents for FBN0751

Page 1: ...hnician Read all instructions including this manual and the Crest Installation and Operation Manual before installing Perform steps in the order given Failure to comply could result in severe personal...

Page 2: ...ted to personal injury or property damage CONTENTS 2 Hazard Definitions 2 PLEASE READ BEFORE PROCEEDING 3 Handling Ceramic Fiber Materials 3 When servicing boiler 4 Boiler operation 4 Boiler water 4 F...

Page 3: ...ca in the form of quartz or cristobalite from occupational sources is carcinogenic to humans Group 1 Normal operating temperatures in this appliance are below the level to convert ceramic fibers to cr...

Page 4: ...ve sediment The high efficiency heat exchanger can be damaged by build up or corrosion due to sediment Do not use petroleum based cleaning or sealing compounds in the boiler system Gaskets and seals i...

Page 5: ...ation Crest boiler operation Initial Setup Set Points Outdoor Reset Ramp Delay BMS Advanced Setup SH Night Setback HWG Night Setback ModBus Cascade Pumps Service Notification Maintenance Service and m...

Page 6: ...W CHECK VALVE TYPICAL Y STRAINER RECOMMENDED RELIEF VALVE BALL VALVE TYPICAL AIR SEPERATOR DRAIN PORT TYPICAL SYSTEM CIRCULATOR BACK FLOW PREVENTER PRESSURE REDUCING VALVE PRESSURE GAUGE EXPANSION TAN...

Page 7: ...e information regarding this screen Main Menu button Pressing this button brings up the Main Menu Screen From this screen navigation to nine 9 other screens is possible Modulation button Pressing this...

Page 8: ...T TEMPERATURE HI LIMIT SENSOR FLUE GAS SENSOR LOUVER PROVING SWITCH FLAME SENSOR 1 2 LOW WATER CUTOFF BLOCKED DRAIN SWITCH DISPLAY PANEL PC INTERFACE SMART CONTROL MODULE AIR PRESSURE SWITCH SYSTEM SE...

Page 9: ...ENT SYSTEM BOILER PUMP CONTACTOR SYSTEM PUMP CONTACTOR HWG PUMP CONTACTOR IGNITOR BLOWER GAS VALVES BOILER RATE OUTPUT DISPLAY PANEL PC INTERFACE 120V SUPPLY SYSTEM PUMP BOILER PUMP DHW PUMP MAX 1 5 A...

Page 10: ...y adjusting control parameters These parameters set operating temperatures and boiler operating modes Sequence of operation Table 1A page 12 shows control module normal sequences of operation for spac...

Page 11: ...reen To adjust the setting use the buttons to the left and right of the current setting Note If the above mentioned buttons to adjust settings do not appear the correct PASSWORD has not been entered P...

Page 12: ...he blower speed constant for a few seconds to allow the flame to stabilize then begin modulating the firing rate in order to maintain the controlling sensor to the desired set point temperature 9 If t...

Page 13: ...Pump Mode 25 N A N A N A No Yes B 1 SH Min User Setpoint 18 32 185 32 No Yes 2 SH Max User Setpoint 18 32 185 185 No Yes 3 SH Setpoint 18 32 185 125 Yes Yes 4 SH Offset 18 0 36 9 9 No Yes 5 SH Differe...

Page 14: ...y Limit 1 20 10 100 20 No Yes 9 Ramp Delay Limit 2 20 10 100 30 No Yes 10 Ramp Delay Limit 3 20 10 100 40 No Yes 11 Ramp Delay Limit 4 20 10 100 55 No Yes 12 Ramp Delay Limit 5 20 10 100 75 No Yes 13...

Page 15: ...0 40 40 No Yes 14 Controlling Sensor 22 0 4 2 No Yes 15 Inlet Control Time Delay 22 0 40 3 No Yes 16 Modulation Factor 23 40 100 100 No Yes 17 Min Boiler Rate 23 4 100 100 No Yes 18 Freeze Protection...

Page 16: ...Night Setback Fri Begin 23 N A N A N A No Yes 12 HWG Night Setback Sat End 23 N A N A N A No Yes 13 HWG Night Setback Sat Begin 23 N A N A N A No Yes 14 HWG Night Setback Sun End 23 N A N A N A No Yes...

Page 17: ...0 33 No Yes 3 Boiler Pump Mode 25 1 3 2 No Yes 4 System Pump Mode 25 1 5 2 No Yes 5 System Pump Delay 25 0 5 2400 30 No Yes 6 System Pump Anti Seize Time 25 0 40 0 33 No Yes 7 HWG Pump Delay 25 0 5 2...

Page 18: ...G Tank Set Point By installing a tank sensor the SMART TOUCH control can perform the tank thermostat function The SMART TOUCH control automatically detects the presence of this sensor and generates a...

Page 19: ...ing see FIG 1 6 However if the user set point is set lower the water temperature will be limited by the user set point instead This parameter can be changed by accessing parameter C1 SH Set Point at H...

Page 20: ...d Once the SH demand has been satisfied the set point will revert back to its calculated setting The boost temperature can be changed by the installer by accessing parameter C8 Shift OA Reset Curve Th...

Page 21: ...m parameter E7 is set by parameter E9 21 BMS Set Point at Maximum Volts When programmed for BMS control through the 0 10V BMS input or through ModBus and the BMS Type is programmed as SETPOINT the set...

Page 22: ...to increase and regulate the system supply temperature in order to maintain the inlet system return temperature to the SH set point This time delay should be long enough for the heated water to work...

Page 23: ...ncy Optimization This method is used when it is desired to have the most efficient system When the first boiler reaches a certain rate default 80 it lowers its rate to 40 and turns on the next boiler...

Page 24: ...to reduce the risk of temperature overshoot with a Cascade this parameter defines the minimum time delay from starting one unit until the next unit may be started The installer can adjust this time d...

Page 25: ...minder Screen at that time This can be programmed by accessing parameters L4 and L5 When selected another menu will appear with PHONE and NAME Note that the phone number is limited to 10 characters an...

Page 26: ...The level of the indicator will rise and fall indicating the approximate power level of the boiler The display box above each power level will display the following 100 A percentage indicates that fir...

Page 27: ...e selected by highlighting the parameter and pressing the SELECT button A maximum of five 5 items can be graphed at one time Figure 1 9 Graph Screen_Parameter Selection Graph Screen Figure 1 10 Graph...

Page 28: ...st ten 10 lockout faults Preceded by each fault is the date and time of when the fault occurred The lockout faults can be reset by pressing the RESET FAULTS button Figure 1 11 History Screen_Lockout F...

Page 29: ...mpted to ignite since the last reset Successful Ignition attempts Shows the number of times the control has successfully ignited since the last reset Total Power hours Show the total number of hours t...

Page 30: ...essed the integrated control will automatically revert back to its original status after the Remaining time in Service counter expires Once the boiler has been placed into Service Mode it will light a...

Page 31: ...and performance verification per Section 9 of the Crest Installation and Operation Manual Flame inspection stable uniform Check both flame signals at least 10 microamps at high fire Test low water cu...

Page 32: ...ws securing the top cover to the condensate trap and remove the cover FIG 2 1 2 Locate the plastic ball inside the float tube Verify there is nothing under the ball causing it to not seat properly 3 F...

Page 33: ...e sense electrodes making sure the gaskets are in good condition and correctly positioned Check ignition ground wiring 1 Inspect boiler ground wire from the heat exchanger access cover to ground termi...

Page 34: ...thepropershutdownprocedure and to schedule an annual start up at the beginning of the next heating season NOTICE The burner gasket burner burner baffle and gas air manifold access cover can only be in...

Page 35: ...n firing 3 Remove the top access panel to remove the gas air manifold assembly 4 Remove the nuts securing the burner to the burner mounting plate Remove the burner reference FIG 2 2 and follow the ste...

Page 36: ...on the outlet piping of the boiler see FIG 2 3 This will begin to restrict the flow and simulate a low flow condition 6 While slowly shutting off the isolation valve refer to the Status Screen to watc...

Page 37: ...oiler startup Check control module fuses ALWAYS check control module fuses before replacing control module or any major components blower etc If one of these fuses is blown it can prevent the control...

Page 38: ...this manual No Burner Operation Main control board temperature set point satisfied Review temperature setting Remote thermostat satisfied Review remote thermostat setting Outside air temperature abov...

Page 39: ...tant to note that the flue inlet air pre mix and outlet water sensors each have two temperature sensing devices in one housing These devices are designated as S1 S9 outlet sensor S3 S1 flue sensor and...

Page 40: ...ner Refer to page 34 in this manual for the burner removal and inspection procedure Clean or replace the burner as necessary Air in the piping system Properly purge all air from the piping system No P...

Page 41: ...a manual reset once condition has been corrected Press the RESET button on the SMART TOUCH display to reset The blocked drain switch has detected excessive condensate build up inside the unit Check c...

Page 42: ...1 0 3 5 kPa Refer to Section 6 Gas Connections of the Crest Installation and Operation Manual for detailed information concerning the gas supply Verify that the plastic hose from gas valve 1 to the ai...

Page 43: ...nual for removal and cleaning procedures Replace if necessary Flame Failure 2 Running will require a manual reset once the condition has been corrected Press the RESET button on the SMART TOUCH displa...

Page 44: ...Auto Reset High Limit The outlet water temperature has exceeded the setting of the automatic reset high limit Verify that the system is full of water and that all air has been properly purged from the...

Page 45: ...er pump motor on a call for heat If voltage is not present check wiring back to the main control board Replace the pump relay if necessary If 120 vac is present on a call for heat and the boiler pump...

Page 46: ...nspect the flue sensor and associated wiring Measure the resistance of the flue sensor and compare to Table 3E on page 39 of this manual Replace the sensor if necessary Verify that the vent air intake...

Page 47: ...e RESET button on the SMART TOUCH display to reset After downloading parameters from a laptop the main control board must be reset Press the RESET button on the SMART TOUCH display panel Sensor Open w...

Page 48: ...the flue side of the heat exchanger Inspect the flue sensor and associated wiring Measure the resistance of the flue sensor and compare to Table 3E on page 39 of this manual Replace the sensor if nec...

Page 49: ...e main control board Wrong Error Code The main control board has detected an internal fault Press the RESET button on the SMART TOUCH display panel Flame Sense Out of Sequence 1 will require a manual...

Page 50: ...metering valve Replace the air metering valve Replace the control board Check the slide switch on the inside of the air metering valve actuator Air Metering Valve Stuck Open will require a manual res...

Page 51: ...ctions between the outlet temperature sensors and the control board Make sure all connections are dry and secure Check the resistance of the two outlet sensors see page 39 Replace the control board Fl...

Page 52: ...ke methods for the Crest boiler Check for obstructions at the vent air intake terminals Gas Supply Pressure Refer to Section 6 Gas Connections of the Crest Installation and Operation Manual for the pr...

Page 53: ...crease CO2 levels After one adjustment on the valve follow the Combustion Analysis Procedure on page 52 of this manual to measure the combustion If combustion is still not within the specified range r...

Page 54: ...3 Troubleshooting 54 NOTES...

Page 55: ...3 Troubleshooting 55 NOTES...

Page 56: ...Revision Notes Revision A ECO C17106 initial release Revision B ECO C17419 reflects the addition of the large Crest models 1501 2001 FBII SER Rev B 03 15...

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