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Service Manual

Please read before proceeding

Installer –

Read all instructions, including

this manual and the Crest Installation
and Operation 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 Crest 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.

When calling or writing about the boiler
– Please have the boiler model and serial
number from the boiler rating plate.

Consider piping and installation when
determining boiler location (see the Crest
Installation and Operation Manual).

Any claims for damage or shortage
in shipment must be filed immediately
against the transportation company by the
consignee.

3

Handling ceramic fiber materials

REMOVAL OF COMBUSTION CHAMBER LINING

The combustion chamber insulation in this appliance contains ceramic fiber material. Ceramic fibers can
be converted to cristobalite in very high temperature applications. The International Agency for Research
on Cancer (IARC) has concluded, “Crystalline silica 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 cristobalite. Abnormal operating conditions would have to be created
to convert the ceramic fibers in this appliance to cristobalite.

The ceramic fiber material used in this appliance is an irritant; when handling or replacing the ceramic
materials it is advisable that the installer follow these safety guidelines.



Avoid breathing dust and contact with skin and eyes.

• Use NIOSH certified dust respirator (N95). This type of respirator is based on the OSHA
  requirements for cristobalite at the time this document was written. Other types of respirators may
  be needed depending on the job site conditions. Current NIOSH recommendations can be found on
the NIOSH website at http://www.cdc.gov/niosh/homepage.html. NIOSH approved respirators,
  manufacturers, and phone numbers are also listed on this website.

• Wear long-sleeved, loose fitting clothing, gloves, and eye protection.



Apply enough water to the combustion chamber lining to prevent airborne dust.



Remove the combustion chamber lining from the appliance and place it in a plastic bag for disposal.



Wash potentially contaminated clothes separately from other clothing. Rinse clothes washer

thoroughly.

NIOSH stated First Aid.



Eye: Irrigate immediately.



Breathing: Fresh air.



WARNING

NOTICE



WARNING

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Содержание Crest 1.5

Страница 1: ...ice technician 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 injury death or substantial property damage WARNING Save this manual for future reference FB SER Rev B ...

Страница 2: ...ated 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 Freeze protection fluids 4 WHAT IS IN THIS MANUAL 5 1 SERVICE Boiler Piping 6 SMART TOUCH Display Home Screen 7 Control Inputs 8 Control Outputs 9 General Operation 10 11 Table 1A Sequence of Operatio...

Страница 3: ...ica 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 cristobalite Abnormal operating conditions would have to be created to convert the ceramic fibers in this appliance to cristobalite The ceramic fiber material used in this appliance is an irritant when...

Страница 4: ...ove 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 in the system may be damaged This can result in substantial property damage Do not use homemade cures or boiler patent medicines Serious damage to the boiler personnel and or property may result Conti...

Страница 5: ...nformation Crest boiler operation Initial Setup Set Points Outdoor Reset Ramp Delay BMS Advanced Setup SH Night Setback HWG Night Setback Cascade Pumps Service Notification Maintenance Service and maintenance schedules Address reported problems Inspect boiler area and boiler interior Clean condensate trap Check all piping for leaks Check air openings Flue vent system and air piping Check water sys...

Страница 6: ...TOR CIRCULATOR BOILER PUMP FLOW 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 TANK 12 MAX FROM SYSTEM TO SYSTEM MAKE UP WATER BOILER DRAIN SYSTEM RETURN SENSOR SYSTEM SUPPLY SENSOR Y STRAINER RECOMMENDED RELIEF VALVE BALL VALVE TYPICAL AIR SEPERATOR D...

Страница 7: ... 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 button brings up the Modulation Screen This screen shows overall boiler modulation individual fan speeds and flame currents Modulation Percentage Displays the current boiler firing rate Home Screen Th...

Страница 8: ...EMPERATURE SENSOR OUTLET 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 SENSOR RETURN AUX SWITCH 1 2 0 10 INPUT FROM SYSTEM PUMP BLOWER PROVING SWITCHES CASCADE INLET AIR SENSORS MANUAL RESET HIGH LIMIT VENT DAMPER PROVING SWITCH MODBUS BOARD Control ...

Страница 9: ...ING MANAGMENT SYSTEM BOILER PUMP CONTACTOR SYSTEM PUMP CONTACTOR HWG PUMP CONTACTOR IGNITOR BLOWERS GAS VALVES BOILER RATE OUTPUT DISPLAY PANEL PC INTERFACE 120V SUPPLY SYSTEM PUMP BOILER PUMP DHW PUMP MAX 1 5 AMPS PER CONNECTION N L FIELD SUPPLIED CONTACTOR MUST BE INSTALLED LINE VOLTAGE TERMINAL STRIP 0 10V OUTPUT TO BOILER PUMP VENT DAMPER Control outputs ...

Страница 10: ...s by 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 space heating and HWG operation The combined operation sequence is for a typical application programmed to provide HWG priority Access modes User The USER can adjust various space heating and HWG opera...

Страница 11: ...creen 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 Press the SAVE button after adjusting a parameter value Additional parameter settings can then be adjusted or other navigation buttons can be used to return to previous screens or the Home Screen FIG ...

Страница 12: ...to the desired set point temperature 9 If the current call for heat is for space heating and a HW call for heat becomes active the control will turn on the HW pump relay output then turn off the boiler pump It will then modulate the blower speed in order to maintain the outlet temperature to the desired HW outlet set point temperature 10 If the first combustion system in the boiler is unable to ma...

Страница 13: ... Pump Mode 24 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 Differential 18 0 72 19 8 No Yes 6 HWG Tank Setpoint 18 32 185 120 Yes Yes 7 HWG Tank Differential 18 0 10 6 3 No Yes 8 MRHL Setting 18 32 205 204 8 Yes Yes 9 ARHL Setting 18 32 200 199 4 Yes Yes 10 HWG Min...

Страница 14: ...ay 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 Ramp Delay Limit 6 20 10 100 100 No Yes E 1 BMS Active Inactive 21 ACTIVE INACTIVE INACTIVE No Yes 2 BMS Mode 21 POWER SETPOINT POWER No Yes 3 BMS Volts at Min Rate 21 0 10 2 No Yes 4 BMS Volts at Ma...

Страница 15: ...0 100 100 No Yes 11 Service Mode Timeout 22 0 40 40 No Yes 12 Controlling Sensor 22 0 4 2 No Yes 13 Inlet Control Time Delay 22 0 40 3 No Yes G 1 SH Night Setback Offset Temp 22 0 90 0 No Yes 2 SH Night Setback Mon End 22 N A N A N A No Yes 3 SH Night Setback Mon Begin 22 N A N A N A No Yes 4 SH Night Setback Tue End 22 N A N A N A No Yes 5 SH Night Setback Tue Begin 22 N A N A N A No Yes 6 SH Nig...

Страница 16: ...ht Setback Fri End 22 N A N A N A No Yes 11 HWG Night Setback Fri Begin 22 N A N A N A No Yes 12 HWG Night Setback Sat End 22 N A N A N A No Yes 13 HWG Night Setback Sat Begin 22 N A N A N A No Yes 14 HWG Night Setback Sun End 22 N A N A N A No Yes 15 HWG Night Setback Sun Begin 22 N A N A N A No Yes I 1 ModBus Active Inactive 23 ACTIVE INACTIVE INACTIVE No Yes 2 ModBus Out of Order Timer 23 5 120...

Страница 17: ... No Yes 3 Boiler Pump Mode 24 N A N A N A No Yes 4 System Pump Mode 24 N A N A N A No Yes 5 System Pump Delay 24 0 5 2400 30 No Yes 6 System Pump Anti Seize Time 24 0 40 0 33 No Yes 7 HWG Pump Delay 24 0 5 2400 30 No Yes 8 HWG Pump Anti Seize Time 24 0 40 0 33 No Yes 9 Delta T Setpoint 24 0 60 0 No Yes L 1 Maintenance Notice Months 25 0 36 12 No Yes 2 Maintenance Notice Running Hours 25 0 100 000 ...

Страница 18: ...WG 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 call for heat when the tank temperature drops below the tank set point minus the differential parameter B7 and finishes the call for heat when the tank temperature reaches tank set point This paramet...

Страница 19: ...s setting 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 High Outdoor Temperature When the outdoor air temperature rises to or above the High Outdoor Temperature setting parameter C4 the water temperature will be at this setting see FIG 1 6 This parame...

Страница 20: ...ed 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 The shift reset curve parameter shifts the actual set point above or below the calculated set point by the number of degrees in this parameter This parameter can be changed by the installer by accessin...

Страница 21: ...inimum 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 point represented by the Volts at Maximum parameter E8 is set by parameter E10 BMS Volts to Enable When programmed for BMS control through the 0 10V BMS input or through ModBus and the BMS Enabl...

Страница 22: ... from the normal set point to determine the set point used during night setback This parameter can be changed by the user or the installer by accessing parameters G2 through G15 and H2 through H15 The temperature range for this parameter is 0 F to 90 F 50 C The feature is turned off with a setting of 0 F Freeze Protection Burner On If running the pumps does not prevent the inlet temperature from f...

Страница 23: ... 2 15 in our example This parameter can be adjusted by the installer by accessing parameter J6 Minimum On Off Time In order to prevent units in a Cascade from short cycling this parameter defines the minimum ON and OFF time for each unit The installer can adjust this time by accessing parameter J7 I ModBus ModBus Active Inactive When BMS is set to ACTIVE see BMS Active Inactive and the boiler is b...

Страница 24: ...h a variable speed output 3 Always OFF not connected The Boiler Pump Mode can be adjusted by accessing parameter K3 System Pump Mode The SMART TOUCH control is able to control the system pump in 5 different ways The options are as follows 1 ON with a call for heat with a constant speed 2 ON with a call for heat with a variable speed input 3 Always ON with a constant speed except during outdoor shu...

Страница 25: ...ller that maintenance is required This parameter is adjustable by the installer by accessing parameter L2 Service Notification Cycles When the boiler control determines that a scheduled service is due based on the number of boiler cycles the boiler display will turn yellow and a new status screen will appear informing the installer that maintenance is required This parameter is adjustable by the i...

Страница 26: ... boiler The display box above each power level will display the following 100 A percentage indicates that firing rate of the corresponding boiler ____ A blank field indicates that the corresponding boiler has lost communication Error Error indicates that the corresponding boiler is in Lockout Off Off indicates that the corresponding boiler is turned off HWG HWG indicates that the corresponding boi...

Страница 27: ...de 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 Screen The Second screen is accessed by pressing the GRAPH button Once the items to be graphed are selected press the GRAPH button to view the graph Each item graphed will have a different color line...

Страница 28: ...ast 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 Faults History Screen Figure 1 12 Graph Screen_Blocking Faults The next screen is the Blocking Faults Screen This screen allows you the view the last ten 10 blocking faults Preceded by each fault is t...

Страница 29: ...empted 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 the control has been powered Total Running hours Show the total number of hours that the boiler has been firing Total ignition attempts Show the total number of times the control has attempted to igni...

Страница 30: ...are pressed the integrated control will automatically revert back to its original status after the Remaining time in Servicer counter expires Once the boiler has been placed into Service Mode it will light and modulate to low fire At any time after that point there are two 2 ways to adjust the firing rate The first way is by pressing one of the six 6 preset buttons The second way is by manually ad...

Страница 31: ...t 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 cutoff If combustion or performance indicate need Clean heat exchanger Remove and clean burner using compressed air only Clean the blower wheels ANNUAL START UP Owner maintenance see the Crest User s I...

Страница 32: ...If any of these are present in the boiler intake air vicinity they must be removed If they cannot be removed reinstall the air and vent lines per this manual Inspect boiler interior 1 Remove the front access covers and inspect the interior of the boiler 2 Vacuum any sediment from inside the boiler and components Remove any obstructions Clean condensate trap 1 Inspect the condensate drain line vent...

Страница 33: ... the Crest Installation and Operation Manual before proceeding further Safety relief valves should be re inspected AT LEAST ONCE EVERY THREE YEARS by a licensed plumbing contractor or authorized inspection agency to ensure that the product has not been affected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally Certain nat...

Страница 34: ...ean the burner Clean the burner thoroughly using a vacuum cleaner or compressed air Do not use compressed air to clean the burner if cleaning is performed inside a building Shut down the boiler Follow the To Turn Off Gas to Appliance instructions for the boiler in Section 9 Startup of the Crest Installation and Operation Manual Do not drain the boiler unless it will be exposed to freezing temperat...

Страница 35: ...ance contains ceramic fiber material Ceramic fibers can be converted to cristobalite in very high temperature applications The International Agency for Research on Cancer IARC has concluded Crystalline silica 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...

Страница 36: ...ing boiler 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 module or other components from operating 1 Turn OFF the power to the boiler at the external line switch 2 Remove the upper and lower doors 3 Remove the four 4 screws securing the control panel c...

Страница 37: ... 38 of 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 above Warm Weather Shutdown WWSD set point for main control board Check location of outside air sensor Check resistance of outdoor air sensor and compare to Table 3C on page 38 of this manual Unit l...

Страница 38: ...d outlet inlet air S11 S13 1 and S12 S14 2 water sensors have two temperature sensing devices in one housing These devices are designated as S1 S9 outlet sensor and S3 S10 flue sensor Please reference the wiring diagram in the Crest Installation and Operation Manual for correct terminal location Outlet S1 R Y Outlet S9 RW Y Pre Mix Air 1 S11 GY Y Pre Mix Air 1 S13 BR Y Pre Mix Air 2 S12 BK Y Pre M...

Страница 39: ...ed burner 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 Pump Operation Boiler Pump System Pump or HWG Pump Blown fuse Replace fuse F4 on the control board see page 36 of this manual Faulty pump Replace pump Internal fault on control board Replace main...

Страница 40: ...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 condensate tube from unit to floor drain for proper installation and obstructions Inspect condensate trap for blockage Clean if necessary Check for loose wiring connection at wire harness plug Bad block...

Страница 41: ... 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 air inlet is connected and is not damaged Verify that the vent air intake pipes are correctly installed and that there are no obstructions If 120 vac is present at the main control board check the wiring betwe...

Страница 42: ...ernal wiring for bad connections Remove and inspect the burner Flame Failure Running 1 will require a manual reset once the condition has been corrected Press the RESET button on the SMART TOUCH display to reset The unit was running and lost the flame signal Inspect flame rod 1 and associated wiring for damage and connection Reference page 34 of this manual for removal and cleaning procedures Repl...

Страница 43: ...s valve to the air inlet is connected and is not damaged Verifythatthevent airintakepipesareinstalledcorrectly and there are no obstructions Inspect flame sensor and associated wiring Reference page 34 of this manual for removal and cleaning procedures Replace if necessary Check combustion Inspecttheburner Referencepage34ofthismanualfor removal and cleaning procedures Replace if necessary Gas Valv...

Страница 44: ...s and compare to Table 3B on page 38 of this manual Replace sensor if necessary Replace the main control board Manual Reset High Limit Open will require a manual reset once the condition has been corrected Press the RESET button on the SMART TOUCH display to reset The outlet water temperature has exceeded the setting of the high limit Verify that the system is full of water and that all air has be...

Страница 45: ...anual for proper lengths Check for obstruction or blockage in the vent air intake pipes or at terminations Check the wiring connections at fan 2 and at the main control board Replace the fan Blown fuse Replace fuse F2 on the control board see page 36 of this manual Fan Speed High 1 will require a manual reset once the condition has been corrected Press the RESET button on the SMART TOUCH display t...

Страница 46: ...tem Refer to Section 5 Hydronic Piping of the Crest Installation and Operation Manual for the proper piping methods for the Crest boiler Check for 120 vac to the boiler pump motor on a call for heat If voltage is not present check the wiring back to the main control board Replace the main control board if necessary If 120 vac is present on a call for heat and the boiler pump is not operating repla...

Страница 47: ...SET 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 Service Blk While the unit is in Service Mode the outlet temperature has exceeded 185 F Establish a heating load to remove the heat from the boiler loop Verify that the system is full of water and that all air has bee...

Страница 48: ...or in flue Replace the sensor if necessary Flue Sensor Shorted will require a manual reset once the condition has been corrected Press the RESET button on the display to reset The flue sensor has been shorted Check the sensor and its associated wiring Repair or replace the sensor or wiring if damaged Measure the resistance of the sensors and compare the resistance to the tables on page 38 of this ...

Страница 49: ... air to burner 2 temperature or vice versa Inspect the combustion air temperature sensor and associated wiring Measure the resistance of the combustion air temperature sensor and compare to Table 3E on page 38 of this manual Replace the sensor if necessary Verify that the vent air intake pipes are properly installed and that there are no obstructions Burner Supply Temperature High 1 will require a...

Страница 50: ...3E on page 38 of this manual Replace the sensor if necessary Verify that the vent air intake pipes are properly installed and that there are no obstructions Replace the main control board Delta T Shutdown The temperature rise across the heat exchanger has exceeded the set parameters for the boiler Verify that the system is full of water and that all air has been properly purged from the system Ver...

Страница 51: ...for the proper piping methods for the Crest boiler Check for voltage to the boiler pump motor on a call for heat If voltage is not present check wiring back to the pump relay Replace the pump relay if necessary If 120 VAC is present on a call for heat and the boiler pump is not operating replace the pump Watch Dog Error The main control board has detected an internal fault Replace the main control...

Страница 52: ...stallation and Operation Manual for the proper venting and air intake 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 proper gas supply for the Crest boiler Dirty Damaged Burner Refer to page 34 of this manual for burner removal and cleaning procedures ...

Страница 53: ...justment 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 repeat the procedure This procedure SHOULD NOT be performed more than four 4 times If after four 4 adjustments and the combustion is still not within the specified range revisit the possible causes in Table 3H on page 52 or replace...

Страница 54: ...3 Troubleshooting 54 NOTES ...

Страница 55: ...55 NOTES ...

Страница 56: ...es Revision A ECO C08179 initial release Revision B ECO C08436 reflects changes made to the parameter table notice added to the parameter descriptions changed out the screens on FIG s 1 8 and 1 14 FB SER Rev B 7 11 ...

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