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Service Manual

w/CON•X•US Interface

Models:

2500 - 6000

This manual must only be used
by a qualified heating installer
/ service 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_100161013_2000004598 Rev R

Содержание SMART TOUCH w/CON-X-US

Страница 1: ...chnician 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 persona...

Страница 2: ...EAD 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...

Страница 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...

Страница 4: ...move 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...

Страница 5: ...formation Crest boiler operation Initial Setup Set Points Outdoor Reset Ramp Delay BMS Advanced Setup SH Night Setback HW Night Setback Cascade Pumps Service Notification Maintenance Service and maint...

Страница 6: ...MP FLOW CHECK VALVE TYPICAL Y STRAINER RELIEF VALVE BALL VALVE TYPICAL AIR SEPERATOR DRAIN PORT TYPICAL SYSTEM CIRCULATOR BACK FLOW PREVENTER PRESSURE REDUCING VALVE PRESSURE GAUGE EXPANSION TANK 12 M...

Страница 7: ...ated in the upstream piping if connected When the ON OFF switch is turned to the ON position the first screen visible on the LCD display will be the Home Screen This screen displays the current status...

Страница 8: ...and controls the blowers and gas valves to regulate heat input and switches the boiler Hot Water Generator HW and system pumps on and off as needed The user programs the control module to meet system...

Страница 9: ...URE 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...

Страница 10: ...M 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...

Страница 11: ...control detects flame current the control will hold the blower speed constant for a few seconds to allow the flame to stabilize then begin modulating the firing rate in order to maintain the controlli...

Страница 12: ...r these features to work correctly the clock must be set when the boiler is first installed or anytime the boiler has been powered off for more than four 4 hours This parameter must be accessed to set...

Страница 13: ...e and changeable control parameters CAUTION Before changing parameters note the settings so that the unit can be returned to its original operating parameters Figure 1 3 Set points HW_Screen A Figure...

Страница 14: ...igh Limit ARHL 32 200 199 4 High Limit MRHL 0 90 0 HW Boiler Set point Set point N A N A N A HW Boiler Set point Offset N A N A N A HW Boiler Set point Differential N A N A N A HW Tank Set point Set p...

Страница 15: ...MART TOUCH control contains an integral Manual Reset High Limit MRHL on the outlet of the heat exchanger Once the outlet temperature exceeds the MRHL set point the boiler will shut down and lock out O...

Страница 16: ...Temperature Max 22 86 86 Outdoor Temp Shutdown 32 122 79 7 Outdoor Temp Diff 32 122 79 7 Shift OA Reset Curve 27 27 0 Boost Time 0 250 20 Boost Temperature 0 25 0 1 Service Service Manual 16 Outdoor...

Страница 17: ...meter the outdoor air temperature must go before the boiler will respond to a SH demand Shift OA Reset Curve The shift reset curve parameter shifts the actual set point above or below the calculated s...

Страница 18: ...ep 2 Ramp Delay Time 1 40 2 Step 2 Ramp Delay Limit 10 100 30 Step 3 Ramp Delay Time 1 40 2 Step 3 Ramp Delay Limit 10 100 40 Step 4 Ramp Delay Time 1 40 1 Step 4 Ramp Delay Limit 10 100 55 Step 5 Ram...

Страница 19: ...ring rate for a fixed period of time at the start of a space heating demand There are six 6 possible limits each with their own time delay The first limit applies as soon as the burner starts Once its...

Страница 20: ...1 Service Service Manual 20 BMS Screens Figure 1 8 BMS_Screen A Figure 1 9 BMS_Screen B...

Страница 21: ...his parameter will determine if the voltage on the 0 10V BMS input is converted to modulation or a set point When set to POWER the voltage determines the modulation of the boiler When set to SETPOINT...

Страница 22: ...ler this parameter must be set to ACTIVE To use the voltage on the 0 10V BMS input to enable the boiler this parameter must be set to INACTIVE BAS BAS Active Inactive The boiler is capable of being mo...

Страница 23: ...l turn on the boiler and system pump outputs whenever the inlet temperature drops below this setting This is done to prevent the water in the heat exchanger from freezing Certain low temperature appli...

Страница 24: ...nlet water temperature drops too much The control will use the inlet water temperature at the time the boiler shut off as the starting point If the inlet temperature drops below this temperature param...

Страница 25: ...ameter will be subtracted from the normal set point to determine the set point used during night setback The temperature range for this parameter is 0 F to 90 F 50 C The feature is turned off with a s...

Страница 26: ...de N A N A N A System Pump Delay 0 00 40 00 0 30 System Pump Anti Seize Time 0 40 00 0 33 Delta T Set point 0 60 0 HW System Pump Mode N A N A N A HW Pump Delay 0 5 2400 30 HW Pump Anti Seize Time 0 4...

Страница 27: ...ter Select Always Off if you want the system pump to always turn off during a HW call for heat Select Always On if you want the system pump to always turn on during a HW call for heat Select Normal if...

Страница 28: ...1 Service Service Manual 28 Cascade Screens Figure 1 13 Cascade Setup Screen A Figure 1 14 Cascade Leader Setup...

Страница 29: ...int F 32 185 185 Max Cascade Non Cond Set point F 68 260 185 Block Time Switching Boiler On Off 0 4 15 60 Minimum Next On Time 0 4 15 60 Number of Boiler Pumps Always On 0 8 0 Rate to Switch On Next B...

Страница 30: ...oiler outlet temperatures reach the maximum cascade set point the boiler will then modulate down on its own in order to keep its outlet temperature within the maximum cascade set point Therefore these...

Страница 31: ...ressed 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...

Страница 32: ...er control determines that a scheduled service is due based on the hours of actual operation the boiler display will turn yellow and a new status screen will appear informing the installer that mainte...

Страница 33: ...arameter is selected by mistake it can be de selected by re selecting the parameter A maximum of eight 8 items can be graphed at one time Figure 1 17 Graph Select Graph Screens Figure 1 18 Graph Scree...

Страница 34: ...ockout Blocking Fault and Runtime History The default screen is the Lockout Blocking Fault screen This screen allows you to view the last 20 lockout blocking faults Succeeded by each fault is the date...

Страница 35: ...as attempted 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...

Страница 36: ...ean and reposition Check wiring and connections Perform start up checkout and performance verification per Section 9 of the Crest Installation and Operation Manual Flame inspection stable uniform Chec...

Страница 37: ...screws 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...

Страница 38: ...good condition and securely attached Check control settings 1 Navigate to the Setup Screen and check all settings See Section 1 of this manual Adjust settings if necessary See Section 1 of this manual...

Страница 39: ...ply could result in severe personal injury WARNING Cleaning boiler heat exchanger 1 Shut down boiler Follow the To Turn Off Gas to Appliance instructions for the boiler in Section 9 Startup Do not dra...

Страница 40: ...ed clothes separately from other clothing Rinse clothes washer thoroughly NIOSH stated First Aid Eye Irrigate immediately Breathing Fresh air WARNING Figure 2 3 Adjust outlet isolation valve Test proc...

Страница 41: ...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...

Страница 42: ...tion 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...

Страница 43: ...mix and outlet water sensors each have two temperature sensing devices in one housing These devices are designated as S1 S9 outlet sensor S3 S10 flue sensor and S11 S13 S12 S14 inlet air pre mix sens...

Страница 44: ...pection 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 HW Pump Blown fuse Replac...

Страница 45: ...e 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...

Страница 46: ...er 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 conn...

Страница 47: ...nternal 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 dis...

Страница 48: ...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 38 of thi...

Страница 49: ...nsors and compare to Table 3B on page 43 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...

Страница 50: ...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 Repl...

Страница 51: ...lation 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...

Страница 52: ...tton 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 u...

Страница 53: ...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 r...

Страница 54: ...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 pa...

Страница 55: ...ble 3E on page 43 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...

Страница 56: ...e 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 neces...

Страница 57: ...Once the heat exchanger has modulated up to rate measure the combustion The values should be in the range listed in Table 3H CO levels should be less than 200 ppm for a properly installed unit If the...

Страница 58: ...2 High on the Service Screen FIG 3 2 page 57 9 Ensure proper probe depth FIG s 3 3 thru 3 5 10 Once the heater analysis is complete test the safety shutoff device by turning the manual shutoff valve...

Страница 59: ...o 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 co...

Страница 60: ...e Maintenance Section on page 35 Revision H ECO C14713 reflects updates made to the torqueing instructions on page 34 R07028 Revision I ECO C15103 reflects edits made to the torqueing instructions on...

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