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Dodge 2010 Caliber Automobile User Manual

1. AIR GAS MANIFOLD MANIFOLD GASKET BURNER ASSEMBLY BURNER GASKET BURNER PLATE FIBERBOARD Check flame signal l At high fire of each combustion system the flame signal shown on the display should be at least 10 microamps A lower flame signal may indicate a fouled or damaged flame sense electrode If cleaning the flame sense electrodes does not improve ground wiring is in good condition and ground continuity is satisfactory replace the flame sense electrode See Section 3 Troubleshooting in this manual for other procedures to deal with low flame signal 2 Maintenance continued Review with owner l Cleaning boiler heat exchanger l A WARNING 10 LA 12 13 14 Review the Crest User s Information Manual with the owner Emphasize the need to perform the maintenance schedule specified in the Crest User s Information Manual and in this manual as well Remind the owner of the need to call a licensed contractor should the boiler or system exhibit any unusual behavior Remind the owner to follow the proper shutdown procedure and to schedule an annual start up at the beginning of the next heating season Shut down boiler Follow the To Turn Off Gas to Appliance instructions for the boiler in Section 9 Startup e Do not drain the boiler unless it will be exposed to freezing temperatures If using freeze prevention fluid in system do not drain Allow time for
2. Bad main control board e Replace the main control board Blown fuse e Replace fuse F2 on the main control board see page 38 of this manual No Display Main control board temperature set point e Review temperature setting satisfied Remote thermostat satisfied e Review remote thermostat setting O ti Outside air temperature above Warm Check location of outside air sensor Check peraticn Weather Shutdown WWSD set point for resistance of outdoor air sensor and compare to Table main control board 3C on page 38 of this manual No Burner Unit locked out on fault Consult display for specific fault Refer to fault descriptions on page 40 of this manual for corrective actions Ramp delay active Check ramp delay parameter settings Optional PC software required Unit Does Not Modulate Turn ramp delay feature off See page 20 of this Up to 100 manual for instructions on how to turn this feature off Boiler controlled by BMS Check BMS parameter settings 37 CREST Service Manual TITSE M te PAE 3 Troubleshooting Checking temperature sensors The boiler temperature sensors inlet water outlet water system water flue and outdoor air are all resistance type devices The following tables show the correct values for the sensors at various temperatures Use an ohmmeter to read the resistance of the sensor at a known temperature If the resistance of the sensor does not closely match its co
3. O O O O lt O 2 Z O fe D n Tr we Punpoeey a os zo e Hwerinpanisesetme a o om ec ee 2 wamenance noice Runa roure 25 0 ron00 Z D 10 000 Z O L Maintenance Notice Cycles 100 000 10 000 Service Contact Number N A N A N A Service Contact Name N A N A N A O O 17 1 Service i FEANSA f Cae E TERSA M ia Service Manual Viewable and changeable control parameters See Table 1B on pages 13 17 of this manual for parameter references listed in this section The parameter NOTICE ar a a e references listed in this section will not appear on the LCD screen Before changing parameters note the CAUTION mae settings so that the unit can be returned to its original operating parameters A Initial Setup Clock and Date The control uses an internal clock for the night setback feature and for logging of events For 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 the clock Parameter A2 sets the date The internal clock does not adjust for NOTICE Daylight Savings Time and therefore will require a manual adjustment Parameters A3 A12 shown in the Initial Setup Menu are grouped here for convenience For a detailed explanation of each parameter reference the specific menu for each parameter B Set Point
4. e Check the wiring connections to switch Wires should be connected to the common and normally closed terminals e Vent air intake lengths exceed the maximum allowed lengths Refer to Section 2 General Venting of the Crest Installation and Operation Manual for proper lengths APS e Check for obstruction or blockage in the vent air will Open intake pipes or at terminations will require a Manua Medtech Blocked flue inlet pressure switch contacts Check reference hose and tubing connected to the ENR are Open pressure switch for blockage or obstruction the RESET button on the e Inspect the burner Reference page 34 of this manual SMART TOUCH display for removal and cleaning procedures Replace if to reset necessary e Inspect the heat exchanger Reference page 35 of this manual for removal and cleaning procedures Replace if necessary e Faulty air pressure switch Replace switch e Verify combustion air blower is operating Replace if necessary T Service Manual CAE N iie Tii eR 3 Troubleshooting continueg Table 3G continued from previous page Troubleshooting Chart Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION The main control board has received a call The control board will release the call for heat after a set time period for heat too quickly after the previous call for Anti cycling heat has ended The control board will release the call for h
5. 12 CREST Service Manual FFP Pa Pa 1 Service continued Parameter table Table 1B This table lists SMART TOUCH control module parameters and where to access them Parameter Name i renn Eor Oeae as shown on the LCD screen Value Value Access Access 185 120 Yes Yes 2 2 EE 1 3 1 32 4 4 22 11 Boiler Pump Mode Ex 2 Pies as ve Ye Pa Tato ee s ee eji e el e a faa Jalajala e Co ajola a e eja a a a a Yes 185 180 Yes Yes ARHL Setting AR WG Minimum User Setpoint WG Maximum User Setpoint WG Boiler Setpoint WG Boiler Offset HWG Boiler Differential oO s z O L 14 SH Setpoint at Low Outdoor Temp me ee ee ee ee ee ee o 10101010101010 SH Setpoint at High Outdoor Temp s N 00 D n o D n ow Outdoor Temperature Ce 1 NO NO _ I N N g oo lt D e9 lt D e9 High Outdoor Temperature Outdoor Air Shutdown s N N N N S N Z O lt D n OUTDOOR RESET SETPOINTS INITIAL SETUP OA Shutdown Differential 8 s N N N N N O lt D n CREST Service Manual 1 Pe A A E 1 Service Parameter table E N aaa a a a aa a a a a l a el Table 1B continued from previous page This table lists SMART TOUCH control module parameters and where to access them Parameter Name See as shown on the LCD screen Page 2 Boost Time 20
6. If the system pump is a variable speed pump ensure that the system flow is not less than the boiler flow If operating on something other than an outlet sensor check temperature setting of the main control board If the optional manual reset high limit has tripped check setting of the device Check resistance of water sensors and compare to Table 3B on page 38 of this manual Replace sensor if necessary Replace the main control board Verify that the system is full of water and that all air has been properly purged from the system Verify that the boiler is piped properly into the heating system Refer to Section 5 Hydronic Piping of the Crest Installation and Operation Manual for the proper piping methods for the Crest boiler Check voltage to boiler pump motor on a call for heat If voltage is not present check wiring back to 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 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 The outlet water temperature has exceeded the setting of the high limit If the system pump is a variable speed pump ensure that the system flow is not less than the boiler flow If operating on either an inlet or system supply sensor check temperature setting of the m
7. F This parameter can be changed by the user or the installer by accessing parameter F1 Display Timeout LCD Backlight Time This is the time in which the display remains illuminated This parameter can be changed by the user or the installer by accessing parameter F2 Freeze Protection Pump On The SMART TOUCH control will 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 applications such as snow melt can operate at temperatures around freezing so this setting needs to be lowered in these cases The installer can adjust the temperature at which the pump outputs are turned on by accessing parameter F3 21 1 Service Freeze Protection Burner On If running the pumps does not prevent the inlet temperature from falling closer to freezing the SMART TOUCH control will fire the burner at low fire if in the ON state The installer can adjust the temperature at which the burner fires by adjusting parameter F4 Freeze Protection Burner Differential Once the burner has started firing due to a low inlet temperature the inlet temperature must increase by this amount before the burner turns back off The installer can adjust this differential by accessing parameter F5 HWG SH Switching Time When a boiler has a HWG demand and it receives a space heating demand the SMART TOUCH control wil
8. 5 AMP PUMP RELAYS F5 5 AMP IGNITOR OUTPUT F6 5 AMP NOT USED SPARE The boiler is shipped with four 4 spare fuses in a plastic bag located inside the control panel If necessary replace open fuse F2 is 3 15 amps F4 F5 and F6 are 5 amps each Note Fuses F2 F4 F5 and F6 are all slow blow fuses A WARNING Do not jumper fuse or replace with any fuse except as specified Failure to comply could result in severe personal injury death or substantial property damage Re install the control panel cover using the four 4 screws removed in Step 3 Re install the upper and lower doors after fuse inspection Restore power to the boiler at the external line switch and verify boiler operation Section 9 Start up in the Crest Installation and Operation Manual after completing boiler service T Service Manual CAR Ae i e R 3 Troubleshooting continueg Table 3A Troubleshooting Chart No Display FAULT CAUSE CORRECTIVE ACTION No 120 vac supplied to unit Check external line switch fuse or breaker Check position of ON OFF switch Turn switch to the ON position Check 120 vac through the ON OFF switch Check wiring harness connection between display board and main control board Connect harness at both points No voltage through the switch e Replace switch Bad display board e Replace board
9. E a a d eS 27 Si SS Service Manual AA A tes Tiii ee 1 Service History Screen The History Screen shows the status of various counters and faults Within the History Screen there are three separate screens These 3 CC screens are the Lockout Faults Blocking Faults and Runtime History The default screen is the Lockout Faults screen This screen allows you to view the last 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 LAST 10 LOCKOUT FAULTS OS 09 11 14 42 gt Flame failure running 1 05 09 11 14 40 gt Parameter programming complete 05 09 11 14 39 gt Flame failure running 1 05 09 11 14 38 gt Parameter programming complete 05 09 11 14 23 gt Flame failure running 2 05 09 11 14 19 gt Flame failure running 7 05 09 11 174 15 gt Flame failure running 1 05 09 11 14 09 gt Flame failure ignition 05 09 11 14 06 gt Parameter programming complete 05 09 11 14 06 gt Flame failure ignition T CD af iE p O ix ak Ey pI 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 the date and time of when the fault occurred The blocking faults can be reset by pressing the RESET FAULTS button Figure 1 12 Graph S
10. F HIGH OUTDOOR TEMPERATURE OUTDOOR TEMPERATURE TEMPERATURE 19 1 Service Outdoor Air Shutdown Differential The outdoor air shutdown differential parameter is the number of degrees below parameter C5 the outdoor air temperature must go before the boiler will respond to a SH demand This parameter can be changed by the installer by accessing parameter C6 Boost Time The boost time parameter sets the amount of time that must elapse with a SH demand before the water temperature calculated set point will be increased This parameter can be changed by the installer by accessing parameter C7 Boost Temperature If a SH demand lasts longer than the programmed boost time delay setting C7 and there have been no HWG demands the control will increase the water temperature set point by the amount in this parameter If the SH demand continues through another time period the set point will be increased again This will continue until either the SH demand ends a maximum of 20 increases has occurred or the maximum set point has been reached 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 Figure 1 7 Ramp Delay Interval RATE RAMP 6 RAMP 5 RAMP 4 RAMP 3 RAMP 2 RAMP 1 CALL TIME gt TIME FOR 1 TIME 3 HEAT gt 2 20 i FEANSA f Cae E TERSA M ia Service Manual
11. CAE Aes a R 3 Troubleshooting Table 3G continued from previous page Troubleshooting Chart Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Louver Proving Sw Open will require a manual e Check function of remote devices evamesiecnencceestensteom AN optional remote proving switch is not ERN A A Making e Check for loose or misplaced jumper if proving switch the RESET button on the is not installed SMART TOUCH display to reset Inspect the heat exchanger Reference page 35 of this manual for the procedure on how to clean the flue side of the heat exchanger Inspect the flue sensor and associated wiring The stack temperature has exceeded the set Measure the resistance of the flue sensor and Flue Temp High parameters for the boiler 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 Verify that the system is full of water and that all air has been properly purged from the system Verify that the boiler is piped properly into the heating system 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 necessa
12. Check supply voltage for proper polarity e Check external wiring for voltage feedback e Check the flame rod and make sure it is clean e Check internal wiring for bad connections e Remove and inspect the burner e Inspect flame rod 1 and associated wiring for damage and connection Reference page 34 of this manual for removal and cleaning procedures Replace if necessary e Check for proper electrical grounding of unit e Check incoming supply gas pressure Natural and L P gas pressures should be between 4 14 inches w c 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 Flame Failure Running 1 will require a manual CAAA The unit was running and lost the flame has been corrected Press the RESET button on the SMART TOUCH display to reset e Verify that the plastic hose from the gas valve to the air inlet is connected and is not damaged e Verify that the vent air intake pipes are installed correctly and there are no obstructions e Inspect flame sensor and associated wiring Reference page 34 of this manual for removal and cleaning procedures Replace if necessary e Check combustion e Inspect the burner Reference page 34 of this manual for removal and cleaning procedures Replace if necessary Es 42 Service Manual ST COME Ae Tii eR 3 Troubleshooting continueg Table 3G continued
13. FIG 3 2 for Model 2 5 see FIG 3 3 and for Models 3 0 and 3 5 see FIG 3 4 Using a screwdriver turn the screw a 1 4 turn counterclockwise to increase CO levels or a 1 4 turn clockwise to decrease CO 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 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 the gas valve REST UGANDE ihr TOi eR Service Manual Figure 3 3 Gas Valve Adjustment Model 2 5 GAS VALVE 2 GAS VALVE 1 THROTTLE THROTTLE Figure 3 4 Gas Valve Adjustment Models 3 0 and 3 5 Figure 3 2 Gas Valve Adjustment Models 1 5 and 2 0 GAS VALVE 2 GAS VALVE 1 THROTTLE THROTTLE GAS VALVE 2 g GAS VALVE 1 fo THROTTLE THROTTLE NOTES St Revision Notes 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
14. Sequence of Operation Sequence of operation Note This unit is equipped with two 2 gas train systems Gas Train 1 will fire first If the demand cannot be met by the first gas train the second gas train Gas Train 2 will fire Upon a call for heat the control turns on the appropriate pumps system and boiler pumps for a space heating call HW pump for a domestic hot water call The control confirms that the low water cutoff contacts are closed and energizes the louvers optional and damper optional relays The control confirms that the gas pressure switch blocked drain switch limits louver proving switch optional and damper proving switch optional contacts close The Pre Purge cycle begins The control confirms both blowers come up to the desired speed both blower proving switches close and the air pressure switch is closed Once the Pre Purge cycle is complete the control lowers the blower speeds initiates sparking of the ignition electrode and opens Gas Valve 1 After a short wait the control stops sparking and checks for the presence of flame current through the flame sense electrode If the control does not detect flame current the control will lockout indefinitely until the RESET button on the touch screen LCD is pressed Models FB 1500 2500 will have one retry If the control detects flame current the control will hold the blower speed constant for a few seconds to allow the flame to stabilize then b
15. 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 accessing parameter C9 D Ramp Delay Ramp Delay Enable Disable This parameter allows the installer to enable or disable the SH ramp delay by accessing parameter D1 SH Ramp Delay The SMART TOUCH control can be programmed to limit the firing 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 time delay expires the second limit is applied and its timer begins The control steps through these limits until the 6th sixth limit expires Note however that the 6th limit will also limit the rate for the rest of that heat demand The installer can adjust the firing limits and time delays by accessing parameters D2 through D13 TIME 5 TIME 4 _ gt 6 MINUTES 1 Service continued E BMS BMS Active Inactive The set point or modulation of the boiler may be controlled through the 0 10V BMS input or through ModBus When parameter E1 set to INACTIVE the 0 10V input will be ignored When set to ACTIVE the set point or modulation will be controlled by the voltage on the 0 10V input in the case of 0 10V BMS control or the 0 10V input value received th
16. Value Value lt es Z Boost Temperature Yes Shift OA Reset Curve p7 2 Ramee men o o Romp OetyTinew o a remos So Ramp Delay Time 4 e Rene Oates fe T Ramp Delay Time 6 N N N N Q1 O Z On O O O O O O D Wn Z O Yes Z O lt D Wn O D n aN D D D O Iolo oO O D n BR O O Bas O 1 1 1 1 1 1 100 amp Delay Limit 1 O 100 100 1S O D D D D D D D n n n Wn n n n amp Delay Limit 2 O O amp Delay Limit 3 amp Delay Limit 4 100 100 100 100 N O lt 14 02 amp Delay Limit 5 ES ER ER 2 2 amp Delay Limit 6 20 a a 2 O lt D e9 JJ ACTIVE INACTIVE INACTIVE No lt D e9 MS Active Inactive MS Mode POWER SETPOINT POWER No lt D e9 BMS Volts at Min Rate BMS Volts at Max Rate MS Rate at Min Volts 4 100 MS Rate at Max Volts 100 100 EN O O O O z lt 14 Z O lt 9 O O O O O O E D Z O 14 14 14 MO 0 20 0 20 20 20 20 20 20 20 20 20 20 20 21 21 21 21 1 1 1 1 1 1 1 1 RAMP DELAY OUTDOOR RESET a ee ee ee MS Volts at Min Setpoint BMS Volts at Max Setpoint No es MS Setpoint at Min Volts 32 185 No Yes 0 MS Setpoint at Max Volts 185 No Yes BMS Volts to Enable afo ww f 2 N Yes 2 Differential to Stop BMS Demand zaf o 1 o5 No 3 BMS Enable Mode ENABLE No Yes 14 C
17. 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 parameter can be changed by the installer by accessing parameter B6 HWG Tank Differential When a tank sensor is installed the tank temperature must drop this amount below the tank set point parameter B6 before the boiler will turn on The installer can adjust this setting by accessing the parameter B7 Manual Reset High Limit The SMART 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 Once the outlet temperature has dropped below this set point the RESET button on the LCD display must be pressed to clear this lockout This set point can be adjusted by accessing parameter B8 Auto Reset High Limit The SMART TOUCH control contains an integral Auto Reset High Limit ARHL on the outlet of the heat exchanger Once the outlet temperature exceeds the ARHL set point the boiler will shut down and lock out Once the outlet temperature has dropped below this set point the RESET button on the LCD display can be pressed to reset this lockout If RESET is not pressed the control will automatically reset the lockout after five 5 minutes This set point can be adjusted by accessing parameter B9 1
18. from boiler sensors and external devices The control module activates and controls the blowers and gas valves to regulate heat input and switches the boiler Hot Water Generator HWG and system pumps on and off as needed The user programs the control module to meet system needs by adjusting control parameters These parameters set operating temperatures and boiler operating modes Sequence of operation R Piit g i ii Table 1A page 12 shows control module normal sequences of h af operation for space heating and HWG operation The combined operation sequence is for a typical application programmed to Home provide HWG priority Access modes User o E E eo j The USER can adjust various space heating and HWG operating Se variables History Navigate to the Initial Setup Screen FIG 1 5 From the Home Screen FIG 1 1 press MAIN MENU then press SETUP on the Main Menu Screen FIG 1 2 Press ENTER on the Password Screen FIG 1 3 henna neer Paxeride do not enter any values and then press INITIAL NOTE For USER tevel access pinasa press onte SETUP on the Setup Screen FIG 1 4 Figure 1 3 Password Screen The USER can set the date and time and adjust temperature set points and outdoor reset points Under the ADVANCED SETUP menu the USER can change the TEMPERATURE UNITS and the LCD BACKLIGHT TIMER Installer Most parameters are available only to the INSTALLER accessible only b
19. is advisable that the installer follow these safety guidelines M Avoid breathing dust and contact with skin and eyes e 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 e Wear long sleeved loose fitting clothing gloves and eye protection M Apply enough water to the combustion chamber lining to prevent airborne dust M Remove the combustion chamber lining from the boiler and place it in a plastic bag for disposal M Wash potentially contaminated clothes separately from other clothing Rinse clothes washer thoroughly NIOSH stated First Aid M Eye Irrigate immediately M Breathing Fresh air 35 3 Troubleshooting A WARNING Labelall wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Always disconnect power to the boiler before servicing Failure to comply could result in severe personal injury death or substantial property damage A WARNING Never jumper bypass any device except for momentary testing as outlined in the Troubleshooting chart Severe personal in
20. parameter J3 i FEANSA f Cae E Service Manual TENSA Ae PAP N Cascade Off On Differential This parameter determines how much the temperature must go below the turn off temperature Set point Offset before the lead boiler turns on This parameter can be adjusted by the installer by accessing parameter J4 Maximum Boiler Set Point for Cascade This parameter determines the set point used by the individual boilers in a Cascade When a boiler is commanded to fire by the Leader boiler it will attempt to achieve this temperature at its outlet If any of the boiler 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 this parameter can be used to limit the outlet temperatures of all the boilers in a Cascade Note that this parameter does not apply when the boiler is heating an indirect HWG tank This parameter is adjustable by the installer by accessing parameter J5 Cascade Type The Cascade divider method is Efficiency Optimization designated as EFF in the menu This method is used as the name implies 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 at 40 The two 2 boilers then modulate at the same rate As the calculated load increases further and both boilers ramp up
21. tank temperature Repair or replace the sensor wiring if damaged Replace the sensor if necessary Check the wiring connections to switch Wires should be connected to the common and normally open terminals Remove switch and check for blockage in the orifice Vent air intake lengths exceed the maximum allowed lengths Refer to Section 2 General Venting of the Crest Installation and Operation Manual for proper lengths Check for obstruction or blockage in the vent air intake pipes or at terminations Inspect the burner Reference page 34 of this manual for removal and cleaning procedures Replace if necessary Verify combustion air blower 1 is operating Replace if necessary e Inspect the heat exchanger Reference page 35 of this manual for removal and cleaning procedures e Faulty pressure switch Replace switch CREST COMBE AAO EC ee 3 Troubleshooting continueg Service Manual Table 3G continued from previous page Troubleshooting Chart Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Blower Proving Switch Open 2 will require a manual reset once the condition has been corrected Press the RESET button on the display to reset Pressure switch contacts are open Burner Supply Temperature Differential will require a manual reset once the condition has been corrected Press the RESET button on the display to reset Combustion air to burner 1 temp
22. the boiler to cool to room temperature if it has been firing Remove the top access panel to remove the gas air manifold assembly Remove the nuts securing the burner to the burner mounting plate Remove the burner FIG 11 2 Remove the nuts securing the burner mounting plate from the heat exchanger and set aside Remove the entire burner mounting plate assembly The boiler contains ceramic fiber materials Use care when handling these materials per instructions on this page Failure to comply could result in severe personal injury Use a vacuum cleaner to remove any accumulation on the tube sheet surfaces Do not use any solvent Brush the heat exchanger tube sheet combustion chamber walls and tube entry while dry using a nylon bristle brush Caution DO NOT use a metal brush Re vacuum the heat exchanger Finish cleaning using a clean cloth dampened with warm water Temporarily remove the condensate drain line from the condensate trap and route directly to a drain Rinse out debris with a low pressure water supply The water will drain through the condensate connection Allow the heat exchanger to thoroughly dry Reconnect the condensate drain line to the condensate trap Close isolation valves on piping to isolate boiler from system Attach a hose to the boiler drain and flush boiler thoroughly with clean water by using purging valves to allow water to flow through the water make up line to the boiler When securi
23. to 80 it lowers the rate of the first two 2 boilers to 53 and brings the next boiler on at 53 The three 3 boilers then modulate together As the calculated load decreases the boilers will reach a lower threshold default 10 at which time the last boiler the third in our example will turn off and the Cascade will increase the rates of the remaining boilers to provide the equivalent total output as before 3 x 10 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 23 1 Service Minimum Next On Time In order 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 delay by accessing parameter J8 Rate to Switch on Next Boiler When the Cascade is programmed in the Efficiency Optimization Mode the currently running boilers must ramp up to a certain firing rate before the next boiler in the Cascade will start This percentage can be adjusted by accessing parameter J9 Rate to Switch off Last Boiler When the Cascade is programmed in the Efficiency Optimization Mode the currently running boiler will stop This perc
24. to reset Either the inlet water or outlet water temperature sensor has been disconnected Either the inlet water or outlet water temperature sensor has been shorted The flue sensor has been disconnected or removed from the flue The flue sensor has been shorted Sensors equipped with an internal limit such as the Lochinvar Squire Indirect Tank the limit has opened due to temperature 195 F or the sensor has become disconnected Blower proving pressure switch 1 contacts are open 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 manual Replace the sensor if necessary Check the sensors and their 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 manual Replace the sensor if necessary 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 manual Replace the sensor in flue Replace the sensor if necessary 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 manual Replace the sensor if necessary Check the
25. ETPOINT the set point represented by the Volts at Minimum parameter E7 is set by parameter F9 Service Manual CREST i IPTA M ie 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 Enable Mode is set to INACTIVE parameter E11 determines the 0 10V BMS input voltage at which the boiler is enabled Differential to Stop BMS Demand When programmed for BMS control through the 0 10V BMS input or through ModBus and the BMS Enable Mode is set to INACTIVE parameter E12 determines how far below the On Volts setting E11 the 0 10V BMS input voltage must be in order to disable the boiler BMS Enable Mode When controlling the boiler through the 0 10V BMS input or through ModBus the boiler can be enabled one of two ways With parameter E13 set to ACTIVE the boiler will be enabled by closing the Enable input When parameter E13 is set to INACTIVE the boiler will be enabled by the voltage level on the 0 10V input in the case of 0 10V BMS control or the 0 10V input value received through ModBus F Advanced Setup Temperature units C F The control can be configured to display temperature in either C or
26. FB SER Rev B CONDENSING BOILER Service Manual Models 1 5 2 0 25 30 3 5 A WARNING 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 fa O the order given Failure to Ese OC comply could result in severe V personal injury death or substantial property damage ar High Efficiency Water Heaters Boilers and Pool Heaters Save this manual for future reference CONT ENTS rcpettecsertsetcietiteet een 2 2 MAINTENANCE Hazard Definitions eases ce ce are eee 2 Maintenance and Annual Startup eee 31 35 PLEASE READ BEFORE PROCEEDING 0 3 3 TROUBLESHOOTING Handling Ceramic Fiber Materials cccccecceeseeeeeeees 3 Before TroubleShooting cccccsccecssseeceeeeeceeeeeseeseesaes 36 When servicing boiler 00 ccceccceseeeesesseeeesseseeeseeneeenes 4 Check Control Module FUSES wiiecssissesorencanceneneeact vances 36 Boiler Operation cccecccessessessesecessessesseseeeeeereereereeseeas 4 Table 3A Troubleshooting Chart No Display 37 Boiler Water eesseisersrerersrersrrerrreruriraririrnriersiersrseersrsess 4 Checking Temperature Sensors iveieisisinssimiciiniraiin 38 Freeze protection fluids ccccccccceccsersesersereeereereereene 4 Table 3F Troubleshooting Cha
27. H approved respirators manufacturers and phone numbers are also listed on this website e Wear long sleeved loose fitting clothing gloves and eye protection M Apply enough water to the combustion chamber lining to prevent airborne dust M 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 WE Eye Irrigate immediately M Breathing Fresh air CREST Service Manual TAP Ae PAP N Please read before proceeding When servicing boiler e To avoid electric shock disconnect electrical supply before performing maintenance e To avoid severe burns allow boiler to cool before performing maintenance Boiler operation e Do not block flow of combustion or ventilation air to the boiler Should overheating occur or gas supply fail to shut off do not turn off or disconnect electrical supply to circulator Instead shut off the gas supply at a location external to the appliance e Do not use this boiler if any part has been under water The possible damage to a flooded appliance can be extensive and present numerous safety hazards Any appliance that has been under water must be replaced Boiler water e Thoroughly flush the system without boiler connected to remove sediment The high efficiency heat exchanger can be damaged by buil
28. IVE ModBus Out of Order Timer When the boiler is being provided with certain commands and temperatures through ModBus this information must be updated frequently If it is not updated before this timer expires the boiler will revert back to its own internal readings and control This parameter is adjustable by the installer by accessing parameter I2 J Cascade Cascade Active Inactive The boiler is part of a group of units sequenced together The designated Leader unit determines the total output needed from the group based on the set point and controlling sensor reading It assigns portions of the output to itself Leader and the Member units When Cascade is active each boiler in the group requires a unique address This setting is adjustable by the installer by accessing parameter Jl Cascade Address The boiler designated as the Leader needs to be programmed with address 0 All the Member boilers require addresses from 1 to 7 and the addresses must be different for each Member The addresses can be in any order regardless of the order in which the units are wired together This parameter is adjustable by the installer by accessing parameter J2 The outdoor air if used and system supply sensor must be connected to the Leader boiler Cascade Offset This parameter determines how much the temperature can go above set point before the lead boiler will turn off This parameter can be adjusted by the installer by accessing
29. NGER DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury A WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious A CAUTION 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 eei A Pe Please read before proceeding A WARNING 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 Handling ceramic fiber materials NOTICE REMOVAL OF COMBUSTION CHAMBER LINING A WARNING The combustion chamber insulation in this appliance contains ceramic fiber material Ceramic fibers can b
30. RESSURE SWITCH MANUAL RESET HIGH LIMIT FLAME SENSOR 1 amp 2 BLOCKED DRAIN SWITCH GAS PRESSURE SWITCHES LOW WATER CUTOFF BLOWER PROVING SWITCHES VENT DAMPER PROVING SWITCH DISPLAY PANEL PC INTERFACE PPA A Ae MO eA S LINE VOLTAGE TERMINAL 1 Service continued Control outputs LOW VOLTAG CONNECTIO SMART CONTROL MODULE Service Manual 0 10V OUTPUT TO BOILER PUMP ALARM CONTACTS LOUVER RELAY RUN TIME CONTACTS BOILER RATE OUTPUT SEQUENCER BUILDING MANAGMENT SYSTEM BOILER PUMP CONTACTOR SYSTEM PUMP CONTACTOR HWG PUMP CONTACTOR IGNITOR BLOWERS GAS VALVES VENT DAMPER DISPLAY PANEL PC INTERFACE Service Manual l AOR A ee OCR be 1 Service General Operation Figure 1 1 Home Screen How the boiler operates The Crest uses an advanced stainless steel heat exchanger STATUS Main Burner On and electronic control module that allows fully condensing Set Point 140 F System Supply operation The blowers pull in air and push flue products out a of the boiler through the heat exchanger and flue piping The control module regulates blower speeds to control the boiler firing rate The gas valves sense the amount of air flowing into the boiler and allow only the right amount of gas to flow How the control modules operate The Crest boiler is equipped with a SMART TOUCH control module The SMART TOUCH control module receives inputs
31. REST Service Manual 1 Service continued Parameter table E a E a a T a a Table 1B continued from previous page This table lists SMART TOUCH control module parameters and where to access them Parameter Name as shown on the LCD screen 7 2 2 2 See Page Value 255 240 Yes Yes gt O Bas a g O lt D n 5 09 N z O lt 14 02 N olo 0 ZIZ O O fe D D n oo T SH to HWG Switching Time 2 o eane fe o riora omena Z ETET SH Night Setback Mon Begin 22 N A N A Yes N A N A Yes A N A N A Yes IA N A N A Yes IA N A N A Yes IA N A N A Yes SH Night Setback Thur Begin 22 N A N A Yes 2 2 N D OO z O lt D e9 ADVANCED SETUP gt A J sje z O g D n SH Night Setback Tue End 22 SH Night Setback Tue Begin 22 SH Night Setback Wed End 22 7 SH Night Setback Wed Begin 22 SH Night Setback Thur End 22 SHiNihaRis image 4 SH Night Setback Tue End 22 a eet sieeve ee 7 SHUNightSetback Wed Begin 22 e SF Nam Seti Trorena 22 SH Night Setback Thur Begin 22 z z zizizIz z z gt gt gt gt a O lt cn L T T 2 Z I T CREST Service Manual A De a te PA 1 Service Parameter table Table 1B continued from previous page This table lists SMART TOUCH control module parameters and where to access them Parameter Name See as shown on the LCD screen Page vVal
32. Service continued HWG Minimum User Set Point This setting controls the minimum user set point for the tank temperature The installer can adjust this by accessing parameter B10 HWG Maximum User Set Point This setting controls the maximum user set point for the tank temperature The installer can adjust this by accessing parameter B11 HWG Boiler Set Point When a HWG call for heat becomes active the control will use the HWG boiler set point to determine the firing rate of the boiler based on the boiler outlet water temperature This parameter can be changed by the installer by accessing parameter B12 HWG Boiler Offset This parameter reflects the degrees above HWG boiler set point the outlet temperature can go before the boiler will shut off This parameter can be changed by the installer by accessing parameter B13 HWG Boiler Differential This parameter reflects the degrees below HWG boiler offset the outlet temperature has to go before the boiler turns on This parameter can be changed by the installer by accessing parameter B14 Figure 1 6 Outdoor Air Reset Curve WATER TEMPERATURE SET POINT SET POINT AT LOW OUTDOOR TEMPERATURE Default 180 F SH SET POINT Default 125 F SET POINT AT HIGH OUTDOOR TEMPERATURE Default 70 F i PP Se Abas Aves cae be Default 25 F LOW OUTDOOR Service Manual C Outdoor Reset SH Set Point at Low Outdoor Temperature When the outdoor air t
33. T TOUCH display to reset e Check for obstruction or blockage in the vent air intake pipes or at terminations e Check the wiring connections at fan 2 and at the main control board e Replace the fan e Replace fuse F2 on the control board see page 36 Blown fuse i of this manual e Vent air intake lengths exceed the maximum allowed lengths Refer to Section 2 General Venting of the Crest Installation and Operation Manual for proper lengths Fan Speed High 1 will require a manual reset once the condition has been corrected Press the RESET button on the SMART TOUCH display to reset e Check for obstruction or blockage in the vent air intake pipes or at terminations The actual fan 1 RPM is 30 higher than what is being called for e Check the wiring connections at the fan and at the main control board e Replace the fan e Vent air intake lengths exceed the maximum allowed lengths Refer to Section 2 General Venting of the Crest Installation and Operation Manual for proper lengths Fan Speed High 2 will require a manual reset once the condition has been corrected Press the RESET button on the SMART TOUCH display to reset e Check for obstruction or blockage in the vent air intake pipes or at terminations The actual fan 2 RPM is 30 higher than what is being called for e Check the wiring connections at the fan and at the main control board e Replace the fan ST Service Manual
34. TION CORRECTIVE ACTION e Verify that the boiler pump is set to the proper speed or that the boiler pump is the proper size Reference Section 5 Hydronic Piping of the Knight Boiler Installation and Operation Manual for boiler pump specifications Outlet Temp High Outlet water temperature has exceeded the continued maximum outlet water temperature Inspect the outlet sensors and associated wiring Measure the resistance of the sensors and compare to the tables on page 38 of this manual Check set point of the external control Check the wiring between the external control and the External control is cycling too often unit Rem Ctrl Fit peed Replace the control Parameters Saved will require a manual reset once the condition After downloading parameters from a laptop has been corrected Press the main control board must be reset the RESET button on the l SMART TOUCH display to reset Press the RESET button on the SMART TOUCH display panel While the unit is in Service Mode the outlet e Establish a heating load to remove the heat from the temperature has exceeded 185 F boiler loop Verify that the system is full of water and that all air has been properly purged from the system Verify that the boiler is piped properly into the heating system Refer to Section 5 Hydronic Piping of the Crest Installation and Operation Manual for the proper piping methods for the Crest boiler Service Blk C
35. a e Refer to the Gas Valve Adjustment Procedure on page 53 of this manual for the proper gas valve setting Verify that the vent air intake lengths do not exceed the maximum listed in the General Venting section of the Crest Installation and Operation Manual Gas air mixture problem Noisy Operation e 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 e Properly purge all air from the piping system e Replace fuse F4 on the control board see page 36 of this manual Blown fuse Boiler Pump SA dte Internal fault on control board e Replace main control board or Faulty pump relay e Replace relay e Reference the Boiler Pump Mode and System Pump Mode parameters in the Service section of this manual Dirty damaged burner Incorrect parameter setting e Lower the system pressure below the rating of the supplied relief valve or replace the standard relief valve with a higher rated valve up to the maximum pressure of the heat exchanger 160 psi 40 kPa System pressure exceeds relief valve setting Relief Valve Opening e Improperly sized expansion tank ST Service Manual UGANDE iir TOi eR 3 Troubleshooting Table 3G Troubleshooting Chart Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Gas Pressure SW e Measure the
36. ain control board If the high limit has tripped check setting of the device and the MRHL set point Check resistance of water sensors and compare to Table 3B on page 38 of this manual Replace sensor if necessary Replace high limit if equipped e Replace main control board CREST Service Manual COME AA Ed be 3 Troubleshooting continued Table 3G continued from previous page Troubleshooting Chart Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION e Vent air intake lengths exceed the maximum allowed lengths Refer to Section 2 General Venting of the Crest Installation and Operation Manual for proper lengths Fan Speed Low 1 CEREREA The actual fan 1 RPM is 30 lower than EAn what is being called for has been corrected Press the RESET button on the SMART TOUCH display to reset e Check for obstruction or blockage in the vent air intake pipes or at terminations e Check the wiring connections at fan 1 and at the main control board e Replace the fan e Replace fuse F2 on the control board see page 36 Blown fuse i of this manual e Vent air intake lengths exceed the maximum allowed lengths Refer to Section 2 General Venting of the Crest Installation and Operation Manual for proper lengths Fan Speed Low 2 EEEn The actual fan 2 RPM is 30 lower than Enn what is being called for has been corrected Press the RESET button on the SMAR
37. al Verify cold fill pressure is correct and that operating pressure does not go too high Check burner flame Inspect flame through observation windows If the flame is unsatisfactory at either high fire or low fire remove and clean 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 34 Service Manual TRAP Be te E e 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 temperatures If using freeze prevention fluid in system do not drain Allow time for the boiler to cool to room temperature if it has been firing Remove the top access panel to remove the gas air manifold assembly Remove the nuts securing the burner to the burner mounting plate Remove the burner FIG 2 2 When replacing the burner ensure gaskets are in good condition and positioned correctly FIG 2 2 When securing the burner be sure to tighten the nuts but DO NOT over tighten Tighten the nuts to a torque setting of no more than 6 2 ft lbs When securing the burner mounting plate be sure to tighten the nuts but DO NOT over tighten Tighten the nuts to a torque setting of no more than 15 5 ft lbs Figure 2 2 Burner Assembly INSULATION
38. all causing it to not seat properly 3 Fill with fresh water until the water begins to pour out of the drain 4 Replace the top cover and the screws removed in Step 1 32 TO FLOOR DRAIN OR NEUTRALIZER KIT 1 PVC CPVC CONNECTION Figure 2 1 Condensate Trap FROM CONDENSATE VENT ON BOILER FROM CONDENSATE DRAIN ON BOILER Check all piping for leaks Eliminate all system or boiler leaks Continual fresh makeup water will reduce boiler life Minerals can build up reducing heat transfer overheating heat exchanger and causing heat exchanger failure Leaking water may also cause severe property damage 1 Inspect all water and gas piping and verify to be leak free 2 Look for signs of leaking lines and correct any problems found 3 Check gas line using the procedure found in Section 6 Gas Connections of the Crest Installation and Operation Manual 2 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 A WARNING 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 install
39. ation will appear on the Maintenance Reminder Screen at that time This can be programmed by accessing parameters L4 and L5 When selected another menu will appear with PHONE and NAME PPE A eee Ea eR Service Manual 25 Service Manual COMER ANIA TONER 1 Service Cascade Screen Figure 1 8 Cascade Screen Cascade a if Mamber 1 Member 2 Member 3 Member 4 Member 5 Member 6 Member 7 la ig b B a a The Cascade Screen provides the status of the Cascade System This screen is only accessible when the boiler is the Leader of an active Cascade There are many items displayed on the Cascade Screen Among them is the Boiler Power Level Indicators For each boiler present in the Cascade a power level indicator will be present above its corresponding Cascade address 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 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 boiler is supplying a hot water generator demand Frost Frost indicates t
40. ays ON with a constant speed except during outdoor shutdown A Always ON with a variable speed input except during outdoor shutdown 5 Always OFF not connected For options 2 and 4 the speed of the system pump is controlled by a separate control system The System Pump Mode can be adjusted by accessing parameter K4 System Pump Delay The system pump delay parameter sets the length of time the system pump if connected will run after a SH demand has been satisfied This parameter is adjustable by the installer by accessing parameter K5 System Pump Anti Seize Delay If the boiler pump does not run for 24 hours it will be turned on briefly to prevent it from seizing The length of time it runs is determined by parameter K6 HWG Pump Delay The HWG pump delay parameter sets the length of time the HWG pump if connected will run after a HWG demand has been satisfied This parameter is adjustable by the installer by accessing parameter K7 HWG Pump Anti Seize Delay If the boiler pump does not run for 24 hours it will be turned on briefly to prevent it from seizing The length of time it runs is determined by parameter K8 AT Set Point The SMART TOUCH control includes a 0 10Vdc output for controlling the speed of a variable speed boiler pump The speed is regulated in order to among other things maintain a minimum delta T across the heat exchanger This helps reduce the electrical consumption of the boiler pump w
41. creen_Blocking Faults LAST 10 BLOCKING FAULTS 05 06 11 14 27 gt High supply temperature 057 06 11 9 07 gt Boiler switched OFF 05 05 11 10 32 gt Boiler switched OFF 05 05 11 8 13 gt Salety thermostat inpul open 05 05 11 8 09 gt False personality plug 05 05 11 8 08 gt False personality plug OS 05 11 7 59 gt Boiler switched OFF 05 04 11 11 41 gt Safety thermostat input open 05 04 11 11 40 gt False personality plug OS 04 11 11 38 gt False personality plug CPT gt sR eoa Rc a iad nee ee ei aa lt a Pe EA T eF 9 35 AM f i TONE T Suud 1 Service continued History Screen Service Manual u MEN iarr OCR e A The third screen is the Runtime History There are several pieces of information that are displayed on this screen Items that can be viewed on this screen are as follows Power hours Shows the number of hours the control has been powered on since the last reset Running hours Shows the number of hours that the boiler has been firing since the last reset Ignition attempts Shows the number of times the control has attempted to ignite since the last reset i 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 i Total Running hours Show the total number of hours that the boiler has been fi
42. d up or corrosion due to sediment e 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 e Do not use homemade cures or boiler patent medicines Serious damage to the boiler personnel and or property may result e Continual fresh make up water will reduce boiler life Mineral buildup in the heat exchanger reduces heat transfer overheats the stainless steel heat exchanger and causes failure Addition of oxygen carried in by makeup water can cause internal corrosion Leaks in boiler piping must be repaired at once to prevent the introduction of makeup water Freeze protection fluids e NEVER use automotive antifreeze Use only inhibited propylene glycol solutions which are specifically formulated for hydronic systems Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems What is in this manual Service Near boiler piping Typical system components The Crest boiler display Display panel readout buttons and their functions Control module inputs e Control module inputs and options Control module outputs e Control module outputs and options General e How the boiler operates e How the control module operates e Access modes user and installer e Sequence of operation HWG space heating Control panel menu access e Accessing programming m
43. e Verify that the vent air intake pipes are properly installed and that there are no obstructions e Check if the vent backflow preventer is installed for boilers commonly vented e Check if the vent backflow preventer is stuck open while the unit is off e Inspect the combustion air temperature sensor and associated wiring e Measure the resistance of the combustion air temperature sensor and compare to Table 3E on page 38 of this manual e Replace the sensor if necessary e Check if the vent backflow preventer is installed for boilers commonly vented e Check if the vent backflow preventer is stuck open while the unit is off e Inspect the combustion air temperature sensor and associated wiring e Measure the resistance of the combustion air temperature sensor and compare to Table 3E on page 38 of this manual e Replace the sensor if necessary CREST Service Manual COMBE AAO EC ee 3 Troubleshooting Table 3G continued from previous page Troubleshooting Chart Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Too Many Resets Try Later Internal Fault Writing to Memos Flue Temp Shutdown Delta T Shutdown 5 Too many manual resets have occurred during a 15 minute period The main control board has detected an internal fault The main control board has detected an internal fault The stack temperature has exceeded the set parameters for the b
44. e 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 Service Manual 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 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 M Avoid breathing dust and contact with skin and eyes e 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 NIOS
45. eat if the outlet temperature drops too quickly The unit has failed to prove main burner ignition It will require a manual reset before attempting to fire again Inspect spark electrode and associated wiring for damage and connection Reference page 34 of this manual for removal and cleaning procedures Replace if necessary Visually check for presence of a spark from the view port Check for proper electrical grounding of the unit Check incoming supply gas pressure Natural and LP gas pressures should be between 4 14 inches w c 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 air inlet is connected and is not damaged Verify that the vent air intake pipes are correctly installed and that there are no obstructions Flame Failure Ignition If 120 vac is present at the main control board check the wiring between the main control board and the gas valve Replace the wiring if necessary Do not disconnect the wiring from the gas valve and attempt to measure voltage at that point The main control board can detect if the gas valve is not connected and will display the Gas Valve Connection fault will require a manual reset once the condition has been corrected Press the RESET button on the SMART TOUCH display to reset If 120 vac is present check the outlet of
46. ed and operational 2 Check the cold fill pressure for the system Verify it is correct must be a minimum of 12 psi 82 7 kPa 3 Watch the system pressure as the boiler heats up during testing to ensure pressure does not rise too high Excessive pressure rise indicates expansion tank sizing or performance problem 4 Inspect automatic air vents and air separators Remove air vent caps and briefly press push valve to flush vent Replace caps Make sure vents do not leak Replace any leaking vents Check expansion tank 1 Expansion tanks provide space for water to move in and out as the heating system water expands due to temperature increase or contracts as the water cools Tanks may be open closed or diaphragm or bladder type See Section 5 Hydronic Piping of the Crest Installation and Operation Manual for suggested best location of expansion tanks and air eliminators Check boiler relief valve 1 Inspect the relief valve and lift the lever to verify flow Before operating any relief valve ensure that it is piped with its discharge in a safe area to avoid severe scald potential Read Section 5 Hydronic Piping of the Crest Installation and Operation Manual before proceeding further CREST Service Manual Safety relief valves should be re inspected aus 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 wa
47. egin modulating the firing rate in order to maintain the controlling sensor to the desired set point temperature 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 If the first combustion system in the boiler is unable to maintain the desired set point temperature the second combustion system in the boiler will be started Both blowers will modulate to a set speed and the second gas valve will be energized The second combustion system will light from the first combustion system The second flame will be monitored much like the first Once both combustion systems are firing the control will work in synchronization to maintain the desired set point temperature If the heat load should decrease sufficiently the second combustion system will be shut down Once both the space heating and HW calls for heat are satisfied the control will turn off the gas valve s and begin the Post Purge cycle Any pumps that are running will begin their respective Pump Delay cycles At the end of the Post Purge cycle the louver relay contacts will de energize The control verifies that the blowers stop running and the blower proving switches open At the end of the Pump Delay cycle s the pump s will be turned off
48. emperature drops to or below the Low Outdoor Temperature setting parameter C3 the water temperature will be at this 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 Cl 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 parameter can be changed by accessing parameter C2 Low Outdoor Temperature When the outdoor air temperature drops to its minimum C3 the water temperature will be at parameter C1 FIG 1 6 As the outdoor temperature continues to drop the water temperature set point will continue to rise 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 C3 High Outdoor Temperature When the outdoor air temperature rises to or above this set point the water temperature will be at parameter C2 FIG 1 6 This parameter can be changed by the installer by accessing parameter C4 Outdoor Air Shutdown When the outdoor temperature rises above this point the control will block all SH demands HWG demands will still be active This parameter can be changed by the installer by accessing parameter C5 Default 70
49. entage can be adjusted by accessing parameter J10 Number of Boiler Pumps Always On When multiple Crest boilers are connected in a Cascade the SMART TOUCH control can keep a minimum number of the boiler pumps running regardless of how many of the boilers are firing This is useful in full flow systems where the system flow is provided by the individual boiler pumps This number can be adjusted by accessing parameter J11 K Pumps Boiler Pump Delay The SH pump delay parameter sets the length of time the boiler pump will run after a SH demand has been satisfied This parameter is adjustable by the installer by accessing parameter K1 Boiler Pump Anti Seize Time If the boiler pump does not run for 24 hours it will be turned on briefly to prevent it from seizing The length of time it runs is determined by parameter K2 Boiler Pump Mode The SMART TOUCH control is able to control the boiler pump in 3 different ways The options are as follows L ON with a call for heat with a constant speed 2 ON with a call for heat with a variable speed output 3 Always OFF not connected The Boiler Pump Mode can be adjusted by accessing parameter K3 24 i ITSA M ie Service Manual System Pump Mode The SMART TOUCH control is able to control the system pump in 5 different ways The options are as follows I ON with a call for heat with a constant speed nA ON with a call for heat with a variable speed input 3 Alw
50. erature is higher than combustion air to burner 2 temperature or vice versa Burner Supply Temperature High 1 will require a manual reset once the condition has been corrected Press the RESET button on the display to reset Combustion air temperature is very high Burner Supply Temperature High 2 will require a manual reset once the condition has been corrected Press the RESET button on the display to reset Combustion air temperature is very high e Check the wiring connections to switch Wires should be connected to the common and normally open terminals e Remove switch and check for blockage in the orifice e Vent air intake lengths exceed the maximum allowed lengths Refer to Section 2 General Venting of the Crest Installation and Operation Manual for proper lengths e Check for obstruction or blockage in the vent air intake pipes or at terminations e Inspect the burner Reference page 34 of this manual for removal and cleaning procedures Replace if necessary e Verify combustion air blower 2 is operating Replace if necessary e Inspect the heat exchanger Reference page 35 of this manual for removal and cleaning procedures e Faulty pressure switch Replace switch e Inspect the combustion air temperature sensor and associated wiring e Measure the resistance of the combustion air temperature sensor and compare to Table 3E on page 38 of this manual e Replace the sensor if necessary
51. erature as measured by the tank sensor in the hot water storage tank if connected Flue Temperature Temperature measured by the flue sensor Time The time is displayed in the lower left hand corner of the display Reference this manual for Night Setback parameters and more information regarding adjusting the date and time Boiler Status button Pressing this button brings up the Boiler Status Screen This screen shows the status of the various safeties inputs and outputs to the control module Reference this manual for more 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 REST Service Manual PVE A ae Ea a 1 Service Control inputs HWG THERMOSTAT SENSOR KH ENABLING DEVICE CASCADE Y LOW VOLTAGE CONNECTION BOARD LOUVER PROVING SWITCH SYSTEM SENSOR SUPPLY SYSTEM SENSOR RETURN OUTDOOR SENSOR MODBUS BOARD SEQUENCER BUILDING MANAGMENT SYSTEM AUX SWITCH 1 amp 2 SMART CONTROL MODULE 0 10 INPUT FROM SYSTEM PUMP INLET TEMPERATURE SENSOR OUTLET TEMPERATURE HI LIMIT SENSOR FLUE GAS SENSOR INLET AIR SENSORS AIR P
52. from previous page Troubleshooting Chart Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Flame Failure Running 2 will require a manual reset once the condition has been corrected Press the RESET button on the SMART TOUCH display to reset Gas Valve Relay Failure 1 will require a manual reset once the condition has been corrected Press the RESET button on the SMART TOUCH display to reset Gas Valve Relay Failure 2 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 The main control board did not detect gas valve 1 The main control board did not detect gas valve 2 e Inspect flame rod 2 and associated wiring for damage and connection Reference page 34 of this manual for removal and cleaning procedures Replace if necessary e Check for proper electrical grounding of unit e Check incoming supply gas pressure Natural and L P gas pressures should be between 4 14 inches w c 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 e Verify that the plastic hose from the gas valve to the air inlet is connected and is not damaged e Verify that the vent air intake pipes are installed correctly and there are no obstructions e Inspect fla
53. hat the corresponding boiler is in frost protection and is not being controlled by the Leader Two dash marks indicate that there is not a demand for the corresponding boiler E 55 Service Manual COANE Ne MON be 1 Service continued Graph Screen The Graph Screen consists of two 2 different screens The First screen is the Parameter Selection Screen By pressing the up and down arrow keys the desired parameter can be selected When the SELECT button is pressed the parameter will appear in the bottom half of the first screen If a parameter is selected by mistake it can be 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 Scroll list up or down to view parameters 3 Tank temperature A System supply temperature 5 Syslem retum temperature Outlet temperature inlet temperature oystem return temperature Flue temperature 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 to represent it The items selected will be shown below the graph along with their corresponding color Press the BACK button to return to the Parameter Selection Screen Figure 1 10 Graph Screen 1 min 30 sec Flue temperature 941 AM RER o TET PT SS
54. hat the reason for relief valve weeping is the valve and not over pressurization of the system due to expansion tank waterlogging or undersizing 33 2 Maintenance Inspect ignition and flame sense electrodes l Remove the ignition and both flame sense electrodes from the burner plate Remove any deposits accumulated on the ignition flame sense electrodes using sandpaper If the electrodes cannot be cleaned satisfactorily replace with new ones Replace ignition flame sense electrodes making sure the gaskets are in good condition and correctly positioned Check ignition ground wiring iE Inspect boiler ground wire from the heat exchanger access cover to ground terminal strip Verify all wiring is in good condition and securely attached Check ground continuity of wiring using continuity meter Replace ground wires if ground continuity is not satisfactory Check all boiler wiring l Inspect all boiler wiring making sure wires are in good condition and securely attached Check control settings l 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 for adjustment procedures Check settings of external limit controls if any and adjust if necessary Perform start up and checks iP Start boiler and perform checks and tests specified in Section 9 Start up of the Crest Installation and Operation Manu
55. he second way is by manually adjusting the firing percentage using the and buttons When Service Mode is no longer needed press the STOP button to return to normal operation Figure 1 14 Service Screen Firing Rate Adjustment mY A l 19 TY A a i ai tse j Set Gas Valve 1 Set Gas Valve 2 Total Boiler A at Max np T pa 2 scat E 7 SSS we FS a SS See ee OE ABS EEA gt Press the Start Stop button to begin end Service mode 39 2 Maintenance PPE M ee EP PE Maintenance and annual startup Table 2A Service and Maintenance Schedules Service technician see the following pages for instructions A H lt H v l lt _ lt lt General e Address reported problems if any e Inspect interior clean and vacuum if necessary e Clean condensate trap and fill with fresh water e Check for leaks water flue condensate gas e Verify flue and air lines in good condition and sealed tight e Check system water pressure system piping expansion tank e Check control settings e Check the ignition and both flame sense electrodes sand off any deposits clean and reposition e Check wiring and connections e Perform start up checkout and performance verification per Section 9 of the Crest Installation and Operation Manual e Flame inspection stable uniform e Check both flame signals at least 10 microamps at high f
56. heck 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 replace the pump Verify that the boiler pump is set to the proper speed or that the boiler pump is the proper size Reference Section 5 Hydronic Piping of the Crest Installation and Operation Manual for boiler pump specifications CREST Service Manual CAR Ae ME eR 3 Troubleshooting Table 3G continued from previous page Troubleshooting Chart Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION e Check the sensors and their associated wiring Sensor Open will require a manual reset once the condition has been corrected Press the RESET button on the display to reset Sensor Shorted will require a manual reset once the condition has been corrected Press the RESET button on the display to reset Flue Sensor Open will require a manual reset once the condition has been corrected Press the RESET button on the display to reset Flue Sensor Shorted will require a manual reset once the condition has been corrected Press the RESET button on the display to reset Tank Open Blower Proving Switch Open 1 will require a manual reset once the condition has been corrected Press the RESET button on the display
57. hen the boiler is firing at less than its maximum rate This feature is active only when a system supply sensor is installed This set point can be adjusted by accessing parameter K9 1 Service continued L Service Notification Service Notification in Months When the boiler control determines that a scheduled service is due based on the months of installation 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 installer by accessing parameter L1 Service Notification Running Hours When the boiler 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 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 installer by accessing parameter L3 Installer Name and Phone Number When a Maintenance Reminder timer or counter has expired a Maintenance Reminder screen will appear on the display By programming the installer s name and phone number this inform
58. ire e Test low water cutoff If combustion or performance indicate need e Clean heat exchanger e Remove and clean burner compressed air only using e Clean the blower wheels Service Manual Owner maintenance see the Crest User s Information Manual for Monthly Every 6 months End of season months instructions e Check boiler area e Check pressure temperature gauge e Check vent piping e Check air piping e Check air and vent termination screens e Check relief valve e Check condensate drain system e Test low water cutoff e Reset button low water cutoff e Check boiler piping gas and water for leaks e Operate relief valve e Shut boiler down unless boiler used for domestic hot water 31 2 Maintenance TP AA Ae MO rR Service Manual Follow the service and maintenance procedures given throughout this manual and in component literature A WARNING l l l j l i shipped with the boiler Failure to perform the service and maintenance could result in damage to the boiler or system Failure to follow the directions in this manual and component literature could result in severe personal injury death or substantial property damage A WARNING The boiler should be inspected annually only by a qualified service technician In addition the maintenance and care of the boiler designated in Table 2A and explained on the following pages must be performed to assure maximum boile
59. jury death or substantial property damage can result Before troubleshooting l Have the following items a Voltmeter that can check 120 vac 24 vac and 12 vdc b Continuity checker c Contact thermometer Check for 120 vac minimum 102 vac to maximum 132 vac to boiler Make sure thermostat is calling for heat and contacts are closed Check for 24 vac between thermostat wire nuts and ground Make sure all external limit controls are installed and operating Check the following l Wire connectors to control module are securely plugged in at the module and originating control Gas pressures e Maximum 14 inches w c 3 5 kPa natural and LP with no flow lockup or with boiler on e Minimum 4 inches w c 1 0 kPa natural and LP with gas flowing verify during boiler startup 36 CREST Pairi Ae Per Service Manual Check control module fuses NOTICE ALWAYS check control module fuses before replacing control module or any major 4 components blower etc If one of these fuses is blown it can prevent the control module or other components from operating Turn OFF the power to the boiler at the external line switch Remove the upper and lower doors Remove the four 4 screws securing the control panel cover to the unit to gain access to the control module Inspect fuses F2 F4 and F5 see FIG 3 1 below Figure 3 1 Control Module Fuses F2 3 15 AMP BLOWER RELAYS F4
60. l start a timer Once the timer expires it will stop the HWG demand and service the space heating demand The installer can adjust the length of time the boiler will service the HWG demand by accessing parameter F6 SH HWG Switching Time When a boiler has a space heating demand and it receives a HWG demand it will immediately switch to the HWG demand and start a timer Once the timer has expired the boiler will switch back to the space heating demand and start another timer Once this timer expires it will switch back to the HWG demand The installer can adjust the length of time the boiler will service the space heating demand by accessing parameter F7 Anti Cycling Time Once a SH demand has been satisfied a set amount of time must elapse before the control will respond to a new SH demand The control will block the new heat demand and anti cycling will be shown in the display until the time has elapsed or the water temperature drops below parameter F9 This parameter can be changed by the installer by accessing parameter F8 Anti Cycling Differential The control will bypass the anti cycling time if the inlet 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 parameter the control will abort anti cycling and allow the boiler to fire This parameter can be changed by the installer by accessi
61. me sensor and associated wiring Reference page 34 of this manual for removal and cleaning procedures Replace if necessary e Check combustion e Inspectthe burner Reference page 34 ofthis manual for removal and cleaning procedures Replace if necessary e Check wiring harness connection at the gas valve and at the main control board e Replace the gas valve wire harness e Replace the gas valve e Check wiring harness connection at the gas valve and at the main control board e Replace the gas valve wire harness e Replace the gas valve CREST Service Manual COME R itie ae 3 Troubleshooting Table 3G continued from previous page Troubleshooting Chart Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION e Verify that the system is full of water and that all air has been properly purged from the system e Verify that the boiler is piped properly into the heating system Refer to Section 5 Hydronic Piping of the Crest Installation and Operation Manual for the proper piping methods for the Crest boiler Check 120 vac to boiler pump motor on a call for heat If voltage is not present check wiring back to the main control board Check the ARHL set point If 120 vac is present on a call for heat and the boiler The outlet water temperature has exceeded l l pump is not operating replace the pump Auto Reset the setting of the automatic reset high limit High Limit
62. n and Operation Manual for boiler pump specifications ST Service Manual OAR Ae MN be 3 Troubleshooting continueg Table 3G continued from previous page Troubleshooting Chart Fault Messages Displayed on Boiler Interface DESCRIPTION CORRECTIVE ACTION e Verify that the system is full of water and that all air has been properly purged from the system e Verify that the boiler is piped properly into the heating system Refer to Section 5 Hydronic Piping of the Crest Installation and Operation Manual for the proper piping methods for the Crest boiler cca nails Outlet water temperature has exceeded the 3 Pa utao maximum outlet water temperature e Check for voltage to the boiler pump motor ona call for heat If voltage is not present check wiring back to the pump relay Replace the pump relay if necessary e If 120 VAC is present on a call for heat and the boiler pump is not operating replace the pump The main control board has detected an Watch Dog Error ateral taut Replace the main control board Write EEProm The main control board has detected an Replace the main control board internal fault CRC Parameters 1ng MaN CONTOR poAo NAS GEIECEO ANI Replace the main control board internal fault The main control board has detected an Press the RESET button on the SMART TOUCH No Error Stored internal fault display panel 51 CREST Service Manual COMPRA Ae Od be 3 Troubleshooting Combu
63. nce the heat exchanger has modulated up You must replace the flue gas temperature sensor to rate measure the combustion The values to prevent flue gas spillage into the room Failure should be in the range listed in Table 3I CO to comply could result in severe personal injury levels should be less than 200 ppm for a properly death or substantial property damage installed unit If the combustion is not within range reference the Troubleshooting Chart below for possible causes and corrective actions Table 3H Troubleshooting Chart Combustion Levels POSSIBLE CAUSE CORRECTIVE ACTION e Refer to Section 2 General Venting of the Crest Installation and Operation Manual Vent Air Intake Length for the proper venting and air intake methods for the Crest boiler or Obstruction e Check for obstructions at the vent air intake terminals eE ETT A E Refer to Section 6 Gas Connections of the Crest Installation and Operation Manual for the proper gas supply for the Crest boiler e Refer to page 34 of this manual for burner removal and cleaning procedures Dirty Damaged Burner e Replace burner if necessary eT CAEN ON A uug Refer to page 53 of this manual for the gas valve adjustment procedure 52 3 Troubleshooting continueg Gas valve adjustment procedure CAUTION Under normal operating conditions this valve should not need adjusting Locate the throttle adjustment screw on the gas valve For Models 1 5 and 2 0 see
64. ng parameter F9 22 Service Manual CREST Ce M i HWG Rate Liming NOT AVAILABLE AT THIS TIME This parameter determines the maximum rate to be used when heating a HWG tank This setting may be used when the tank is unable to accept all of the BTU s available from the boiler This parameter may be adjusted by the installer by accessing parameter F10 Service Mode Timeout The Service Mode allows the installer to set the unit to any firing rate for the purpose of combustion analysis The delay sets the length of time the boiler will stay in the Service Mode if no keys have been pressed before going back to its original state This parameter can only be changed by the installer by accessing parameter F11 Controlling Sensor The SH controlling sensor parameter selects the sensor the control will use to regulate the boiler firing rate This parameter is adjustable by the installer by accessing parameter F12 The sensor selections are as follows The outlet sensor regulates the firing rate based on the outlet water temperature of the boiler and the inlet sensor regulates the firing rate based on the inlet water temperature of the boiler If the outlet sensor is selected and the optional system supply sensor is connected the control will regulate the firing rate based on the system supply sensor temperature Inlet Control Time Delay When the inlet sensor is selected as the controlling sensor the SMART TOUCH control will star
65. ng the burner be sure to tighten the nuts but DO NOT over tighten Tighten the nuts to a torque setting of no more than 6 2 ft lbs When securing the burner mounting plate be sure to tighten the nuts but DO NOT over tighten Tighten the nuts to a torque setting of no more than 15 5 ft lbs TE AEE EP Pl te PAE 15 16 Service Manual Replace the burner mounting plate assembly and gas air manifold assembly Ensure gaskets are in good condition and positioned properly Restore boiler to operation Perform start up and check out procedures in the Check Flame and Combustion Section 9 Startup of the Crest Installation and Operation Manual Handling ceramic fiber materials REMOVAL OF COMBUSTION CHAMBER LINING A WARNING 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
66. ode and locating menus See separate guide covering the PC interface Control panel parameter access e Accessing and changing parameters from the display panel Quick start information table e An index of available adjustments and readouts where to access them and where to find detailed information parameter Crest boiler operation Initial Setup e Set Points e Outdoor Reset e Ramp Delay e BMS e Advanced Setup e SH Night Setback e HWG Night Setback e Cascade e Pumps e Service Notification i EAIA ir Pr e be Service Manual fF Be Ae Maintenance e Service and maintenance schedules e Address reported problems Inspect boiler area and boiler interior e Clean condensate trap e Check all piping for leaks e Check air openings Flue vent system and air piping e Check water system e Check expansion tank e Check boiler relief valve Inspect ignition electrode e Check ignition ground wiring e Check all boiler wiring e Check control settings Perform start up and checks e Check burner flame e Check flame signal e Check flue gas temperature e General maintenance e Review with owner e Cleaning boiler heat exchanger e Oiled bearing circulators Troubleshooting e Troubleshooting table No display e Checking temperature sensors e Sensor tables e Troubleshooting table Fault messages displayed on boiler interface e Combustion analysis procedure e Gas valve adjustment proced
67. oiler The temperature rise across the heat exchanger has exceeded the set parameters for the boiler e Wait 15 minutes and try again e Turn power off to unit wait 30 seconds and then turn power back on e Replace the main control board e Replace the main control board e Inspect the heat exchanger Reference page 35 of this manual for the procedure on how to clean the flue side of the heat exchanger e Inspect the flue sensor and associated wiring Measure the resistance of the flue 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 Replace the main control board Verify that the system is full of water and that all air has been properly purged from the system Verify that the boiler is piped properly into the heating system Refer to Section 5 Hydronic Piping of the Crest Installation and Operation Manual 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 the 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 Verify that the boiler pump is set to the proper speed or that the pump is the proper size Reference Section 5 Hydronic Piping of the Crest Installatio
68. r efficiency and reliability Failure to service and maintain the boiler and system could result in equipment failure Electrical shock hazard Turn off power to the boiler before any service operation on the boiler except as A WARNING a ae l l i l noted otherwise in this instruction manual Failure to turn off electrical power could result in electrical shock causing severe personal injury or death Address reported problems 1 Inspect any problems reported by the owner and correct before proceeding Inspect boiler area 1 Verify that boiler area is free of any combustible materials gasoline and other flammable vapors and liquids 2 Verify that air intake area is free of any of the contaminants listed in Section 1 of this manual 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 line condensate PVC fittings and condensate trap Flush condensate trap with water 1 Remove the four 4 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 b
69. re The boiler can be started and stopped by pressing the ON OFF button The Boiler Status Screen and Main Menu Screen can be accessed by pressing the appropriate button Home Screen STATUS Main burner ON Boiler Status Set Point 110 F Sys Outlet Main Menu O CE EE we Bmnoerathre j Hlat we Ale Tey if Bratre bey j b real j F Arzi f IHLU f i i iam Retum Temperature Modulation 100 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 of the Crest boiler The following items can be viewed or interacted with on the Home Screen On Off button Pressing this button allows the boiler to be placed in either Manual Shutdown Mode or Standby Mode Status This line shows the current operating status of the Crest boiler and the current set point 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 is the outdoor air temperature if connected HWG Temperature This is the temp
70. ring Total ignition attempts Show the total number of times the control has attempted to ignite Total Successful ignition attempts Show the total number of times the control has successfully ignited The top left of this screen details the running hours based on 4 different running positions Figure 1 13 History Screen_Runtime History RUNTIME HISTORY BY PERCENTAGE 100 75 9 hours 75 50 1 hours 50 25 0 hours Less than 25 0 hours 90 10 0 0 Total hours 10 hours Power hours Running hours Total Power hours Total Ignition attempts 5 Total Successful Ignition attempts Se eee EE 59 Service Manual CANOE Nee Tii be 1 Service continued Service Screen The Service Screen allows the integrated control to override all other heat demands and operate Valve 1 and Valve 2 at high fire and low fire conditions To place the boiler into Service Mode press the START button As specified above the integrated control will override all other heat demands however all safeties will be active If no buttons 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 T
71. rough ModBus BMS Mode Power Set Point When programmed for BMS control through the 0 10V BMS input or through ModBus the 0 10V signal can be interpreted as either a modulation command or a set point When parameter E2 is set to POWER the 0 10V signal will control the modulation When set to SETPOINT the 0 10V signal will control the SH set point BMS Volts at Minimum Rate or Set Point When programmed for BMS control through the 0 10V BMS input or through ModBus parameters E3 or E7 should be set to the minimum voltage signal sent to the SMART TOUCH control BMS Volts at Maximum Rate or Set Point When programmed for BMS control through the 0 10V BMS input or through ModBus parameter E4 or E8 should be set to the maximum voltage signal sent to the SMART TOUCH control BMS Rate at Minimum Volts When programmed for BMS control through the 0 10V BMS input or through ModBus and the BMS Type is programmed as POWER the modulation percentage represented by the Volts at Minimum parameter E3 is set by parameter E5 BMS Rate at Maximum Volts When programmed for BMS control through the 0 10V BMS input or through ModBus and the BMS Type is programmed as POWER the modulation percentage represented by the Volts at Maximum parameter E4 is set by parameter E6 BMS Set Point at Minimum Volts When programmed for BMS control through the 0 10V BMS input or through ModBus and the BMS Type is programmed as S
72. rresponding table replace the sensor It is important to note that the flue and outlet inlet air 11 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 3 S10 flue sensor Please reference the wiring diagram in the Crest Installation and Operation Manual for correct terminal location Table 3B Inlet Water System Sensor Resistance vs Table 3C Outdoor Air Sensor Resistance vs Temperature Temperature Temperature Resistance Temperature Resistance Temperature Resistance Temperature Resistance 18 780 1 990 490 813 46 218 68 12 263 1 458 336 606 34 558 86 819 1 084 234 196 26 099 165 180 19 900 5 592 118 018 60 15 311 a ae 122 85 362 11 883 wa 62 465 80 929 sa eKy sa ow 158 158 176 176 194 194 21 212 Oo 58 piss 3478 n 7 2492 P19 pia 816 Pa Ooo a 5 S10 WY a 25 030 o 68 1235500 176 12000 o 86 16090 o 86 8o220 194 8674 o 2 35270 o o n ww wo o 38 T Service Manual CAO Ae i e R 3 Troubleshooting continueo Table 3F Troubleshooting Chart Noisy System FAULT CAUSE CORRECTIVE ACTION e Refer to Section 6 Gas Connections of the Crest Installation and Operation Manual for detailed information concerning the gas supply Supply gas problem Natural and LP gas pressures should be between 4 inches w c 1 0 kPa and 14 inches w c 3 5 kP
73. rt Noisy System 39 WHAT IS IN THIS MANUAL o oo 5 Table 3G Troubleshooting Chart Fault Messages 40 51 1 SERVICE Combustion Analysis Procedure cccccccceceeeceeeeeeeees 52 Boiler Piping 0 ccccecsessesecessessceesessescesestsseseeseevereseeeenes 6 Table 3H Troubleshooting Chart Combustion Levels 52 SMART TOUCH Display Home Screen 0000008 7 Table 3I Flue PIOAUCS eiorinctasiorndcaccontihas miieehesuoeaeds 52 Control INDUtS cee eeeeceeseeccescesceeeceeserssseesveeeansereeseees 8 Gas Valve Adjustment Procedur riisiin 53 Control OUPUlS ssr 9 Revision NOTOS ssisisisiisssrssnrerrsiroinisiiiniiiiniiieias Back Cover General Operation xs05 2 scceencsnsacesceatetassssccaceceedearke 10 11 Table 1A Sequence of Operation cccccseeeeeeeeees 12 Table 1B Parameter Table ccccssceeeesseeeeeees 13 17 Viewable and Changeable Control Parameters 18 25 Cascade OC Oates ccs Seco cdece een coeseieacecaswiait cnaatecuniecdeceeecae 26 Graph Screen anwesavasns dantanueaesacausaxonsavancdatetaacseaneastbesenasbaness 27 HIStory SCOE aasaran antann ee nee 28 29 Service SCreen ccc ceccceccceeccceneeceececeeeeeeeetaneeeaneeeaneeaeeeaes 30 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 DA
74. ry Delta T High The temperature rise across the heat exchanger has exceeded the set parameters If 120 vac is present on a call for heat and the boiler for the boiler pump is not operating replace the pump Verify that the boiler pump is set to the proper speed or that the pump is the proper size Reference Section 5 Hydronic Piping of the Crest Installation and Operation Manual for boiler pump specifications Inspect the inlet and outlet sensors and associated wiring Measure the resistance of the sensors and compare to the tables on page 38 of this manual Verify that the system is full of water and that all air has been properly purged from the system Verify that the boiler is piped properly into the heating system Refer to Section 5 Hydronic Piping of the Crest Installation and Operation Manual Outlet Temp for the proper piping methods for the Crest boiler High Outlet water temperature has exceeded the maximum outlet water temperature Check for 120 vac to the boiler pump motor on a call for heat If voltage is not present check wiring back to the main control board Replace the main control board if necessary e If 120 vac is present on a call for heat and the boiler pump is not operating replace the pump p 46 T Service Manual ADEN iir Tii eR 3 Troubleshooting continueg Table 3G continued from previous page Troubleshooting Chart Fault Messages Displayed on Boiler Interface FAULT DESCRIP
75. s Space Heating SH Minimum Set Point The SH minimum set point sets the minimum water temperature set point that can be used for space heating operation The user or installer will not be able to program the control with a lower SH set point This parameter can only be changed by the installer by accessing parameter B1 Space Heating SH Maximum Set Point The SH maximum set point sets the maximum water temperature set point that can be used for space heating The user or installer will not be able to program the control with a higher SH set point This parameter can only be changed by the installer by accessing parameter B2 Space Heating SH Set Point The SH set point sets the water temperature set point used during space heating calls This parameter can be changed by the installer by accessing parameter B3 18 SH Offset The SH offset sets how many degrees above set point the temperature can go before the boiler will shut off This parameter can only be changed by the installer by accessing parameter B4 SH Differential The SH differential sets how many degrees below the offset the temperature has to drop before the boiler turns back on This parameter can only be changed by the installer by accessing parameter B5 HWG 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
76. stion Analysis Table 3I Flue Products Procedure 1 Turn the main power off to the boiler by placing Gas natrateas Propane the On Off switch in the OFF position Valve 2 Remove the flue temperature sensor from the co o co o flue collector Note Combustion measurements 4 High 3 5 5 5 11 2 14 8 5 1 6 8 10 5 13 2 will be made at this point f 2 High 7 8 8 6 5 6 7 1 9 4 11 0 4 1 6 6 3 Turn the main power on to the boiler by placing the On Off switch in the ON position 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 4 Navigate to the Service Screen from the Home Screen by pressing the MAIN MENU button and 9 Once the heater analysis is complete test the safety shutoff device then the SERVICE button by turning the manual shutoff valve to the OFF position and ensuring that the heater shuts down and registers an alarm Open 5 On the Service Screen place heater into Service P the manual shutoff valve and reset the control Mode by selecting the START button then selecting Set Gas Valve 1 High 10 Turn the main power off to the boiler and replace the 6 Insert the probe from a combustion analyzer flue temperature sensor into the flue pipe connection into the hole left by the removal of the flue 1 Place the boiler back into normal operation temperature sensor 7 O
77. supply gas pressure to determine cause Open of failure Natural and LP gas pressures should be will require a manual between 4 14 inches w c 1 0 3 5 kPa CEA AN Either the low gas pressure switch or one of EANN A R the high gas pressure switches tripped the RESET button on the SMART TOUCH display to reset e Correct the supply gas pressure if necessary e Refer to Section 6 Gas Connections of the Crest Installation and Operation Manual for detailed information concerning the gas supply e Reset the LWCO from the RESET button on the front Low Water control panel Cutoff Open will require a manual reset once condition has been corrected Press the RESET button on the SMART TOUCH display to reset e Replace fuse F2 on the control board see page 38 BIOWD IUSE of this manual Blocked Drain SW e Check condensate tube from unit to floor drain for Open proper installation and obstructions will require a manual e Inspect condensate trap for blockage Clean if ANCEN The blocked drain switch has detected necessary DSR S excessive condensate build up inside the the RESET button on the unit e Check for loose wiring connection at wire harness SMART TOUCH display plug to reset e Verify system is full of water and all air has been The low water cutoff is not making purged from the system e Check for loose or misplaced jumpers if flow switch or LWCO is not installed e Bad blocked drain switch Replace switch
78. t by controlling the outlet system supply temperature to the SH set point After a time delay the control will start 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 its way through the system loop and be measured by the inlet system return sensor This time delay is adjustable by the installer by accessing parameter F13 G H SH HWG Night Setback The installer may adjust the space heating night setback offset by accessing parameter G1 and the HWG night setback offset by accessing parameter H1 Once the internal clock has been set correctly the SH night setback feature can be used to program a lower set point The value of this parameter will be subtracted 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 1 Service continued I ModBus ModBus Active Inactive When BMS is set to ACTIVE see BMS Active Inactive and the boiler is being controlled through ModBus set parameter Il to ACTIVE Otherwise set the ModBus parameter to INACTIVE Note that the boiler can still be monitored by ModBus with this parameter set to INACT
79. ter conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally Certain naturally occurring conditions may corrode the valve or its components over time rendering the valve inoperative Such conditions are not detectable unless the valve and its components are physically removed and inspected This inspection must only be conducted by a plumbing contractor or authorized inspection agency not by the owner Failure to re inspect the boiler relief valve as directed could result in unsafe pressure buildup which can result in severe personal injury death or substantial property damage Following installation the valve lever A WARNING must be operated AT LEAST ONCE A YEAR to ensure that waterways are clear Certain naturally occurring mineral deposits may adhere to the valve rendering it inoperative When manually operating the lever water will discharge and precautions must be taken to avoid contact with hot water and to avoid water damage Before operating lever check to see that a discharge line is connected to this valve directing the flow of hot water from the valve to a proper place of disposal Otherwise severe personal injury may result If no water flows valve is inoperative Shut down the boiler until a new relief valve has been installed After following the above warning directions if the relief valve weeps or will not seat properly replace the relief valve Ensure t
80. the valve to ensure the valve is flowing gas With a manometer connected to the outlet tap of the gas valve when the unit is in the prepurge period there should be a negative pressure present When the valve is energized a change in pressure should occur If the pressure change does not occur the gas valve is not Opening Replace the gas valve Inspect flame sensor and associated wiring Reference page 34 of this manual for removal and cleaning procedures Replace if necessary Inspect the burner Reference page 34 of this manual for removal and cleaning procedures Replace if necessary 7 41 ST Service Manual CAE Ae a R 3 Troubleshooting Table 3G continued from previous page Troubleshooting Chart Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Flame Out of Sequence 1 will require a manual Raametemieesetstess e flame detector 1 circuit is seeing a flame EAS n Signal while no flame is present Press the RESET button e Check supply voltage for proper polarity e Check external wiring for voltage feedback e Check the internal wiring for bad connections on the SMART TOUCH display to reset e Check combustion of burner 1 and adjust valve 1 if Flame Out of necessary Sequence 2 will require a manual Reameemimeeeetstom The flame detector 2 circuit is seeing a flame EAN A Signal from burner 1 Press the RESET button on the SMART TOUCH display to reset e
81. ue a HWG Night Setback Offset Temp 2 2 HWG Night Setback Mon End 22 NA Value Value Soo HWG Night Setback Tue End a ae Ce a 2 D te rsa ede 2 a eve Sees aes G ena 1a e menonsa nn a m e e menonsa a wa ie P o naesesa sason a a erie inens a oo ae 23 Z 2 md Be oe gt gt gt gt gt lt O lt aa Lu U zr O ModBus Active Inactive ACTIVE INACTIVE INACTIVE INACTIVE INACTIVE ModBus Out of Order Timer 23 ascade Active Inactive 23 ACTIVE Cascade Address N oO Cascade Offset NO oO oO Cascade Differential Q N ES Minimum Next On Time oaj 0 Rate to Switch On Next Boiler afa 10 Rate to Switch Off Last Boiler aja Number of Boiler Pumps Always On oaf o MOD 5 Max Boiler Setpoint for Cascade 23 EE J Cascade Type 23 N A ONA kA Block Time Switching Boiler On Off zj o 60 16 CREST Service Manual PE a te PA i 1 Service continued Parameter table E SSS a a a ae a a E R Table 1B continued from previous page This table lists SMART TOUCH control module parameters and where to access them Parameter Name See Min as shown on the LCD screen Page Value Boiler Pump Delay 4 05 2400 Boiler Pump Anti Seize Time EJ Boiler Pump Mode 24 NA a na T System Pump Delay 24 05 2400 30 EJ System Pump Anti Seize Time zaj o 40 0 33 Value 30 0 33 N A l il D O O lt D e9
82. ure Service Manual MOR Ae Aii be 1 Service Boiler piping This piping reference is included to specify the Boiler Piping specific to the Crest boiler This piping scheme is important for proper operation of the SMART TOUCH control See the Crest Installation and Operation Manual for more detailed piping diagrams Single Boiler Recommended Primary Secondary Piping with a Hot Water Generator FROM SYSTEM N SYSTEM RETURN SENSOR BALL VALVE HOT WATER TYPICAL GENERATOR AIR SEPERATOR DRAIN PORT TYPICAL A 2 SYSTEM SUPPLY SENSOR g SYSTEM ha SK CIRCULATOR PRESSURE REDUCING VALVE BACK io ee PREVENTER GS WATER GENERATOR EXPANSION PRESSURE CIRCULATOR TANK GAUGE Y STRAINER RECOMMENDED FLOW CHECK VALVE TYPICAL BOILER PUMP Single Boiler Alternate Full Flow System Piping RELIEF VALVE BALL VALVE TYPICAL FROM SYSTEM N AIR SEPERATOR BOILER DRAIN DRAIN PORT TYPICAL SYSTEM CIRCULATOR Y STRAINER RECOMMENDED EXPANSION AR NS TO SYSTEM PAESS RE PRESSURE CAUCE REDUCING VALVE BACK FLOW hoa MAKE UP PREVENTER WATER Service Manual 1 Service continued N TOUCH The Home Screen displays status modulation rate outlet water temperature inlet water temperature flue temperature system supply temperature system return temperature outdoor air temperature and domestic hot water tank temperatu
83. y entering the installer password 5309 in the Password Screen see the User Section Ee arms gt Se i Teas 10 55 AM U TEME EE 0 CREST Service Manual ONDEN SING irii A 1 Service continued Saving parameters reference the Parameter Table Figure 1 4 Setup Screen Table 1B on pages 13 17 of this manual To adjust and save parameters reference FIG 1 5 To change a parameter use the arrows next to the parameter list on the Menu Screen to highlight the desired parameter then press SELECT A short description of the parameter and its current setting are then displayed on the bottom half of the screen To adjust the setting use the buttons to the left and right of the current setting Adiante ed Seh i SEPISH i l l l Came mp Note If the above mentioned buttons to adjust settings do not appear the correct PASSWORD has not been entered Hwg ii 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 1 1 Figure 1 5 Initial Setup Screen Note The SAVE button MUST BE pressed to ensure proper programming of the control Failure to press the SAVE button will require all changes to be reprogrammed Initial Setup s rnll lisi Lp or coven bi wma p rameinrs E 7 CREST Service Manual Pa FF Be al Ae Fae 1 Service Table 1A

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