Lochinvar CREST 35 User Manual

FB-SER Rev B  
Service Manual  
Models: 1.5 - 2.0 - 2.5 - 3.0 - 3.5  
This manual must only be  
used by a qualified heating  
installer / service technician.  
ƽ WARNING  
Read  
all  
instructions,  
including this manual and  
the Crest Installation and  
Operation Manual, before  
installing. Perform steps in  
the order given. Failure to  
comply could result in severe  
personal injury, death, or  
substantial property damage.  
Save this manual for future reference.  
Service Manual  
Please read before proceeding  
InstallerReadallinstructions,including  
ƽ WARNING  
When calling or writing about the boiler  
– Please have the boiler model and serial  
number from the boiler rating plate.  
NOTICE  
this manual and the Crest Installation  
and Operation Manual, before installing.  
Perform steps in the order given.  
Consider piping and installation when  
determining boiler location (see the Crest  
Installation and Operation Manual).  
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.  
Any claims for damage or shortage  
in shipment must be filed immediately  
against the transportation company by the  
consignee.  
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  
REMOVAL OF COMBUSTION CHAMBER LINING  
The combustion chamber insulation in this appliance contains ceramic fiber material. Ceramic fibers can  
be converted to cristobalite in very high temperature applications. The International Agency for Research  
on Cancer (IARC) has concluded, “Crystalline silica in the form of quartz or cristobalite from occupational  
sources is carcinogenic to humans (Group 1).” Normal operating temperatures in this appliance are below  
the level to convert ceramic fibers to cristobalite. Abnormal operating conditions would have to be created  
to convert the ceramic fibers in this appliance to cristobalite.  
ƽ WARNING  
The ceramic fiber material used in this appliance is an irritant; when handling or replacing the ceramic  
materials it is advisable that the installer follow these safety guidelines.  
Avoid breathing dust and contact with skin and eyes.  
• Use NIOSH certified dust respirator (N95). This type of respirator is based on the OSHA  
requirements for cristobalite at the time this document was written. Other types of respirators may  
be needed depending on the job site conditions. Current NIOSH recommendations can be found on  
manufacturers, and phone numbers are also listed on this website.  
• Wear long-sleeved, loose fitting clothing, gloves, and eye protection.  
Apply enough water to the combustion chamber lining to prevent airborne dust.  
Remove the combustion chamber lining from the appliance and place it in a plastic bag for disposal.  
Wash potentially contaminated clothes separately from other clothing. Rinse clothes washer  
thoroughly.  
NIOSH stated First Aid.  
Eye: Irrigate immediately.  
Breathing: Fresh air.  
3
Service Manual  
Please read before proceeding  
When servicing boiler –  
• To avoid electric shock, disconnect electrical supply  
before performing maintenance.  
• To avoid severe burns, allow boiler to cool before  
performing maintenance.  
Boiler operation –  
• 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.  
• 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 –  
• Thoroughly flush the system (without boiler  
connected) to remove sediment. The high-efficiency  
heat exchanger can be damaged by build-up or  
corrosion due to sediment.  
• Do not use petroleum-based cleaning or sealing  
compounds in the boiler system. Gaskets and seals in  
the system may be damaged. This can result in  
substantial property damage.  
• Do not use “homemade cures” or “boiler patent  
medicines”. Serious damage to the boiler, personnel,  
and/or property may result.  
• 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 –  
• 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.  
4
Service Manual  
What is in this manual?  
Service  
Maintenance  
• Service and maintenance schedules  
• Address reported problems  
Near boiler piping  
• Typical system components  
• Inspect boiler area and boiler interior  
• Clean condensate trap  
• Check all piping for leaks  
• Check air openings  
The Crest boiler display  
• Display panel readout, buttons and their functions  
• Flue vent system and air piping  
• Check water system  
• Check expansion tank  
Control module inputs  
• Control module inputs and options  
• Check boiler relief valve  
• Inspect ignition electrode  
• Check ignition ground wiring  
• Check all boiler wiring  
• Check control settings  
• Perform start-up and checks  
• Check burner flame  
• Check flame signal  
• Check flue gas temperature  
• General maintenance  
Control module outputs  
• Control module outputs and options  
General  
• How the boiler operates  
• How the control module operates  
• Access modes -- user and installer  
• Sequence of operation -- HWG/space heating  
Control panel menu access  
• Review with owner  
• Cleaning boiler heat exchanger  
• Oiled bearing circulators  
• Accessing programming mode and locating menus  
(See separate guide covering the PC interface.)  
Control panel parameter access  
Troubleshooting  
• Accessing and changing parameters from the display panel  
• Troubleshooting table - No display  
• Checking temperature sensors  
• Sensor tables  
• Troubleshooting table - Fault messages displayed on  
boiler interface  
Quick start information -- parameter  
table  
• An index of available adjustments and readouts, where to  
access them and where to find detailed information.  
• Combustion analysis procedure  
• Gas valve adjustment procedure  
Crest boiler operation  
• Initial Setup  
• Set Points  
• Outdoor Reset  
• Ramp Delay  
• BMS  
• Advanced Setup  
• SH Night Setback  
• HWG Night Setback  
• Cascade  
• Pumps  
• Service Notification  
5
Service Manual  
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  
SYSTEM RETURN  
SENSOR  
12"  
MAX  
BALL VALVE  
RELIEF  
VALVE  
HOT WATER  
GENERATOR  
(TYPICAL)  
AIR SEPERATOR  
DRAIN PORT  
(TYPICAL)  
SYSTEM SUPPLY  
SENSOR  
SYSTEM  
CIRCULATOR  
TO SYSTEM  
BOILER  
DRAIN  
PRESSURE  
REDUCING VALVE  
MAKE UP  
WATER  
BACK FLOW  
PREVENTER  
WATER  
PRESSURE  
EXPANSION  
TANK  
GENERATOR  
CIRCULATOR  
GAUGE  
Y-STRAINER  
(RECOMMENDED)  
FLOW CHECK  
VALVE (TYPICAL)  
BOILER PUMP  
Single Boiler - Alternate - Full Flow System Piping  
RELIEF  
VALVE  
BALL VALVE  
(TYPICAL)  
FROM SYSTEM  
AIR SEPERATOR  
BOILER DRAIN  
DRAIN PORT  
(TYPICAL)  
SYSTEM  
CIRCULATOR  
Y-STRAINER  
(RECOMMENDED)  
EXPANSION  
TANK  
TO SYSTEM  
PRESSURE  
PRESSURE  
GAUGE  
REDUCING VALVE  
BACK FLOW  
PREVENTER  
MAKE UP  
WATER  
6
Service Manual  
1 Service  
(continued)  
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 temperature.  
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  
HWG Temperature - This is the temperature as measured by  
the tank sensor in the hot water storage tank (if connected).  
When the ON/OFF switch is turned to the ON position,  
the first screen visible on the LCD display will be the Home  
Screen. This screen displays the current status of the Crest  
boiler. The following items can be viewed or interacted with  
on the Home Screen:  
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  
On/Off button - Pressing this button allows the boiler to be  
and more information regarding adjusting the date and time.  
placed in either Manual Shutdown Mode or Standby Mode.  
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.  
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  
Main Menu button - Pressing this button brings up the Main  
Menu Screen. From this screen navigation to nine (9) other  
screens is possible.  
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).  
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.  
System Return Temperature - This is the water temperature  
measured by the system return sensor located in the upstream  
piping (if connected).  
OutsideAirTemperature -Thisistheoutdoorairtemperature  
(if connected).  
7
Service Manual  
1 Service  
Control inputs  
HWG THERMOSTAT /  
SENSOR  
ENABLING DEVICE  
CASCADE  
LOW VOLTAGE  
CONNECTION  
BOARD  
LOUVER PROVING SWITCH  
SYSTEM SENSOR -  
SUPPLY  
SYSTEM SENSOR -  
RETURN  
OUTDOOR SENSOR  
MODBUS  
BOARD  
SEQUENCER / BUILDING  
MANAGMENT SYSTEM  
AUX SWITCH 1 & 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 PRESSURE SWITCH  
MANUAL RESET  
HIGH LIMIT  
FLAME SENSOR 1 & 2  
BLOCKED DRAIN SWITCH  
GAS PRESSURE SWITCHES  
LOW WATER CUTOFF  
BLOWER PROVING  
SWITCHES  
VENT DAMPER  
PROVING SWITCH  
DISPLAY PANEL  
PC INTERFACE  
8
Service Manual  
1 Service  
(continued)  
Control outputs  
0-10V OUTPUT TO  
BOILER PUMP  
ALARM CONTACTS  
LOW VOLTAGE  
CONNECTION  
BOARD  
LOUVER RELAY  
RUN TIME CONTACTS  
BOILER RATE OUTPUT  
SEQUENCER / BUILDING  
MANAGMENT SYSTEM  
LINE VOLTAGE  
TERMINAL  
STRIP  
BOILER PUMP  
CONTACTOR  
SYSTEM PUMP  
CONTACTOR  
HWG PUMP  
CONTACTOR  
IGNITOR  
BLOWERS  
SMART CONTROL  
MODULE  
GAS VALVES  
VENT DAMPER  
DISPLAY PANEL  
PC INTERFACE  
9
Service Manual  
1 Service  
General Operation  
Figure 1-1 Home Screen  
How the boiler operates  
The Crest uses an advanced stainless steel heat exchanger  
and electronic control module that allows fully condensing  
operation. The blowers pull in air and push flue products out  
of the boiler through the heat exchanger and flue piping. The  
control module regulates blower speeds to 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  
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.  
Figure 1-2 Main Menu Screen  
Sequence of operation  
Table 1A (page 12) shows control module normal sequences of  
operation for space heating and HWG operation. The combined  
operation sequence is for a typical application, programmed to  
provide HWG priority.  
Access modes  
User  
The USER can adjust various space heating and HWG operating  
variables:  
-
-
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).  
Figure 1-3 Password Screen  
-
Press ENTER on the Password Screen (FIG. 1-3)  
(do not enter any values) and then press INITIAL  
SETUP on the Setup Screen (FIG. 1-4).  
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 by entering the installer password (5309) in the Password  
Screen (see the User Section).  
10  
Service Manual  
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.  
Note: If the above mentioned buttons to adjust settings do  
not appear, the correct PASSWORD has not been entered.  
Press the SAVE button after adjusting a parameter value.  
Additional parameter settings can then be adjusted or other  
navigation buttons can be used to return to previous screens  
or the Home Screen (FIG. 1-1).  
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.  
Figure 1-5 Initial Setup Screen  
11  
Service Manual  
1 Service  
Table 1A 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).  
1.  
The control confirms that the low water cutoff contacts are closed and energizes the louvers (optional) and damper  
(optional) relays.  
2.  
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.  
3.  
The control confirms both blowers come up to the desired speed, both blower proving switches close, and the air  
pressure switch is closed.  
4.  
Once the Pre-Purge cycle is complete, the control lowers the blower speeds, initiates sparking of the ignition electrode,  
and opens Gas Valve 1.  
5.  
After a short wait, the control stops sparking and checks for the presence of flame current through the flame sense  
electrode.  
6.  
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.  
7.  
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 begin modulating the firing rate in order to maintain the controlling sensor to the desired set  
point temperature.  
8.  
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.  
9.  
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  
10.  
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.  
11.  
At the end of the Post-Purge cycle, the louver relay contacts will de-energize.  
12.  
The control verifies that the blowers stop running and the blower proving switches open.  
13.  
At the end of the Pump Delay cycle(s), the pump(s) will be turned off.  
14.  
12  
Service Manual  
1 Service  
(continued)  
Parameter table  
Table 1B This table lists SMART TOUCH control module parameters and where to access them  
Max  
User  
Installer  
Access  
Min  
Default  
Sub  
Item  
See  
Page  
Parameter Name  
Menu  
(as shown on the LCD screen)  
Value Value Value Access  
1
2
3
4
5
6
Clock  
18  
18  
18  
18  
18  
18  
N/A  
N/A  
32  
N/A  
N/A  
185  
185  
205  
200  
N/A  
N/A  
120  
120  
205  
200  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Date  
SH Setpoint  
HWG Tank Setpoint  
MRHL Setpoint  
ARHL Setpoint  
32  
32  
32  
A
7
8
SH Setpoint at Low Outdoor Temp.  
SH Setpoint at High Outdoor Temp.  
Low Outdoor Temperature  
High Outdoor Temperature  
Boiler Pump Mode  
19  
19  
19  
19  
24  
24  
18  
18  
18  
18  
18  
18  
32  
32  
-22  
-22  
N/A  
N/A  
32  
32  
32  
0
185  
185  
86  
180  
68  
Yes  
Yes  
Yes  
Yes  
No  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
9
23  
10  
11  
12  
1
86  
86  
N/A  
N/A  
185  
185  
185  
36  
N/A  
N/A  
32  
System Pump Mode  
SH Min User Setpoint  
SH Max User Setpoint  
SH Setpoint  
No  
No  
2
185  
125  
9.9  
19.8  
120  
No  
3
Yes  
No  
4
SH Offset  
5
SH Differential  
0
72  
No  
6
HWG Tank Setpoint  
32  
185  
Yes  
7
8
HWG Tank Differential  
MRHL Setting  
18  
18  
18  
19  
0
10  
6.3  
204.8  
199.4  
60  
No  
Yes  
Yes  
No  
Yes  
Yes  
Yes  
Yes  
B
32  
32  
32  
205  
200  
185  
9
ARHL Setting  
10  
HWG Minimum User Setpoint  
11  
12  
13  
14  
1
HWG Maximum User Setpoint  
HWG Boiler Setpoint  
19  
19  
19  
19  
19  
19  
19  
19  
19  
20  
32  
32  
0
185  
185  
36  
185  
180  
9.9  
No  
No  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
HWG Boiler Offset  
No  
HWG Boiler Differential  
0
72  
185  
180  
68  
No  
SH Setpoint at Low Outdoor Temp.  
SH Setpoint at High Outdoor Temp  
Low Outdoor Temperature  
High Outdoor Temperature  
Outdoor Air Shutdown  
32  
32  
-22  
-22  
32  
32  
185  
185  
86  
Yes  
Yes  
Yes  
Yes  
No  
2
3
23  
C
4
86  
86  
5
122  
122  
79.7  
79.7  
6
OA Shutdown Differential  
No  
13  
Service Manual  
1 Service  
Parameter table  
Table 1B (continued from previous page) This table lists SMART TOUCH control module parameters and where to  
access them  
Max  
User  
Value Access  
Installer  
Access  
Min  
Default  
Sub  
See  
Parameter Name  
Menu  
C
(as shown on the LCD screen)  
Item  
Page  
Value  
Value  
7
8
9
1
2
3
4
5
Boost Time  
20  
20  
20  
20  
20  
20  
20  
20  
0
0
250  
25  
20  
0
No  
No  
No  
No  
No  
No  
No  
No  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Boost Temperature  
Shift OA Reset Curve  
Ramp Delay Mode  
Ramp Delay Time #1  
Ramp Delay Time #2  
Ramp Delay Time #3  
Ramp Delay Time #4  
-27  
N/A  
1
27  
0
N/A  
40  
N/A  
2
1
40  
2
1
40  
2
1
40  
1
6
7
Ramp Delay Time #5  
Ramp Delay Time #6  
Ramp Delay Limit #1  
Ramp Delay Limit #2  
Ramp Delay Limit #3  
Ramp Delay Limit #4  
Ramp Delay Limit #5  
Ramp Delay Limit #6  
BMS Active/Inactive  
BMS Mode  
20  
20  
20  
20  
20  
20  
20  
20  
21  
1
40  
1
1
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
D
1
40  
8
10  
10  
10  
10  
10  
10  
100  
100  
100  
100  
100  
100  
20  
30  
40  
55  
75  
100  
9
10  
11  
12  
13  
1
ACTIVE INACTIVE INACTIVE  
2
21 POWER SETPOINT POWER  
3
4
5
6
BMS Volts at Min Rate  
BMS Volts at Max Rate  
BMS Rate at Min Volts  
BMS Rate at Max Volts  
21  
21  
21  
21  
0
0
4
0
10  
10  
2
10  
4
No  
No  
No  
No  
Yes  
Yes  
Yes  
Yes  
100  
100  
100  
E
7
8
BMS Volts at Min Setpoint  
BMS Volts at Max Setpoint  
BMS Setpoint at Min Volts  
BMS Setpoint at Max Volts  
BMS Volts to Enable  
21  
21  
21  
21  
21  
21  
0
0
10  
10  
2
10  
No  
No  
No  
No  
No  
No  
No  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
9
32  
32  
0
185  
185  
10  
68.9  
178.7  
2
10  
11  
12  
13  
Differential to Stop BMS Demand  
BMS Enable Mode  
0
10  
0.5  
21 ENABLE VOLTAGE VOLTAGE  
14  
Service Manual  
1 Service  
(continued)  
Parameter table  
Table 1B (continued from previous page) This table lists SMART TOUCH control module parameters and where to  
access them  
Max  
User  
Default  
Value Access  
Installer  
Access  
Min  
Sub  
Item  
See  
Page  
Parameter Name  
Menu  
(as shown on the LCD screen)  
Value  
Value  
1
2
3
4
5
6
7
8
Temperature Units  
21  
21  
21  
22  
22  
22  
22  
22  
°F  
0
°C  
255  
45  
°F  
240  
44.6  
37.4  
5
Yes  
Yes  
No  
No  
No  
No  
No  
No  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
LCD Backlight Time  
Freeze Protection; Pump On  
Freeze Protection; Burner On  
Freeze Protection; Burner Diff  
HWG to SH Switching Time  
SH to HWG Switching Time  
Anti-Cycling Time  
-22  
-22  
0
45  
20  
0
240  
240  
40  
30  
0
30  
F
0
10  
9
10  
11  
12  
13  
1
Anti-Cycling Differential  
HWG Rate Limiting  
22  
22  
22  
22  
22  
22  
22  
22  
22  
22  
0
10  
0
40  
100  
40  
1
100  
40  
2
No  
No  
No  
No  
No  
No  
No  
No  
No  
No  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Service Mode Timeout  
Controlling Sensor  
0
4
Inlet Control Time Delay  
SH Night Setback Offset Temp  
SH Night Setback Mon End  
SH Night Setback Mon Begin  
SH Night Setback Tue End  
SH Night Setback Tue Begin  
0
40  
3
0
90  
0
2
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
3
4
5
6
7
8
9
SH Night Setback Wed End  
SH Night Setback Wed Begin  
SH Night Setback Thur End  
SH Night Setback Thur Begin  
22  
22  
22  
22  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
No  
No  
No  
No  
Yes  
Yes  
Yes  
Yes  
G
10  
11  
12  
13  
14  
15  
SH Night Setback Fri End  
SH Night Setback Fri Begiin  
SH Night Setback Sat End  
SH Night Setback Sat Begin  
SH Night Setback Sun End  
SH Night Setback Sun Begin  
22  
22  
22  
22  
22  
22  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
No  
No  
No  
No  
No  
No  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
15  
Service Manual  
1 Service  
Parameter table  
Table 1B (continued from previous page) This table lists SMART TOUCH control module parameters and where to  
access them  
Max  
User  
Default  
Value Access  
Installer  
Access  
Min  
Sub  
Item  
See  
Page  
Parameter Name  
Menu  
(as shown on the LCD screen)  
Value  
Value  
1
2
3
4
5
6
7
8
HWG Night Setback Offset Temp  
HWG Night Setback Mon End  
HWG Night Setback Mon Begin  
HWG Night Setback Tue End  
HWG Night Setback Tue Begin  
HWG Night Setback Wed End  
HWG Night Setback Wed Begin  
HWG Night Setback Thur End  
22  
22  
22  
22  
22  
22  
22  
22  
0
90  
0
No  
No  
No  
No  
No  
No  
No  
No  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
H
9
HWG Night Setback Thur Begin  
HWG Night Setback Fri End  
HWG Night Setback Fri Begin  
HWG Night Setback Sat End  
HWG Night Setback Sat Begin  
HWG Night Setback Sun End  
HWG Night Setback Sun Begin  
ModBus Active / Inactive  
22  
22  
22  
22  
22  
22  
22  
23  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
No  
No  
No  
No  
No  
No  
No  
No  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
10  
11  
12  
13  
14  
15  
1
ACTIVE INACTIVE INACTIVE  
120 30  
ACTIVE INACTIVE INACTIVE  
I
2
1
ModBus Out of Order Timer  
Cascade Active / Inactive  
23  
23  
5
No  
No  
Yes  
Yes  
2
3
4
5
Cascade Address  
23  
23  
23  
23  
0
0
7
1
No  
No  
No  
No  
Yes  
Yes  
Yes  
Yes  
Cascade Offset  
40  
10  
Cascade Differential  
Max Boiler Setpoint for Cascade  
0
72  
20  
32  
185  
185  
J
6
7
Cascade Type  
23  
23  
24  
24  
24  
24  
N/A  
0
N/A  
255  
255  
100  
100  
8
N/A  
60  
60  
80  
10  
0
No  
No  
No  
No  
No  
No  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Block Time Switching Boiler On / Off  
Minimum Next On Time  
8
0
9
Rate % to Switch On Next Boiler  
Rate % to Switch Off Last Boiler  
Number of Boiler Pumps Always On  
1
10  
11  
1
0
16  
Service Manual  
1 Service  
(continued)  
Parameter table  
Table 1B (continued from previous page) This table lists SMART TOUCH control module parameters and where to  
access them  
Max  
User  
Default  
Value Access  
Installer  
Access  
Min  
Sub  
Item  
See  
Page  
Parameter Name  
Menu  
(as shown on the LCD screen)  
Value  
Value  
1
2
3
4
5
6
7
8
Boiler Pump Delay  
24  
24  
24  
24  
24  
24  
24  
24  
0.5  
0
2400  
40  
30  
0.33  
N/A  
N/A  
30  
No  
No  
No  
No  
No  
No  
No  
No  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Boiler Pump Anti-Seize Time  
Boiler Pump Mode  
N/A  
N/A  
0.5  
0
N/A  
N/A  
2400  
40  
System Pump Mode  
System Pump Delay  
K
System Pump Anti-Seize Time  
HWG Pump Delay  
0.33  
30  
0.5  
0
2400  
40  
HWG Pump Anti-Seize Time  
0.33  
9
1
2
3
4
5
Delta T Setpoint  
24  
25  
25  
25  
25  
25  
0
0
60  
36  
0
No  
No  
No  
No  
No  
No  
Yes  
Yes  
Yes  
Yes  
Yes  
Yes  
Maintenance Notice - Months  
Maintenance Notice - Running Hours  
Maintenance Notice - Cycles  
Service Contact Number  
Service Contact Name  
12  
0
100,000  
100,000  
N/A  
10,000  
10,000  
N/A  
0
L
N/A  
N/A  
N/A  
N/A  
17  
Service Manual  
1 Service  
Viewable and changeable control parameters  
See Table 1B on pages 13 - 17 of this manual for parameter references listed in this section. The parameter  
references listed in this section will not appear on the LCD screen.  
NOTICE  
Before changing parameters, note the  
settings so that the unit can be returned to  
its original operating parameters.  
SH Offset  
CAUTION  
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.  
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.  
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  
The internal clock does not adjust for  
Daylight Savings Time and therefore,  
NOTICE  
By installing a tank sensor, the SMART TOUCH control can  
perform the tank thermostat function. The SMART TOUCH  
control automatically detects the presence of this sensor, and  
generates a call for heat when the tank temperature drops below  
the tank set point minus the differential (parameter B7), and  
finishes the call for heat when the tank temperature reaches  
tank set point. This parameter can be changed by the installer  
by accessing parameter B6.  
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 Points  
HWG Tank Differential  
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.  
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  
Space Heating (SH) Maximum Set Point  
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.  
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  
Auto Reset High Limit  
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.  
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.  
18  
Service Manual  
1 Service  
(continued)  
HWG Minimum User Set Point  
C: Outdoor Reset  
SH Set Point at Low Outdoor Temperature  
This setting controls the minimum user set point for the  
tank temperature. The installer can adjust this by accessing  
parameter B10.  
When the outdoor air temperature 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 C1.  
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.  
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.  
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.  
Low Outdoor Temperature  
This parameter can be changed by the installer by accessing  
parameter B12.  
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.  
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.  
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.  
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.  
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.  
Figure 1-6 Outdoor Air Reset Curve  
SET POINT AT  
LOW OUTDOOR  
TEMPERATURE  
(SH)  
SET POINT  
SET POINT AT  
HIGH OUTDOOR  
TEMPERATURE  
HIGH OUTDOOR  
TEMPERATURE  
LOW OUTDOOR  
TEMPERATURE  
19  
Service Manual  
1 Service  
Outdoor Air Shutdown Differential  
Shift OA Reset Curve  
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.  
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  
Boost Time  
Ramp Delay (Enable / Disable)  
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.  
This parameter allows the installer to enable or disable the SH  
ramp delay by accessing parameter D1.  
SH Ramp Delay  
Boost Temperature  
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.  
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  
20  
Service Manual  
1 Service  
(continued)  
BMS Set Point at Maximum Volts  
E: BMS  
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 (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 through ModBus.  
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.  
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.  
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 Volts at Minimum (Rate or Set Point)  
BMS Enable Mode  
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.  
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.  
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.  
F: Advanced Setup  
Temperature units (°C / °F)  
BMS Rate at Minimum Volts  
The control can be configured to display temperature in either  
°C or °F. This parameter can be changed by the user or the  
installer by accessing parameter F1.  
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.  
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.  
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.  
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  
BMS Set Point at Minimum Volts  
When programmed for BMS control through the 0 - 10V this setting needs to be lowered in these cases. The installer can  
BMS input or through ModBus and the BMS Type is adjust the temperature at which the pump outputs are turned on  
programmed as SETPOINT, the set point represented by by accessing parameter F3.  
the Volts at Minimum parameter (E7) is set by parameter  
E9.  
21  
Service Manual  
1 Service  
HWG Rate Liming (NOT AVAILABLE AT THIS TIME)  
Freeze Protection Burner On  
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.  
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.  
Service Mode Timeout  
Freeze Protection Burner Differential  
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.  
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  
Controlling Sensor  
When a boiler has a HWG demand and it receives a space  
heating demand, the SMART TOUCH control will 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.  
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.  
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.  
Inlet Control Time Delay  
When the inlet sensor is selected as the controlling sensor, the  
SMART TOUCH control will start 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.  
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.  
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.  
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 accessing parameter F9.  
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.  
22  
Service Manual  
1 Service  
(continued)  
Cascade Off-On Differential  
I: ModBus  
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.  
ModBus (Active / Inactive)  
When BMS is set to ACTIVE (see BMS Active / Inactive)  
and the boiler is being controlled through ModBus, set  
parameter I1 to ACTIVE. Otherwise, set the ModBus  
parameter to INACTIVE. Note that the boiler can still  
be monitored by ModBus with this parameter set to  
INACTIVE.  
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.  
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 Type  
Cascade Active / Inactive  
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  
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.  
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  
J1.  
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.  
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.  
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  
parameter J3.  
23  
Service Manual  
1 Service  
System Pump Mode  
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.  
The SMART TOUCH control is able to control the system  
pump in 5 different ways. The options are as follows:  
1.  
2.  
3.  
ON with a call for heat, with a constant speed.  
ON with a call for heat, with a variable speed input.  
Always ON, with a constant speed, except during  
outdoor shutdown.  
Rate % to Switch on Next Boiler  
4.  
5.  
Always ON, with a variable speed input, except during  
outdoor shutdown.  
Always OFF (not connected).  
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.  
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.  
Rate % to Switch off Last Boiler  
System Pump Delay  
When the Cascade is programmed in the Efficiency  
Optimization Mode, the currently running boiler will stop.  
This percentage can be adjusted by accessing parameter  
J10.  
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.  
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.  
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  
K: Pumps  
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.  
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.  
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.  
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.  
ΔT 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 when 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.  
Boiler Pump Mode  
The SMART TOUCH control is able to control the boiler  
pump in 3 different ways. The options are as follows:  
1.  
2.  
ON with a call for heat, with a constant speed.  
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  
Service Manual  
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 information 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.  
25  
Service Manual  
1 Service  
Cascade Screen  
Figure 1-8 Cascade Screen  
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 that 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.  
26  
Service Manual  
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  
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  
27  
Service Manual  
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  
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  
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 Screen_Blocking Faults  
28  
Service Manual  
1 Service  
(continued)  
History Screen  
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.  
Successful Ignition attempts - Shows the number of times the control has successfully ignited since the  
last reset.  
Total Power hours – Show the total number of hours the control has been powered.  
Total Running hours – Show the total number of hours that the boiler has been firing.  
Total ignition attempts – Show the total number of times the control has attempted to 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  
29  
Service Manual  
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. The 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  
30  
Service Manual  
2 Maintenance  
Maintenance and annual startup  
Table 2A Service and Maintenance Schedules  
Owner maintenance  
(see the Crest User’s Information Manual for  
instructions)  
Service technician  
(see the following pages for instructions)  
General:  
• Address reported problems, if any  
• Check boiler area  
• Inspect interior; clean and vacuum if  
necessary;  
Daily  
• Check pressure/temperature  
gauge  
• Clean condensate trap and fill with fresh  
water  
• Check for leaks (water, gas, flue,  
condensate)  
• Verify flue and air lines in good condition  
and sealed tight  
• Check vent piping  
• Check air piping  
• Check system water pressure/system  
piping/expansion tank  
Monthly  
• Check air and vent termination  
screens  
• Check control settings  
• Check the ignition and both flame sense  
electrodes (sand off any deposits; clean  
and reposition)  
• Check relief valve  
• Check condensate drain system  
• Check wiring and connections  
• Perform start-up checkout and  
performance verification per Section 9 of  
the Crest Installation and Operation  
Manual.  
• Test low water cutoff  
• Reset button (low water  
cutoff)  
Every  
• Flame inspection (stable, uniform)  
6 months  
• Check both flame signals (at least 10  
microamps at high fire)  
• Check boiler piping (gas and  
water) for leaks  
• Test low water cutoff.  
• Operate relief valve  
If combustion or performance  
indicate need:  
• Clean heat exchanger  
End  
of season  
months  
Shut boiler down (unless boiler  
used for domestic hot water)  
• Remove and clean burner using  
compressed air only  
• Clean the blower wheels  
31  
Service Manual  
2 Maintenance  
Follow the service and maintenance procedures given throughout this manual and in component literature  
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.  
ƽ 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 boiler efficiency and reliability. Failure to service and maintain the boiler and system could  
result in equipment failure.  
ƽ WARNING  
Electrical shock hazard – Turn off power to the boiler before any service operation on the boiler except as  
noted otherwise in this instruction manual. Failure to turn off electrical power could result in electrical shock,  
causing severe personal injury or death.  
ƽ WARNING  
Address reported problems  
Figure 2-1 Condensate Trap  
1. Inspect any problems reported by the owner and correct  
before proceeding.  
FROM CONDENSATE  
VENT ON BOILER  
FROM CONDENSATE  
DRAIN ON BOILER  
Inspect boiler area  
TO FLOOR DRAIN  
OR NEUTRALIZER KIT  
1” PVC / CPVC CONNECTION  
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.  
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.  
ƽ WARNING  
Inspect boiler interior  
1. Remove the front access covers and inspect the interior of  
the boiler.  
1. Inspect all water and gas piping and verify to be leak free.  
2. Vacuum any sediment from inside the boiler and  
components. Remove any obstructions.  
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.  
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 ball 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  
Service Manual  
2 Maintenance  
(continued)  
Safety relief valves should be re-inspected  
AT LEAST ONCE EVERY THREE YEARS,  
by a licensed plumbing contractor or  
authorized inspection agency, to ensure  
that the product has not been affected by  
corrosive water conditions and to ensure  
that the valve and discharge line have not  
been altered or tampered with illegally.  
Certain 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.  
Flue vent system and air piping  
ƽ WARNING  
1. Visually inspect the entire flue gas venting system and air  
piping for blockage, deterioration or leakage. Repair any  
joints that show signs of leakage. Verify that air inlet pipe  
is connected and properly sealed.  
2. Verify that boiler vent discharge and air intake are clean  
and free of obstructions.  
Failure to inspect for the above conditions  
and have them repaired can result in  
severe personal injury or death.  
ƽ WARNING  
Check water system  
1. Verify all system components are correctly installed 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.  
Following installation, the valve lever  
must be operated AT LEAST ONCE  
A YEAR to ensure that waterways are  
ƽ WARNING  
clear.  
Certain naturally occurring  
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.  
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.  
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.  
2. After following the above warning directions, if the relief  
valve weeps or will not seat properly, replace the relief  
valve. Ensure that the reason for relief valve weeping is  
the valve and not over-pressurization of the system due  
to expansion tank waterlogging or undersizing.  
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.  
33  
Service Manual  
2 Maintenance  
• Shut down the boiler:  
Inspect ignition and flame  
sense electrodes  
- Follow the “To Turn Off Gas to Appliance” instructions  
for the boiler in Section 9 - Startup of the Crest Installation  
and Operation Manual.  
1. Remove the ignition and both flame sense electrodes  
from the burner plate.  
- Do not drain the boiler unless it will be exposed to  
freezing temperatures. If using freeze prevention fluid  
in system, do not drain.  
2. Remove any deposits accumulated on the ignition/  
flame sense electrodes using sandpaper. If the  
electrodes cannot be cleaned satisfactorily, replace  
with new ones.  
3. Allow time for the boiler to cool to room temperature if it has  
been firing.  
4. Remove the top access panel to remove the gas/air manifold  
assembly.  
3. Replace ignition/flame sense electrodes, making  
sure the gaskets are in good condition and correctly  
positioned.  
5. Remove the nuts securing the burner to the burner mounting  
plate. Remove the burner (FIG. 2-2).  
Check ignition ground wiring  
1. Inspect boiler ground wire from the heat exchanger  
6. When replacing the burner, ensure gaskets are in good condition  
and positioned correctly (FIG. 2-2).  
access cover to ground terminal strip.  
7. 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.  
2. Verify all wiring is in good condition and securely  
attached.  
3. Check ground continuity of wiring using continuity  
meter.  
Figure 2-2 Burner Assembly  
4. Replace ground wires if ground continuity is not  
satisfactory.  
INSULATION  
Check all boiler wiring  
1. Inspect all boiler wiring, making sure wires are in  
AIR/GAS  
MANIFOLD  
MANIFOLD  
GASKET  
good condition and securely attached.  
BURNER  
ASSEMBLY  
Check control settings  
1. Navigate to the Setup Screen and check all settings.  
See Section 1 of this manual. Adjust settings  
if necessary. See Section 1 of this manual for  
adjustment procedures.  
BURNER  
GASKET  
BURNER PLATE  
FIBERBOARD  
2. Check settings of external limit controls (if any) and  
adjust if necessary.  
Perform start-up and checks  
1. Start boiler and perform checks and tests specified  
in Section 9 - Start-up of the Crest Installation and  
Operation Manual.  
2. Verify cold fill pressure is correct and that operating  
pressure does not go too high.  
Check flame signal  
1. At high fire of each combustion system, the flame signal shown  
on the display should be at least 10 microamps.  
Check burner flame  
1. Inspect flame through observation windows.  
2. 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.  
2. 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.  
3. See Section 3 - Troubleshooting in this manual for other  
procedures to deal with low flame signal.  
34  
Service Manual  
2 Maintenance  
(continued)  
15. Replace the burner mounting plate assembly and gas/air  
manifold assembly. Ensure gaskets are in good condition  
and positioned properly. Restore boiler to operation.  
16. Perform start-up and check-out procedures in the Check  
Flame and Combustion - Section 9 - Startup of the Crest  
Installation and Operation Manual.  
Review with owner  
1. Review the Crest User’s Information Manual with the  
owner.  
2. Emphasize the need to perform the maintenance schedule  
specified in the Crest User’s Information Manual (and in  
this manual as well).  
3. Remind the owner of the need to call a licensed contractor  
should the boiler or system exhibit any unusual behavior.  
4. Remind the owner to follow the proper shutdown procedure  
and to schedule an annual start-up at the beginning of the  
next heating season.  
Handling ceramic fiber materials  
REMOVAL OF COMBUSTION CHAMBER  
LINING  
The combustion chamber insulation in this  
ƽ WARNING  
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.  
Cleaning boiler heat exchanger  
1. Shut down boiler:  
• Follow the “To Turn Off Gas to Appliance” instructions  
for the boiler in Section 9 - Startup.  
• Do not drain the boiler unless it will be exposed to  
freezing temperatures. If using freeze prevention fluid  
in system, do not drain.  
2. Allow time for the boiler to cool to room temperature if it  
has been firing.  
3. Remove the top access panel to remove the gas/air manifold  
assembly.  
4. Remove the nuts securing the burner to the burner  
mounting plate. Remove the burner (FIG. 11-2).  
5. Remove the nuts securing the burner mounting plate from  
the heat exchanger and set aside. Remove the entire burner  
mounting plate assembly.  
The ceramic fiber material used in this appliance  
is an irritant; when handling or replacing the  
ceramic materials it is advisable that the installer  
follow these safety guidelines.  
Avoid breathing dust and contact with skin  
and eyes.  
The boiler contains ceramic fiber materials.  
Use care when handling these materials per  
ƽ WARNING  
• Use NIOSH certified dust respirator (N95).  
ThistypeofrespiratorisbasedontheOSHA  
requirements for cristobalite at the  
time this document was written.  
Other types of respirators may  
be needed depending on the job  
instructions on this page. Failure to comply  
could result in severe personal injury.  
6. Use a vacuum cleaner to remove any accumulation on the  
tube sheet surfaces. Do not use any solvent.  
7. 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.  
8. Finish cleaning using a clean cloth dampened with warm  
water.  
9. Temporarily remove the condensate drain line from the  
condensate trap and route directly to a drain.  
site conditions.  
Current NIOSH  
recommendations can be found on  
the NIOSH website at http://  
w w w . c d c . g o v / n i o s h / h o m e p a g e .  
html.  
NIOSH approved respirators,  
manufacturers, and phone numbers are  
also listed on this website.  
10. Rinse out debris with a low pressure water supply. The  
water will drain through the condensate connection.  
11. Allow the heat exchanger to thoroughly dry.  
12. Reconnect the condensate drain line to the condensate trap.  
13. 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.  
14. 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.  
• Wear long-sleeved, loose fitting clothing,  
gloves, and eye protection.  
Apply enough water to the combustion  
chamber lining to prevent airborne dust.  
Remove the combustion chamber lining  
from the boiler and place it in a plastic bag  
for disposal.  
Wash potentially contaminated clothes  
separately from other clothing. Rinse  
clothes washer thoroughly.  
NIOSH stated First Aid.  
Eye: Irrigate immediately.  
Breathing: Fresh air.  
35  
Service Manual  
3 Troubleshooting  
Label all wires prior to disconnection  
Check control module fuses  
ƽ WARNING  
when servicing controls. Wiring  
errors can cause improper and  
dangerous operation.  
disconnect power to the boiler  
before servicing. Failure to comply  
could result in severe personal  
injury, death, or substantial  
property damage.  
ALWAYS check control module fuses before  
replacing control module or any major  
components (blower, etc.). If one of these fuses  
is blown, it can prevent the control module or  
other components from operating.  
NOTICE  
Always  
1. Turn OFF the power to the boiler at the external line  
switch.  
2. Remove the upper and lower doors.  
Never jumper (bypass) any device  
except for momentary testing as  
outlined in the Troubleshooting  
chart. Severe personal injury, death,  
or substantial property damage can  
result.  
ƽ WARNING  
3. Remove the four (4) screws securing the control panel cover to  
the unit to gain access to the control module.  
4. Inspect fuses F2, F4, and F5, see FIG 3-1 below.  
Figure 3-1 Control Module Fuses  
F2 - 3.15 AMP  
BLOWER RELAYS  
Before troubleshooting:  
F4 - 5 AMP  
PUMP RELAYS  
1. Have the following items:  
a. Voltmeter that can check 120 vac, 24 vac, and  
12 vdc.  
b. Continuity checker.  
c. Contact thermometer.  
F5 - 5 AMP  
IGNITOR OUTPUT  
2. Check for 120 vac (minimum 102 vac to maximum  
132 vac) to boiler.  
F6 - 5 AMP  
NOT USED  
(SPARE)  
3. Make sure thermostat is calling for heat and  
contacts are closed. Check for 24 vac between  
thermostat wire nuts and ground.  
4. Make sure all external limit controls are installed  
and operating.  
5. The boiler is shipped with four (4) spare fuses in a plastic bag  
located inside the control panel.  
Check the following:  
6. If necessary, replace open fuse (F2 is 3.15 amps, F4, F5 and F6  
are 5 amps each).  
1. Wire connectors to control module are securely  
plugged in at the module and originating control.  
Note: Fuses F2, F4, F5 and F6 are all slow blow fuses.  
2. Gas pressures:  
Do not jumper fuse or replace with any fuse  
ƽ WARNING  
• Maximum: 14 inches w.c. (3.5 kPa) (natural and  
LP) with no flow (lockup) or with boiler on  
• Minimum: 4 inches w.c. (1.0 kPa) (natural and  
LP), with gas flowing (verify during boiler  
startup)  
except as specified. Failure to comply could  
result in severe personal injury, death, or  
substantial property damage.  
7. 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.  
8. 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.  
36  
Service Manual  
3 Troubleshooting  
(continued)  
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 Display  
- No voltage through the switch.  
- Bad display board.  
• Replace switch.  
• Replace board.  
- Bad main control board.  
- Blown fuse.  
• Replace the main control board.  
• Replace fuse F2 on the main control board, see  
page 38 of this manual.  
- Main control board temperature set point • Review temperature setting.  
satisfied.  
- Remote thermostat satisfied.  
• Review remote thermostat setting.  
No Burner  
Operation  
- Outside air temperature above Warm • Check location of outside air sensor.  
Check  
Weather Shutdown (WWSD) set point for  
main control board.  
resistance of outdoor air sensor and compare to Table  
3C on page 38 of this manual.  
- Unit locked out on fault.  
- Ramp delay active.  
• Consult display for specific fault. Refer to fault  
descriptions on page 40 of this manual for corrective  
actions.  
• Check ramp delay parameter settings. Optional PC  
software required.  
Unit Does Not  
Modulate  
Up to 100%  
• Turn ramp delay feature off. See page 20 of this  
manual for instructions on how to turn this feature off.  
• Check BMS parameter settings.  
- Boiler controlled by BMS.  
37  
Service Manual  
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 corresponding table, replace the sensor  
It is important to note that the flue and outlet inlet air - S11/S13 #1 and S12/S14 #2 water sensors have two temperature sensing  
devices in one housing. These devices are designated as S1/S9, outlet sensor and S3/S10, flue sensor. Please reference the wiring  
diagram in the Crest Installation and Operation Manual for correct terminal location.  
Table 3B - Inlet Water/System Sensor Resistance vs.  
Table3C-OutdoorAirSensorResistancevs.Temperature  
Temperature  
Temperature Resistance Temperature Resistance  
Temperature Resistance Temperature Resistance  
-50  
-40  
-30  
-20  
10  
490,813  
336,606  
234,196  
165,180  
118,018  
85,362  
20  
30  
40  
50  
60  
70  
80  
46,218  
34,558  
26,099  
19,900  
15,311  
11,883  
9,299  
50  
68  
18,780  
12,263  
8,194  
5,592  
3,893  
2,760  
158  
176  
194  
212  
1,990  
1,458  
1,084  
817  
86  
104  
122  
140  
0
10  
62,465  
Table 3D - Outlet Water Sensor Resistance vs. Temperature  
Outlet  
S1  
R/Y  
Outlet  
S9  
RW/Y  
BR/Y  
T/Y  
Pre-Mix Air 1  
Pre-Mix Air 2  
S11  
S12  
GY/Y  
BK/Y  
Pre-Mix Air 1  
Pre-Mix Air 2  
S13  
S14  
Temperature Resistance Temperature Resistance Temperature Resistance Temperature Resistance  
50  
68  
19,553  
12,690  
8,406  
5,715  
3,958  
2,786  
158  
176  
194  
212  
2,004  
1,464  
1,084  
816  
50  
68  
40,030  
25,030  
16,090  
10,610  
7,166  
158  
176  
194  
212  
3,478  
2,492  
1,816  
1,344  
86  
86  
104  
122  
140  
104  
122  
140  
4,943  
Table 3E - Flue Sensor Resistance vs. Temperature  
Flue S3 GY/Y  
Flue  
S10  
W/Y  
Temperature Resistance Temperature Resistance Temperature Resistance Temperature Resistance  
50  
68  
40,030  
25,030  
16,090  
10,610  
7,166  
158  
176  
194  
212  
3,478  
2,492  
1,816  
1,344  
50  
68  
258,500  
125,500  
80,220  
52,590  
35,270  
24,160  
158  
176  
194  
212  
16,870  
12,000  
8,674  
86  
86  
104  
122  
140  
104  
122  
140  
6,369  
4,943  
38  
Service Manual  
3 Troubleshooting  
(continued)  
Table 3F Troubleshooting Chart - Noisy System  
FAULT  
CAUSE  
CORRECTIVE ACTION  
- Supply gas problem. Natural and LP gas • Refer to Section 6 - Gas Connections of the Crest  
pressures should be between 4 inches w.c. Installation and Operation Manual for detailed  
(1.0 kPa) and 14 inches w.c. (3.5 kPa).  
information concerning the gas supply.  
- Gas/air mixture problem.  
• 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.  
Noisy  
Operation  
- Dirty/damaged burner.  
- Air in the piping system.  
- Blown fuse.  
• Refer to page 34 in this manual for the burner removal  
and inspection procedure. Clean or replace the burner  
as necessary.  
• Properly purge all air from the piping system.  
• Replace fuse F4 on the control board, see page 36 of  
this manual.  
No Pump  
Operation -  
Boiler Pump  
System Pump  
or  
• Replace pump.  
- Faulty pump.  
• Replace main control board.  
• Replace relay.  
- Internal fault on control board.  
- Faulty pump relay.  
HWG Pump  
• Reference the Boiler Pump Mode and System  
Pump Mode parameters in the Service section of this  
manual.  
- Incorrect parameter setting.  
- System pressure exceeds relief valve • Lower the system pressure below the rating of  
setting.  
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).  
Relief Valve  
Opening  
• Improperly sized expansion tank.  
39  
Service Manual  
3 Troubleshooting  
Table 3G Troubleshooting Chart - Fault Messages Displayed on Boiler Interface  
FAULT  
DESCRIPTION  
CORRECTIVE ACTION  
• Measure the supply gas pressure to determine cause  
of failure. Natural and LP gas pressures should be  
between 4 - 14 inches w.c. (1.0 - 3.5 kPa).  
Gas Pressure SW  
Open  
(will require a manual  
reset once the condition  
has been corrected. Press  
the RESET button on the  
SMART TOUCH display  
to reset.)  
Either the low gas pressure switch or one of  
the high gas pressure switches tripped.  
• Refer to Section 6 - Gas Connections of the  
Crest Installation and Operation Manual for detailed  
information concerning the gas supply.  
• Correct the supply gas pressure if necessary.  
• Reset the LWCO from the RESET button on the front  
control panel.  
Low Water  
Cutoff Open  
• Verify system is full of water and all air has been  
purged from the system.  
The low water cutoff is not making.  
(will require a manual  
reset once condition has  
been corrected. Press  
the RESET button on the  
SMART TOUCH display  
to reset.)  
• Check for loose or misplaced jumpers if flow switch or  
LWCO is not installed.  
• Replace fuse F2 on the control board, see page 38  
of this manual.  
Blown fuse.  
• Check condensate tube from unit to floor drain for  
proper installation and obstructions.  
Blocked Drain SW  
Open  
(will require a manual  
reset once condition has  
been corrected. Press  
the RESET button on the  
SMART TOUCH display  
to reset.)  
• Inspect condensate trap for blockage. Clean if  
necessary.  
The blocked drain switch has detected  
excessive condensate build up inside the  
unit.  
• Check for loose wiring connection at wire harness  
plug.  
• Bad blocked drain switch. Replace switch.  
• Check the wiring connections to switch. Wires should  
be connected to the common and normally closed  
terminals.  
• 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  
Open  
• Check for obstruction or blockage in the vent/air  
intake pipes or at terminations.  
(will require a manual  
reset once the condition  
has been corrected. Press  
the RESET button on the  
SMART TOUCH display  
to reset.)  
• Check reference hose and tubing connected to the  
pressure switch for blockage or obstruction.  
Blocked flue/inlet pressure switch contacts  
are open.  
• Inspect the burner. Reference page 34 of this manual  
for removal and cleaning procedures. Replace if  
necessary.  
• Inspect the heat exchanger. Reference page 35 of  
this manual for removal and cleaning procedures.  
Replace if necessary.  
• Faulty air pressure switch. Replace switch.  
• Verify combustion air blower is operating. Replace if  
necessary.  
40  
Service Manual  
3 Troubleshooting  
(continued)  
Table 3G (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface  
FAULT  
DESCRIPTION  
CORRECTIVE ACTION  
• The control board will release the call for heat after a  
set time period.  
The main control board has received a call  
for heat too quickly after the previous call for  
heat has ended.  
Anti-cycling  
• The control board will release the call for heat if the  
outlet temperature drops too quickly.  
The unit has failed to prove main burner • Inspect spark electrode and associated wiring for  
ignition. It will require a manual reset before  
attempting to fire again.  
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 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.  
41  
Service Manual  
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  
• Check supply voltage for proper polarity.  
• Check external wiring for voltage feedback.  
• Check the internal wiring for bad connections.  
(will require a manual  
reset once the condition  
has been corrected.  
The flame detector 1 circuit is seeing a flame  
signal while no flame is present.  
Press the RESET button  
on the SMART TOUCH  
display to reset.)  
• Check combustion of burner 1 and adjust valve 1 if  
necessary.  
Flame Out of  
Sequence 2  
• Check supply voltage for proper polarity.  
• Check external wiring for voltage feedback.  
• Check the flame rod and make sure it is clean.  
• Check internal wiring for bad connections.  
• Remove and inspect the burner.  
(will require a manual  
reset once the condition  
has been corrected.  
The flame detector 2 circuit is seeing a flame  
signal from burner 1.  
Press the RESET button  
on the SMART TOUCH  
display to reset.)  
• 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.  
• Check for proper electrical grounding of unit.  
• 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  
reset once the condition  
has been corrected.  
Press the RESET button  
on the SMART TOUCH  
display to reset.)  
• Verify that the plastic hose from the gas valve to the air  
inlet is connected and is not damaged.  
The unit was running and lost the flame  
signal.  
• Verify that the vent/air intake pipes are installed correctly  
and there are no obstructions.  
• Inspect flame sensor and associated wiring. Reference  
page 34 of this manual for removal and cleaning  
procedures. Replace if necessary.  
• Check combustion.  
• Inspect the burner. Reference page 34 of this manual for  
removal and cleaning procedures. Replace if necessary.  
42  
Service Manual  
3 Troubleshooting  
(continued)  
Table 3G (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface  
FAULT  
DESCRIPTION  
CORRECTIVE ACTION  
• Inspect flame rod 2 and associated wiring for damage  
and connection. Reference page 34 of this manual for  
removal and cleaning procedures.  
necessary.  
Replace if  
• Check for proper electrical grounding of unit.  
• Check incoming supply gas pressure. Natural and  
L.P.gaspressuresshouldbebetween4-14inchesw.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 2  
(will require a manual  
reset once the condition  
has been corrected. Press  
the RESET button on the  
SMART TOUCH display  
to reset.)  
• Verify that the plastic hose from the gas valve to the air  
inlet is connected and is not damaged.  
The unit was running and lost the flame  
signal.  
Verifythatthevent/airintakepipesareinstalledcorrectly  
and there are no obstructions.  
• Inspect flame sensor and associated wiring. Reference  
page 34 of this manual for removal and cleaning  
procedures. Replace if necessary.  
• Check combustion.  
• Inspecttheburner. Referencepage34ofthismanualfor  
removal and cleaning procedures.  
necessary.  
Replace if  
Gas Valve / Relay  
Failure 1  
• Check wiring harness connection at the gas valve and  
at the main control board.  
(will require a manual  
reset once the condition  
has been corrected. Press  
the RESET button on the  
SMART TOUCH display  
to reset.)  
The main control board did not detect gas  
valve 1.  
• Replace the gas valve wire harness.  
• Replace the gas valve.  
Gas Valve / Relay  
Failure 2  
• Check wiring harness connection at the gas valve and  
at the main control board.  
(will require a manual  
reset once the condition  
has been corrected. Press  
the RESET button on the  
SMART TOUCH display  
to reset.)  
The main control board did not detect gas  
valve 2.  
• Replace the gas valve wire harness.  
• Replace the gas valve.  
43  
Service Manual  
3 Troubleshooting  
Table 3G (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface  
FAULT  
DESCRIPTION  
CORRECTIVE ACTION  
• 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 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  
pump is not operating, replace the pump.  
The outlet water temperature has exceeded  
the setting of the automatic reset high limit.  
Auto Reset  
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 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 main 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).  
• Replace main control board.  
44  
Service Manual  
3 Troubleshooting  
(continued)  
Table 3G (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface  
FAULT  
DESCRIPTION  
CORRECTIVE ACTION  
• 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  
(will require a manual  
reset once the condition  
has been corrected. Press  
the RESET button on the  
SMART TOUCH display  
to reset.)  
The actual fan 1 RPM is 30% lower than  
what is being called for.  
• Check for obstruction or blockage in the vent/air  
intake pipes or at terminations.  
• Check the wiring connections at fan 1 and at the  
main control board.  
• Replace the fan.  
• Replace fuse F2 on the control board, see page 36  
of this manual.  
Blown fuse.  
• 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  
(will require a manual  
reset once the condition  
has been corrected. Press  
the RESET button on the  
SMART TOUCH display  
to reset.)  
• Check for obstruction or blockage in the vent/air  
intake pipes or at terminations.  
The actual fan 2 RPM is 30% lower than  
what is being called for.  
• Check the wiring connections at fan 2 and at the  
main control board.  
• Replace the fan.  
• Replace fuse F2 on the control board, see page 36  
of this manual.  
Blown fuse.  
• 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.)  
• 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.  
• Check the wiring connections at the fan and at the  
main control board.  
• Replace the fan.  
• 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.)  
• 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.  
• Check the wiring connections at the fan and at the  
main control board.  
• Replace the fan.  
45  
Service Manual  
3 Troubleshooting  
Table 3G (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface  
FAULT  
DESCRIPTION  
CORRECTIVE ACTION  
Louver Proving  
Sw Open  
• Check function of remote devices.  
(will require a manual  
reset once the condition  
has been corrected. Press  
the RESET button on the  
SMART TOUCH display  
to reset.)  
An optional remote proving switch is not  
making.  
• Check for loose or misplaced jumper if proving switch  
is not installed.  
• 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.  
Measure the resistance of the flue sensor and  
compare to Table 3E on page 38 of this manual.  
Replace the sensor if necessary.  
The stack temperature has exceeded the set  
parameters for the boiler.  
Flue Temp High  
• 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 necessary.  
Delta T High  
The temperature rise across the heat  
exchanger has exceeded the set parameters  
for the boiler.  
• 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  
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  
High  
for the proper piping methods for the Crest boiler.  
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.  
• If 120 vac is present on a call for heat and the boiler  
pump is not operating, replace the pump.  
46  
Service Manual  
3 Troubleshooting  
(continued)  
Table 3G (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface  
FAULT  
DESCRIPTION  
CORRECTIVE ACTION  
• 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  
(continued)  
Outlet water temperature has exceeded the  
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  
unit.  
External control is cycling too often.  
Rem Ctrl Flt  
• Replace the control.  
Parameters  
Saved  
(will require a manual  
reset once the condition  
has been corrected. Press  
the RESET button on the  
SMART TOUCH display  
to reset.)  
• Press the RESET button on the SMART  
TOUCH display panel.  
After downloading parameters from a laptop,  
the main control board must be reset.  
While the unit is in Service Mode, the outlet • 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  
• Check 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.  
47  
Service Manual  
3 Troubleshooting  
Table 3G (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface  
FAULT  
DESCRIPTION  
CORRECTIVE ACTION  
• Check the sensors and their associated wiring.  
Repair or replace the sensor or wiring if damaged.  
Either the inlet water or outlet water • Measure the resistance of the sensors and compare  
Sensor Open  
(will require a manual  
reset once the condition  
has been corrected. Press  
the RESET button on the  
display to reset.)  
temperature sensor has been disconnected.  
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.  
Sensor Shorted  
(will require a manual  
reset once the condition  
has been corrected. Press  
the RESET button on the  
display to reset.)  
Either the inlet water or outlet water • Measure the resistance of the sensors and compare  
temperature sensor has been shorted.  
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.  
Flue Sensor  
Open  
• Measure the resistance of the sensors and compare  
the resistance to the tables on page 38 of this  
manual.  
(will require a manual  
reset once the condition  
has been corrected. Press  
the RESET button on the  
display to reset.)  
The flue sensor has been disconnected or  
removed from the flue.  
• 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.  
Flue Sensor  
Shorted  
(will require a manual  
reset once the condition  
has been corrected. Press  
the RESET button on the  
display to reset.)  
• Measure the resistance of the sensors and compare  
the resistance to the tables on page 38 of this  
manual.  
The flue sensor has been shorted.  
• Replace the sensor if necessary.  
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.  
• Check the tank temperature.  
®
• Repair or replace the sensor wiring if damaged.  
• Replace the sensor if necessary.  
Tank Open  
• 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.  
Blower Proving  
Switch Open 1  
(will require a manual  
reset once the condition  
has been corrected. Press  
the RESET button on the  
display to reset.)  
• Check for obstruction or blockage in the vent/air  
intake pipes or at terminations.  
Blower proving pressure switch 1 contacts  
are open.  
• 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.  
• Inspect the heat exchanger. Reference page 35 of  
this manual for removal and cleaning procedures.  
• Faulty pressure switch. Replace switch.  
48  
Service Manual  
3 Troubleshooting  
(continued)  
Table 3G (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface  
FAULT  
DESCRIPTION  
CORRECTIVE ACTION  
• 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.  
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.)  
• Check for obstruction or blockage in the vent/air  
intake pipes or at terminations.  
Pressure switch contacts are open.  
• Inspect the burner. Reference page 34 of this manual  
for removal and cleaning procedures. Replace if  
necessary.  
• Verify combustion air blower 2 is operating. Replace if  
necessary.  
• Inspect the heat exchanger. Reference page 35 of  
this manual for removal and cleaning procedures.  
• Faulty pressure switch. Replace switch.  
• Inspect the combustion air temperature sensor and  
associated wiring.  
Burner Supply  
Temperature  
• Measure the resistance of the combustion air  
temperature sensor and compare to Table 3E on  
page 38 of this manual  
Combustion air to burner 1 temperature  
is higher than combustion air to burner 2  
temperature or vice versa.  
Differential  
(will require a manual  
reset once the condition  
has been corrected. Press  
the RESET button on the  
display to reset.)  
• Replace the sensor if necessary.  
• Verify that the vent / air intake pipes are properly  
installed and that there are no obstructions.  
• Check if the vent backflow preventer is installed for  
boilers commonly vented.  
Burner Supply  
Temperature  
High 1  
• Check if the vent backflow preventer is stuck open  
while the unit is off.  
• Inspect the combustion air temperature sensor and  
associated wiring.  
(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.  
• Measure the resistance of the combustion air  
temperature sensor and compare to Table 3E on  
page 38 of this manual.  
• Replace the sensor if necessary.  
• Check if the vent backflow preventer is installed for  
boilers commonly vented.  
Burner Supply  
Temperature  
High 2  
• Check if the vent backflow preventer is stuck open  
while the unit is off.  
• Inspect the combustion air temperature sensor and  
associated wiring.  
(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.  
• Measure the resistance of the combustion air  
temperature sensor and compare to Table 3E on  
page 38 of this manual.  
• Replace the sensor if necessary.  
49  
Service Manual  
3 Troubleshooting  
Table 3G (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface  
FAULT  
DESCRIPTION  
CORRECTIVE ACTION  
• Wait 15 minutes and try again.  
Too Many  
Resets - Try Later  
Too many manual resets have occurred  
during a 15 minute period.  
• Turn power off to unit, wait 30 seconds and then turn  
power back on.  
The main control board has detected an  
internal fault.  
• Replace the main control board.  
• Replace the main control board.  
Internal Fault  
Writing to  
Memos  
The main control board has detected an  
internal fault.  
• 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.  
Measure the resistance of the flue sensor and  
compare to Table 3E on page 38 of this manual.  
Replace the sensor if necessary.  
Flue Temp  
Shutdown  
The stack temperature has exceeded the  
set parameters for the boiler.  
• 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.  
Delta T  
Shutdown  
The temperature rise across the heat  
exchanger has exceeded the set parameters  
for the boiler.  
• 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  
Installation and Operation Manual for boiler  
pump specifications.  
50  
Service Manual  
3 Troubleshooting  
(continued)  
Table 3G (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface  
FAULT  
DESCRIPTION  
CORRECTIVE ACTION  
• 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.  
Outlet Temp  
Shutdown  
Outlet water temperature has exceeded the  
maximum outlet water temperature.  
• Check for voltage to the boiler pump motor on a call  
for heat. If voltage is not present, check wiring back  
to the pump relay. Replace the pump relay if  
necessary.  
• If 120 VAC is present on a call for heat and the boiler  
pump is not operating, replace the pump.  
The main control board has detected an  
internal fault.  
• Replace the main control board.  
• Replace the main control board.  
• Replace the main control board.  
Watch Dog Error  
Write EEProm  
The main control board has detected an  
internal fault.  
The main control board has detected an  
internal fault.  
CRC Parameters  
The main control board has detected an • Press the RESET button on the SMART TOUCH  
internal fault. display panel.  
No Error Stored  
51  
Service Manual  
3 Troubleshooting  
Combustion Analysis  
Procedure  
Table 3I Flue Products  
Natural Gas  
Propane  
1. Turn the main power off to the boiler by placing  
the “On/Off” switch in the OFF position.  
Gas  
Valve  
CO2  
O2  
CO2  
O2  
2. Remove the flue temperature sensor from the  
flue collector. Note: Combustion measurements  
will be made at this point.  
1 - High 3.5% - 5.5% 11.2% - 14.8% 5.1% - 6.8% 10.5% - 13.2%  
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.  
8. 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  
then the SERVICE button.  
9. Once the heater analysis is complete, test the safety shutoff device  
by turning the manual shutoff valve to the OFF position and  
ensuring that the heater shuts down and registers an alarm. Open  
the manual shutoff valve and reset the control.  
5. On the Service Screen place heater into Service  
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  
flue temperature sensor into the flue pipe connection.  
6. Insert the probe from a combustion analyzer  
into the hole left by the removal of the flue  
temperature sensor.  
11. Place the boiler back into normal operation.  
You must replace the flue gas temperature sensor  
ƽ WARNING  
7. Once the heat exchanger has modulated up  
to rate, measure the combustion. The values  
should be in the range listed in Table 3I. CO  
levels should be less than 200 ppm for a properly  
installed unit. If the combustion is not within  
range reference the Troubleshooting Chart below  
for possible causes and corrective actions.  
to prevent flue gas spillage into the room. Failure  
to comply could result in severe personal injury,  
death, or substantial property damage.  
Table 3H Troubleshooting Chart - Combustion Levels  
POSSIBLE CAUSE  
CORRECTIVE ACTION  
• Refer to Section 2 - General Venting of the Crest Installation and Operation Manual  
for the proper venting and air intake methods for the Crest boiler.  
Vent/Air Intake Length  
or Obstruction  
• Check for obstructions at the vent/air intake terminals.  
• Refer to Section 6 - Gas Connections of the Crest Installation and Operation  
Manual for the proper gas supply for the Crest boiler.  
Gas Supply Pressure  
• Refer to page 34 of this manual for burner removal and cleaning procedures.  
• Replace burner if necessary.  
Dirty/Damaged Burner  
Gas Valve Adjustment  
52  
• Refer to page 53 of this manual for the gas valve adjustment procedure.  
Service Manual  
3 Troubleshooting  
(continued)  
Gas valve adjustment procedure  
Figure 3-3 Gas Valve Adjustment: Model 2.5  
Under normal operating conditions this  
valve should not need adjusting.  
CAUTION  
THROTTLE  
Locate the throttle adjustment screw on the gas valve. For  
Models 1.5 and 2.0 see 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 CO2 levels or a 1/4 turn clockwise to decrease  
CO2 levels. After one adjustment on the valve, follow the  
Combustion Analysis Procedure on page 52 of this manual  
to measure the combustion.  
GAS  
VALVE 2  
THROTTLE  
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.  
GAS  
VALVE 1  
Figure 3-4 Gas Valve Adjustment: Models 3.0 and 3.5  
Figure 3-2 Gas Valve Adjustment: Models 1.5 and 2.0  
THROTTLE  
THROTTLE  
GAS  
VALVE 2  
THROTTLE  
GAS  
VALVE 2  
THROTTLE  
GAS  
VALVE 1  
GAS  
VALVE 1  
53  
NOTES  
54  
NOTES  
55  
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  

Philips GoGear SA2425BT User Manual
Panasonic PV7665S User Manual
Panasonic CQ C1305U User Manual
Panasonic Blu ray Player DMP BDT500 User Manual
Nortel Networks 207344 B User Manual
Magic Chef MCWC30MCG User Manual
Logitech S715i User Manual
Lanzar Car Audio LANZAR VIBE X6 User Manual
KitchenAid 4KFP750CR0 User Manual
Kenwood KDC W9537U User Manual