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
Installer–Readallinstructions,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
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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.
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(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
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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
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(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.
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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
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(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.
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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
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(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.
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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
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