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FB-SER Rev B
Service Manual
Models: 1.5 - 2.0 - 2.5 - 3.0 - 3.5
This manual must only be
WARNING
used by a qualified heating
installer / service technician.
Read all instructions,
including this manual and
the Crest Installation and
Operation Manual, before
installing. Perform steps in
the order given. Failure to
comply could result in severe
personal injury, death, or
substantial property damage.
Save this manual for future reference.
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Contents 2. MAINTENANCE CONTENTS ........................................................................ 2 Maintenance and Annual Startup ................................ 31-35 Hazard Definitions .............................................................. 2 3. TROUBLESHOOTING PLEASE READ BEFORE PROCEEDING ........................ 3 Before Troubleshooting .................................................... 36 Handling Ceramic Fiber Materials ...................................... 3 Check C
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Service Manual Please read before proceeding Installer – Read all instructions, including When calling or writing about the boiler WARNING NOTICE this manual and the Crest Installation – Please have the boiler model and serial and Operation Manual, before installing. number from the boiler rating plate. Perform steps in the order given. Consider piping and installation when User – This manual is for use only by determining boiler location (see the Crest
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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 of
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Service Manual What is in this manual? Service Maintenance � Service and maintenance schedules Near boiler piping � Address reported problems � Typical system components � Inspect boiler area and boiler interior � Clean condensate trap The Crest boiler display � Check all piping for leaks � Display panel readout, buttons and their functions � Check air openings � Flue vent system and air piping Control module inputs � Check water system � Control module inputs and
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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 HOT WATER RELIEF (TYPICAL) GENER
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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 Temper
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Service Manual 1 1 Service Service Control inputs HWG THERMOSTAT / SENSOR ENABLING DEVICE CASCADE LOW VOLTAGE CONNECTION LOUVER PROVING SWITCH BOARD SYSTEM SENSOR - SUPPLY SYSTEM SENSOR - RETURN OUTDOOR SENSOR MODBUS BOARD SEQUENCER / BUILDING MANAGMENT SYSTEM AUX SWITCH 1 & 2 SMART CONTROL 0-10 INPUT FROM SYSTEM PUMP MODULE INLET TEMPERATURE SENSOR OUTLET TEMPERATURE / HI-LIMIT SENSOR FLUE GAS SENSOR INLET AIR SENSORS AIR PRESSURE SWITCH MANUAL RESET HIGH LI
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MAX. 1.5 AMPS PER CONNECTION 120V SUPPLY SYSTEM PUMP BOILER PUMP DHW PUMP FIELD SUPPLIED CONTACTOR MUST NL BE INSTALLED Service Manual 1 1 Service Service (continued) Control outputs 0-10V OUTPUT TO BOILER PUMP ALARM CONTACTS LOW VOLTAGE CONNECTION LOUVER RELAY BOARD 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 G
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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 th
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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
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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, 1. HW pump for a domestic hot water call). The control confirms that the low water
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Service Manual 1 1 Service Service (continued) Parameter table Table 1B This table lists SMART TOUCH control module parameters and where to access them Max User Installer Min Default Sub See Parameter Name Menu (as shown on the LCD screen) Item Page Value Value Value Access Access 1 Clock 18 N/A N/A N/A Yes Yes 2 Date 18 N/A N/A N/A Yes Yes 3 SH Setpoint 18 32 185 120 Yes Yes 4 HWG Tank Setpoint 18 32 185 120 Yes Yes 5 MRHL Setpoint 18 32 205 205 Yes Yes 6 AR
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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 Installer Min Default Sub See Parameter Name Menu (as shown on the LCD screen) Item Page Value Value Value Access Access 7 Boost Time 20 0 250 20 No Yes C 8 Boost Temperature 20 0 25 0 No Yes 9 Shift OA Reset Curve 20 -27 27 0 No Yes 1 Ramp Delay Mode 20 N/A N/A N/A No Yes 2 Ramp Delay Time #1
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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 Installer Min Default Sub See Parameter Name Menu (as shown on the LCD screen) Item Page Value Value Value Access Access 1 Temperature Units 21 °F °C °F Yes Yes 2 LCD Backlight Time 21 0 255 240 Yes Yes 3 Freeze Protection; Pump On 21 -22 45 44.6 No Yes 4 Freeze Protection; Burner O
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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 Installer Min Default Sub See Parameter Name Menu (as shown on the LCD screen) Item Page Value Value Value Access Access 1 HWG Night Setback Offset Temp 22 0 90 0 No Yes 2 HWG Night Setback Mon End 22 N/A N/A N/A No Yes 3 HWG Night Setback Mon Begin 22 N/A N/A N/A No Yes 4 HWG Night Setback Tue
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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 Installer Min Default Sub See Parameter Name Menu (as shown on the LCD screen) Item Page Value Value Value Access Access 1 Boiler Pump Delay 24 0.5 2400 30 No Yes 2 Boiler Pump Anti-Seize Time 24 0 40 0.33 No Yes 3 Boiler Pump Mode 24 N/A N/A N/A No Yes 4 System Pump Mode 24 N/A N/A
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Service Manual 1 Service Viewable and changeable control parameters See Table 1B on pages 13 - 17 of this manual for parameter references listed in this section. The parameter NOTICE references listed in this section will not appear on the LCD screen. Before changing parameters, note the SH Offset CAUTION settings so that the unit can be returned to The SH offset sets how many degrees above set point the its original operating parameters. temperature can go
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Service Manual 1 Service (continued) HWG Minimum User Set Point C: Outdoor Reset SH Set Point at Low Outdoor Temperature This setting controls the minimum user set point for the tank temperature. The installer can adjust this by accessing When the outdoor air temperature drops to or below the parameter B10. Low Outdoor Temperature setting (parameter C3), the water temperature will be at this setting (see FIG. 1-6). However, if HWG Maximum User Set Point
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Service Manual 1 Service Outdoor Air Shutdown Differential Shift OA Reset Curve The outdoor air shutdown differential parameter is the The shift reset curve parameter shifts the actual set point above number of degrees below parameter C5 the outdoor air or below the calculated set point by the number of degrees in temperature must go before the boiler will respond to a SH this parameter. This parameter can be changed by the installer demand. This parameter ca
