Lochinvar Crest 1.5 User manual

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.
Read all instructions,
including this manual and
the Crest Installation and
Operation Manual, before
installing. Perform steps in
the order given. Failure to
comply could result in severe
personal injury, death, or
substantial property damage.
WARNING
Save this manual for future reference.
FB-SER Rev B

2
Hazard definitions
The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or
to important information concerning the life of the product.
DANGER
WARNING
CAUTION
CAUTION
NOTICE
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious
injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury.
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not
avoided, may result in property damage.
NOTICE indicates special instructions on installation, operation, or maintenance that are important but not
related to personal injury or property damage.
CONTENTS........................................................................ 2
Hazard Definitions.............................................................. 2
PLEASE READ BEFORE PROCEEDING ........................ 3
Handling Ceramic Fiber Materials...................................... 3
When servicing boiler ................................................... 4
Boiler operation............................................................ 4
Boiler water................................................................... 4
Freeze protection fluids ................................................ 4
WHAT IS IN THIS MANUAL .............................................. 5
1. SERVICE
Boiler Piping ....................................................................... 6
SMART TOUCH Display (Home Screen) .......................... 7
Control Inputs ............................................................... 8
Control Outputs............................................................. 9
General Operation ................................................. 10-11
Table 1A - Sequence of Operation .................................. 12
Table 1B - Parameter Table........................................ 13-17
Viewable and Changeable Control Parameters.......... 18-25
Cascade Screen............................................................... 26
Graph Screen................................................................... 27
History Screen............................................................. 28-29
Service Screen................................................................. 30
2. MAINTENANCE
Maintenance and Annual Startup................................ 31-35
3. TROUBLESHOOTING
Before Troubleshooting.................................................... 36
Check Control Module Fuses .......................................... 36
Table 3A - Troubleshooting Chart - No Display............... 37
Checking Temperature Sensors ...................................... 38
Table 3F - Troubleshooting Chart - Noisy System .......... 39
Table 3G - Troubleshooting Chart - Fault Messages . 40-51
Combustion Analysis Procedure ...................................... 52
Table 3H - Troubleshooting Chart - Combustion Levels 52
Table 3I - Flue Products................................................... 52
Gas Valve Adjustment Procedure.................................... 53
Revision Notes .................................................. Back Cover
Contents

Service Manual
Please read before proceeding
Installer – Read all instructions, including
this manual and the Crest Installation
and Operation Manual, before installing.
Perform steps in the order given.
User – This manual is for use only by
a qualified heating installer/service
technician. Refer to the Crest User’s
Information Manual for your reference.
Have this boiler serviced/inspected by
a qualified service technician at least
annually.
Failure to comply with the above could
result in severe personal injury, death or
substantial property damage.
When calling or writing about the boiler
– Please have the boiler model and serial
number from the boiler rating plate.
Consider piping and installation when
determining boiler location (see the Crest
Installation and Operation Manual).
Any claims for damage or shortage
in shipment must be filed immediately
against the transportation company by the
consignee.
3
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.
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
the NIOSH website at http://www.cdc.gov/niosh/homepage.html. NIOSH approved respirators,
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.
WARNING NOTICE
WARNING

4
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.

Service Manual
5
What is in this manual?
Service
Near boiler piping
• Typical system components
The Crest boiler display
• Display panel readout, buttons and their functions
Control module inputs
• Control module inputs and options
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
• Accessing programming mode and locating menus
(See separate guide covering the PC interface.)
Control panel parameter access
• Accessing and changing parameters from the display panel
Quick start information -- parameter
table
• An index of available adjustments and readouts, where to
access them and where to find detailed information.
Crest boiler operation
• Initial Setup
• Set Points
• Outdoor Reset
• Ramp Delay
• BMS
• Advanced Setup
• SH Night Setback
• HWG Night Setback
• Cascade
• Pumps
• Service Notification
Maintenance
• Service and maintenance schedules
• Address reported problems
• Inspect boiler area and boiler interior
• Clean condensate trap
• Check all piping for leaks
• Check air openings
• Flue vent system and air piping
• Check water system
• Check expansion tank
• 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
• Review with owner
• Cleaning boiler heat exchanger
• Oiled bearing circulators
Troubleshooting
• Troubleshooting table - No display
• Checking temperature sensors
• Sensor tables
• Troubleshooting table - Fault messages displayed on
boiler interface
• Combustion analysis procedure
• Gas valve adjustment procedure

1 Service
6
Service Manual
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
HOT WATER
GENERATOR
WATER
GENERATOR
CIRCULATOR
BOILER PUMP
FLOW CHECK
VALVE (TYPICAL)
Y-STRAINER
(RECOMMENDED)
RELIEF
VALVE
BALL VALVE
(TYPICAL)
AIR SEPERATOR
DRAIN PORT
(TYPICAL)
SYSTEM
CIRCULATOR
BACK FLOW
PREVENTER
PRESSURE
REDUCING VALVE
PRESSURE
GAUGE
EXPANSION
TANK
12"
MAX
FROM SYSTEM
TO SYSTEM
MAKE UP
WATER
BOILER
DRAIN
SYSTEM RETURN
SENSOR
SYSTEM SUPPLY
SENSOR
Y-STRAINER
(RECOMMENDED)
RELIEF
VALVE
BALL VALVE
(TYPICAL)
AIR SEPERATOR
DRAIN PORT
(TYPICAL)
SYSTEM
CIRCULATOR
BACK FLOW
PREVENTER
PRESSURE
REDUCING VALVE
PRESSURE
GAUGE
EXPANSION
TANK
FROM SYSTEM
TO SYSTEM
MAKE UP
WATER
BOILER DRAIN
Single Boiler - Alternate - Full Flow System Piping

Service Manual
7
1 Service (continued)
Outlet Water Temperature - This is the boiler outlet
temperature.
Inlet Water Temperature - This is the boiler inlet temperature.
System Supply Temperature - This is the water temperature
as measured by the system supply sensor located in the
downstream piping (if connected).
System Return Temperature - This is the water temperature
measured by the system return sensor located in the upstream
piping (if connected).
Outside AirTemperature - This is the outdoor air temperature
(if connected).
HWG Temperature - This is the temperature as measured by
the tank sensor in the hot water storage tank (if connected).
Flue Temperature - Temperature measured by the flue sensor.
Time - The time is displayed in the lower left-hand corner of the
display. Reference this manual for Night Setback parameters
and more information regarding adjusting the date and time.
Boiler Status button - Pressing this button brings up the Boiler
Status Screen. This screen shows the status of the various
safeties, inputs, and outputs to the control module. Reference
this manual for more information regarding this screen.
Main Menu button - Pressing this button brings up the Main
Menu Screen. From this screen navigation to nine (9) other
screens is possible.
Modulation button - Pressing this button brings up the
Modulation Screen. This screen shows overall boiler
modulation, individual fan speeds, and flame currents.
Modulation Percentage - Displays the current boiler firing
rate.
Home Screen
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.
When the ON/OFF switch is turned to the ON position,
the first screen visible on the LCD display will be the Home
Screen. This screen displays the current status of the Crest
boiler. The following items can be viewed or interacted with
on the Home Screen:
On/Off button - Pressing this button allows the boiler to be
placed in either Manual Shutdown Mode or Standby Mode.
Status - This line shows the current operating status of the
Crest boiler and the current set point.

1 Service
8
Service Manual
1 Service
GAS PRESSURE SWITCHES
HWG THERMOSTAT /
SENSOR
ENABLING DEVICE
SYSTEM SENSOR -
SUPPLY
OUTDOOR SENSOR
SEQUENCER / BUILDING
MANAGMENT SYSTEM
LOW VOLTAGE
CONNECTION
BOARD
INLET TEMPERATURE
SENSOR
OUTLET TEMPERATURE /
HI-LIMIT SENSOR
FLUE GAS SENSOR
LOUVER PROVING SWITCH
FLAME SENSOR 1 & 2
LOW WATER CUTOFF
BLOCKED DRAIN SWITCH
DISPLAY PANEL PC INTERFACE
SMART CONTROL
MODULE
AIR PRESSURE SWITCH
SYSTEM SENSOR -
RETURN
AUX SWITCH 1 & 2
0-10 INPUT FROM
SYSTEM PUMP
BLOWER PROVING
SWITCHES
CASCADE
INLET AIR SENSORS
MANUAL RESET
HIGH LIMIT
VENT DAMPER
PROVING SWITCH
MODBUS
BOARD
Control inputs

1 Service
Service Manual
9
1 Service (continued)
LOW VOLTAGE
CONNECTION
BOARD
SMART CONTROL
MODULE
ALARM CONTACTS
LOUVER RELAY
RUN TIME CONTACTS
SEQUENCER / BUILDING
MANAGMENT SYSTEM
BOILER PUMP
CONTACTOR
SYSTEM PUMP
CONTACTOR
HWG PUMP
CONTACTOR
IGNITOR
BLOWERS
GAS VALVES
BOILER RATE OUTPUT
DISPLAY PANEL
PC INTERFACE
120V
SUPPLY
SYSTEMPUMP BOILER PUMP DHW PUMP
MAX. 1.5 AMPS PER CONNECTION
NL FIELD SUPPLIED CONTACTOR MU ST
BEI NSTALLED
LINE VOLTAGE
TERMINAL
STRIP
0-10V OUTPUT TO
BOILER PUMP
VENT DAMPER
Control outputs

1 Service
10
Service Manual
General Operation
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.
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).
- 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).
Figure 1-1 Home Screen
Figure 1-2 Main Menu Screen
Figure 1-3 Password Screen