Lochinvar Crest w/RealTime O2 Trim 100 Series User manual

Service Manual
Models: 1000 - 6000
Series: 100
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.
100343237_2000600598_Rev A
Combustion Technology
w/RealTime O2 TrimTM

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
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 w/CON•X•US Interface ........................... 7
General Operation ......................................................... 8
Control Inputs ............................................................... 9
Control Outputs........................................................... 10
Table 1A - Sequence of Operation .................................. 11
Initial Setup Screen ........................................................... 12
Viewable and Changeable Control Parameters............... 13
Set Point Screen.................................................... 13-15
Outdoor Reset Screen........................................... 16-17
Ramp Delay Screen .............................................. 18-19
BMS Screen............................................................20-22
Advanced Setup Screen.........................................23-24
Night Setback Screen..............................................25-26
Pump Screen ...........................................................27-28
Cascade Screens ....................................................29-31
Service Screen.............................................................. 32
Graph Screens.............................................................. 33
History Screens............................................................. 34
2. MAINTENANCE
Maintenance and Annual Startup................................ 35-40
3. TROUBLESHOOTING
Before Troubleshooting.................................................... 41
Check Control Module Fuses .......................................... 41
Table 3A - Troubleshooting Chart - No Display............... 42
Table 3B - 3E Checking Temperature Sensors ............... 43
Table 3F - Troubleshooting Chart - Noisy System .......... 44
Table 3G - Troubleshooting Chart - Fault Messages . 45-54
Combustion Analysis Procedure ...................................... 55
Table 3H - Flue Products ................................................. 55
Table 3I - Troubleshooting Chart - Combustion Levels . 56
Gas Valve Adjustment Procedure.................................... 57
Revision Notes .................................................. Back Cover

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 -- DHW/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
• DHW Night Setback
• Cascade
• Pumps
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
• Check/replace filter
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
Single Boiler - Alternate - Full Flow System Piping
DIR #2000559501 01
INDIRECT
DHW
TANK BOILER
TP
MAKE UP
WATER
P
TO
SYSTEM
FROM
SYSTEM
MAY SUBTITUTE
LOW LOSS HEADER
NOT TO EXCEED 4 PIPE DIA OR
MAX OF 12” APART
COLD
WATER IN
DWH HOT
WATER OUT
LEGEND
AIR SEPARATOR
CIRCULATION
PUMP FLOW CHECK VALVE
PRESSURE GAUGE
P
TEMPERATURE &
PRESSURE GAUGE
TP
SYSTEM SUPPLY
SENSOR
BACKFLOW
PREVENTER MAGNETIC SEPARATOR WATER METER
STRAINER / FILTER
PRESSURE
REDUCING VALVE
PRESSURE RELIEF
VALVE
BALL VALVE EXPANSION TANK
PIPING
DRAIN PORT
DIFFERENTIAL
PRESSURE
BYPASS VALVE
2 WAY MOTORIZED
VALVE (OPTIONAL)
MIXING VALVE
ANTI SCALD
FLOW SWITCH
OPTIONAL
WIRING
DIR #2000598465 00
MAKE UP
WATER
P
TO
SYSTEM
FROM
SYSTEM
LEGEND
AIR SEPARATOR
CIRCULATION
PUMP FLOW CHECK VALVE
PRESSURE GAUGE
P
TEMPERATURE &
PRESSURE GAUGE
TP
SYSTEM SUPPLY
SENSOR
BACKFLOW
PREVENTER MAGNETIC SEPARATOR WATER METER
STRAINER / FILTER
PRESSURE
REDUCING VALVE
PRESSURE RELIEF
VALVE
BALL VALVE EXPANSION TANK
PIPING
DRAIN PORT
DIFFERENTIAL
PRESSURE
BYPASS VALVE
2 WAY MOTORIZED
VALVE (OPTIONAL)
MIXING VALVE
ANTI SCALD
FLOW SWITCH
OPTIONAL
WIRING
BOILER
TP

Service Manual
7
1 Service (continued)
Figure 1-1 Home Screen
The Home Screen displays the available basic system information divided into the following sections: Status, Demand,
Modulation, Sensors, and Navigation.
HOME
VIEW
SETUP
INFORMATION
SETTINGS
• The Status Section is located on the top left of the screen
and displays how the unit is currently running (i.e. Off,
Stand-by, Blocking, and Lockout) including: current
driving demand, the next Hot Water Setback scheduled,
the reason for any blocking or lockout, and a power button.
• The Setpoint Demand Section is located on the bottom
left of the screen and displays information about the targets
and limits of the current demand being serviced.
• The Modulation Section is located on the top right of the
screen and displays the target modulation of the unit. This
section also includes target and actual fan speeds.
• The Boiler Sensor Section is located on the bottom right of
the screen and displays both factory installed and
field installed sensor including: Outdoor Air, Hot Water
Temperature, System Supply, System Return, Inlet Water,
Delta T, Outlet Water, Flue Temperature, and Flame
Current.
• The Navigation Section is located down the left side of the
screen. There are five (5) sections located below the
Lochinvar icon: Home, View, Setup, Information
(About), and Settings. The Home Section is the screen
shown above. The View Section provides more detailed
information including subsections for: History, Cascade,
Graphing, and a complete list of current Sensor Values.
The Setup Section has several screens to aid in setting
up the appliance. The Setup Section includes screens for
adjusting: Set Points, Pump Settings, Cascade, BMS, Ramp
Delay, and Night Setback. The Information Section
provides information about the hardware and software
including the current software version of the interface, the
version of the boiler control, and the CON·X·US device
serial number. The Setting Section enables several interface
setup features including: Time Setup, Temperature Unit
Select, Loch’n Link, System Update, and WiFi Setup.

Service Manual
8
1 Service
General Operation
How the boiler operates
The Crest uses an advanced stainless steel heat exchanger and
an electronic control module that allows fully condensing
operation. The blower pulls in air and pushes flue products
out of the boiler through the heat exchanger and flue piping.
The control modules regulate the firing rate of the boiler by
adjusting blower speeds and valve positions to maintain the
proper fuel air ratios.
How the control modules operate
The Crest boiler is equipped with a SMART TOUCH
CON•X•US Interface. The 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
(DHW), and system pumps on and off as needed. The user
programs the control module to meet system needs by adjusting
control parameters through the SMART TOUCH CON•X•US
Interface. These parameters set operating temperatures and
boiler operating modes.
Sequence of operation
Table 1A (page 11) shows control module normal
sequences of operation for space heating and DHW
operation. The combined operation sequence is for
a typical application, programmed to provide DHW
priority.
Access modes
User
The USER can set the SH set point, DHW set point, turn
the unit OFF and ON and set up WiFi.
Installer
Most parameters are available only to the INSTALLER,
accessible only by entering the installer password (5309)
when selecting the Setup Section.
Note: The password will timeout after an hour from
entry.

1 Service
9
Service Manual
1 Service (continued)
GAS PRESSURE SWITCHES
FLAME SENSOR 1 & 2
AUXILIARY LOW WATER CUTOFF
BLOCKED DRAIN SWITCH
PC INTERFACE
AIR PRESSURE SWITCH
AIR PROVING
PRESSURE SWITCH
MANUAL RESET
HIGH LIMIT
VENT DAMPER
PROVING SWITCH
HELLCAT
COMBUSTION
FEEDBACK BOARD
AIR AND GAS DAMPER MOTORS
O2 SENSOR
COMFORT
CONTROL BOARD
O2 SENSOR BOARD
BAS BOARD
HWG THERMOSTAT /
SENSOR
ENABLING DEVICE
SYSTEM SENSOR -
SUPPLY
OUTDOOR SENSOR
SEQUENCER / BUILDING
MANAGEMENT SYSTEM
LOUVER PROVING SWITCH
SYSTEM SENSOR -
RETURN
AUX SWITCH 1 & 2
0-10 INPUT FROM
SYSTEM PUMP
CASCADE
FLOW SWITCH
INLET AIR SENSOR
SMART CONTROL MODULE
DISPLAY PANEL
Control inputs

1 Service
Service Manual
10
1 Service
SMART CONTROL MODULE
VENT DAMPER
IGNITOR
GAS VALVES
COMBUSTION
FEEDBACK BOARD
AIR AND GAS DAMPER MOTORS
COMFORT
CONTROL BOARD
BAS BOARD
0-10V OUTPUT TO
BOILER PUMP
ALARM CONTACTS
SEQUENCER / BUILDING
MANAGEMENT SYSTEM
RUN TIME CONTACTS
LOUVER RELAY
BOILER RATE OUTPUT
PUMP RELAY BOARD
BOILER PUMP
CONTACTOR
SYSTEM PUMP
CONTACTOR
HWG PUMP
CONTACTOR
DISPLAY PANEL
PC INTERFACE
BLOWER
Control outputs