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Lochinvar 3.5 manual

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Table of contents for the manual

  • Page 1

    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[...]

  • Page 2

    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 [...]

  • Page 3

    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 you[...]

  • Page 4

    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 overhea[...]

  • Page 5

    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 co[...]

  • Page 6

    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 Pi[...]

  • Page 7

    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 i[...]

  • Page 8

    1 Service 8 Service Manual 1 Service GAS PRESSURE S W ITCHES HWG THERMOSTAT / SENSOR ENABLING DEVICE SYSTEM SENS OR - SUPPLY OUTDOOR SENSOR SEQUENCE R / BUILDING MANAGM ENT SYSTEM LOW VOLT AGE CONNECTION BOARD INLET TEMPERATURE SENSOR OUTLET TEMPERATURE / HI-LIMIT SENSOR FLUE GAS SENSOR LOUVER PR OVING SW ITCH FLAME SENSO R 1 & 2 LOW W ATER CUT[...]

  • Page 9

    1 Service Service Manual 9 1 Service (continued) LOW VOLTAGE CONNEC TION BOARD SMART CONTRO L MODULE ALARM CONTACTS LOUVER RELAY RUN TIME CONTACTS SEQUENCER / BUILDING MANAGM ENT SYSTEM BOILER PUMP CONTACTOR SYSTEM PUM P CONTACTOR HW G PUMP CONTACTOR IGNITOR BLOW ERS GAS VALVES BOILER RATE OUTPUT DISPLAY PANEL PC INTERFACE 120V SUPPLY SYSTEM PUMP B[...]

  • Page 10

    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 [...]

  • Page 11

    Service Manual 11 1 Service (continued) Saving parameters (reference the Parameter Table - 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[...]

  • Page 12

    1 Service 12 Service Manual Table 1A Sequence of Operation Sequence of operation 1. 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). 2. The control confirms that the low water cutoff contacts are closed and energizes the louvers (optional) and[...]

  • Page 13

    1 Service 13 Service Manual 1 Service (continued) Parameter table Table 1B This table lists SMART TOUCH control module parameters and where to access them Menu Sub Item Parameter Name (as shown on the LCD screen) See Page Min Max Default User Installer Value Value Value Access Access A 1 Clock 18 N/A N/A N/A Yes Yes 2 Date 18 N/A N/A N/A Yes Yes 3 [...]

  • Page 14

    1 Service Service Manual 14 Parameter table Table 1B (continued from previous page) This table lists SMART TOUCH control module parameters and where to access them Menu Sub Item Parameter Name (as shown on the LCD screen) See Page Min Max Default User Installer Value Value Value Access Access C 7 Boost Time 20 0 250 20 No Yes 8 Boost Temperature 20[...]

  • Page 15

    1 Service (continued) Service Manual 15 Parameter table Table 1B (continued from previous page) This table lists SMART TOUCH control module parameters and where to access them Menu Sub Item Parameter Name (as shown on the LCD screen) See Page Min Max Default User Installer Value Value Value Access Access F 1 Temperature Units 21 °F °C °F Yes Yes[...]

  • Page 16

    1 Service Service Manual 16 Parameter table Table 1B (continued from previous page) This table lists SMART TOUCH control module parameters and where to access them Menu Sub Item Parameter Name (as shown on the LCD screen) See Page Min Max Default User Installer Value Value Value Access Access H 1 HWG Night Setback Offset Temp 22 0 90 0 No Yes 2 HWG[...]

  • Page 17

    1 Service (continued) Service Manual 17 Parameter table Table 1B (continued from previous page) This table lists SMART TOUCH control module parameters and where to access them Menu Sub Item Parameter Name (as shown on the LCD screen) See Page Min Max Default User Installer Value Value Value Access Access K 1 Boiler Pump Delay 24 0.5 2400 30 No Yes [...]

  • Page 18

    1 Service Service Manual 18 Viewable and changeable control parameters 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 fou[...]

  • Page 19

    1 Service (continued) Service Manual 19 HWG Minimum User Set Point This setting controls the minimum user set point for the tank temperature. The installer can adjust this by accessing parameter B10 . HWG Maximum User Set Point This setting controls the maximum user set point for the tank temperature. The installer can adjust this by accessing para[...]

  • Page 20

    1 Service 20 Service Manual Outdoor Air Shutdown Differential 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 . Boost Time The boost time parameter se[...]

  • Page 21

    1 Service (continued) Service Manual E: BMS 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 [...]

  • Page 22

    1 Service Service Manual 22 1 Service HWG Rate Liming (NOT AVAILABLE AT THIS TIME) 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 . Servic[...]

  • Page 23

    1 Service 23 Service Manual 1 Service (continued) Cascade Off-On Differential 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 . Maximum Boiler Set Point for Cascade This parameter [...]

  • Page 24

    1 Service Service Manual 24 1 Service 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 . Rate % to Switch on Next Boiler When the Cascade[...]

  • Page 25

    1 Service (continued) 25 Service Manual 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 adjusta[...]

  • Page 26

    1 Service Service Manual 26 The Cascade Screen pro v ides the status of the Cascade Syst em. This screen is only ac cessible when the boiler is the Leader of an activ e Cascade. There ar e many items displa yed on the Cascade Screen. Among them is the Boiler P ower Level I ndicators. F or each boiler present in the Cascade a po wer level indicator [...]

  • Page 27

    1 Service (continued) Service Manual 27 The Graph Screen co nsists of two (2) different screens. The First screen is the P arameter Selection Screen. By pressing the u p and down arrow k eys the desired parameter can be selected. W hen the SELECT button is pressed the parameter will appear in the bottom half of the fi rst screen. If a parameter is[...]

  • Page 28

    1 Service Service Manual 28 The History Screen shows the status of various counters and faults. W ithin the History Screen there are thr ee separate screens . These screens are the “Lockout F aults” , “B locking Faults” and “R untime History” . The default screen is the “Lockout Faults ” screen. This screen allows y ou to view the l[...]

  • Page 29

    1 Service (continued) Service Manual 29 The third screen is the “Runtime H istor y” . There ar e several pieces of information that are display ed on this screen. Items that can be viewed on this screen are as follo ws: • P ower hours – Sho ws the number of hours the control has been po wered on since the last r eset. • Running hours – [...]

  • Page 30

    1 Service (continued) Service Manual 30 The Serv ice Screen allo ws the integrated control to o verride all other heat demands and oper ate V alv e 1 and V alve 2 at high fi re and low fi re conditions. T o place the boiler into Serv ice M ode, pr ess the ST ART butt on. As specifi ed abov e the integrated control will ov er ride all other heat [...]

  • Page 31

    2 Maintenance Service Manual 31 Maintenance and annual startup Table 2A Service and Maintenance Schedules Service technician (see the following pages for instructions) General: • Address reported problems, if any • Inspect interior; clean and vacuum if necessary; • Clean condensate trap and fill with fresh water • Check for leaks (water, ga[...]

  • Page 32

    2 Maintenance 32 Service Manual 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[...]

  • Page 33

    2 Maintenance (continued) Service Manual 33 Flue vent system and air piping 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 c[...]

  • Page 34

    2 Maintenance 34 Service Manual Inspect ignition and flame sense electrodes 1. Remove the ignition and both flame sense electrodes from the burner plate. 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. Replace ignition/flame sen[...]

  • Page 35

    2 Maintenance (continued) Service Manual 35 The boiler contains ceramic fiber materials. Use care when handling these materials per instructions on this page. Failure to comply could result in severe personal injury.  WARNING Cleaning boiler heat exchanger 1. Shut down boiler: • Follow the “To Turn Off Gas to Appliance” instructions for th[...]

  • Page 36

    3 Troubleshooting 36 Service Manual Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Always disconnect power to the boiler before servicing. Failure to comply could result in severe personal injury, death, or substantial property damage. Never jumper (bypass) any device except[...]

  • Page 37

    3 Troubleshooting (continued) Service Manual 37 Table 3A Troubleshooting Chart - No Display FAULT CAUSE CORRECTIVE ACTION No Display - 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 harne[...]

  • Page 38

    3 Troubleshooting 38 Service Manual Table 3B - Inlet Water/System Sensor Resistance vs. Temperature Temperature Resistance Temperature Resistance 50 18,780 158 1,990 68 12,263 176 1,458 86 8,194 194 1,084 104 5,592 212 817 122 3,893 140 2,760 Table 3C - Outdoor Air Sensor Resistance vs. Temperature Temperature Resistance Temperature Resistance -50 [...]

  • Page 39

    3 Troubleshooting (continued) Service Manual 39 Table 3F Troubleshooting Chart - Noisy System FAULT CAUSE CORRECTIVE ACTION Noisy Operation - Supply gas problem. Natural and LP gas pressures should be between 4 inches w.c. (1.0 kPa) and 14 inches w.c. (3.5 kPa). • Refer to Section 6 - Gas Connections of the Crest Installation and Operation Manual[...]

  • Page 40

    3 Troubleshooting Service Manual Table 3G Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION 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[...]

  • Page 41

    3 Troubleshooting (continued) Service Manual 41 Table 3G (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Anti-cycling The main control board has received a call for heat too quickly after the previous call for heat has ended. • The control board will release t[...]

  • Page 42

    3 Troubleshooting 42 Service Manual Table 3G (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Flame Out of Sequence 1 (will require a manual reset once the condition has been corrected. Press the RESET button on the SMART TOUCH display to reset.) The flame detect[...]

  • Page 43

    3 Troubleshooting (continued) Service Manual 43 Table 3G (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION 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.) The [...]

  • Page 44

    3 Troubleshooting Service Manual 44 Table 3G (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Auto Reset High Limit The outlet water temperature has exceeded the setting of the automatic reset high limit. • Verify that the system is full of water and that all a[...]

  • Page 45

    3 Troubleshooting (continued) Service Manual 45 Table 3G (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION 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 f[...]

  • Page 46

    3 Troubleshooting 46 Service Manual Table 3G (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Louver Proving Sw Open (will require a manual reset once the condition has been corrected. Press the RESET button on the SMART TOUCH display to reset.) An optional remot[...]

  • Page 47

    3 Troubleshooting (continued) Service Manual 47 Table 3G (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Outlet Temp High (continued) Outlet water temperature has exceeded the maximum outlet water temperature. • Verify that the boiler pump is set to the proper[...]

  • Page 48

    3 Troubleshooting Table 3G (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Sensor Open (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 temperature sensor [...]

  • Page 49

    3 Troubleshooting (continued) Table 3G (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION 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.) Pressure switch contacts are [...]

  • Page 50

    3 Troubleshooting Table 3G (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Too Many Resets - Try Later Too many manual resets have occurred during a 15 minute period. • Wait 15 minutes and try again. • Turn power off to unit, wait 30 seconds and then turn po[...]

  • Page 51

    3 Troubleshooting (continued) 51 Service Manual Table 3G (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Outlet Temp Shutdown Outlet water temperature has exceeded the maximum outlet water temperature. • Verify that the system is full of water and that all air[...]

  • Page 52

    3 Troubleshooting Service Manual 52 Combustion Analysis Procedure 1. Turn the main power off to the boiler by placing the “On/Off” switch in the OFF position. 2. Remove the flue temperature sensor from the flue collector. Note: Combustion measurements will be made at this point. 3. Turn the main power on to the boiler by placing the “On/Off?[...]

  • Page 53

    3 Troubleshooting (continued) Service Manual 53 Gas valve adjustment procedure GAS VALVE 2 GAS VALVE 1 THROTTLE THROTTLE Figure 3-2 Gas Valve Adjustment: Models 1.5 and 2.0 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 screwdriv[...]

  • Page 54

    3 Troubleshooting 54 NOTES[...]

  • Page 55

    55 NOTES[...]

  • Page 56

    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[...]