Lochinvar Crest w/RealTime O2 Trim 100 Series Service Manual
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Lochinvar Crest w/RealTime O2 Trim 100 Series Service Manual

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100343237_2000600598_Rev A
w/RealTime O2 Trim
TM
Service Manual
Models:
1000 - 6000
Series: 100
C o m b u s t i o n
T e c h n o l o g y
⚠ WARNING
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.
Save this manual for future reference.

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Summary of Contents for Lochinvar Crest w/RealTime O2 Trim 100 Series

  • Page 1 100343237_2000600598_Rev A w/RealTime O2 Trim Service Manual Models: 1000 - 6000 Series: 100 C o m b u s t i o n T e c h n o l o g y ⚠ WARNING This manual must only be used by a qualified heating installer / service technician.

  • Page 2: Table Of Contents

    Contents Night Setback Screen ..........25-26 CONTENTS ............... 2 Pump Screen ............27-28 Hazard Definitions .............. 2 Cascade Screens ............29-31 PLEASE READ BEFORE PROCEEDING ..... 3 Service Screen.............. 32 Handling Ceramic Fiber Materials ........3 Graph Screens .............. 33 When servicing boiler ........... 4 History Screens.............

  • Page 3: Please Read Before Proceeding

    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.

  • Page 4: When Servicing Boiler

    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.

  • Page 5: What Is In This Manual

    Service Manual What is in this manual? Service Maintenance Near boiler piping • Service and maintenance schedules • Address reported problems • Typical system components • Inspect boiler area and boiler interior The Crest boiler display • Clean condensate trap •...

  • Page 6: Service Boiler Piping

    Service Manual 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.

  • Page 7: Smart Touch W/Con•X•Us Interface

    (i.e. Off, screen. There are five (5) sections located below the Stand-by, Blocking, and Lockout) including: current Lochinvar icon: Home, View, Setup, Information driving demand, the next Hot Water Setback scheduled, (About), and Settings. The Home Section is the screen the reason for any blocking or lockout, and a power button.

  • Page 8: General Operation

    Service Manual Service General Operation How the boiler operates Sequence of operation Table 1A (page 11) shows control module normal The Crest uses an advanced stainless steel heat exchanger and sequences of operation for space heating and DHW an electronic control module that allows fully condensing operation.

  • Page 9: Control Inputs

    Service Manual Service Service (continued) Control inputs SMART CONTROL MODULE AIR PRESSURE SWITCH MANUAL RESET HIGH LIMIT FLAME SENSOR 1 & 2 BLOCKED DRAIN SWITCH GAS PRESSURE SWITCHES AUXILIARY LOW WATER CUTOFF AIR PROVING PRESSURE SWITCH VENT DAMPER PROVING SWITCH INLET AIR SENSOR HELLCAT AIR AND GAS DAMPER MOTORS...

  • Page 10: Control Outputs

    Service Manual Service Service Control outputs SMART CONTROL MODULE IGNITOR GAS VALVES VENT DAMPER BLOWER AIR AND GAS DAMPER MOTORS COMBUSTION FEEDBACK BOARD PC INTERFACE 0-10V OUTPUT TO BOILER PUMP ALARM CONTACTS LOUVER RELAY DISPLAY PANEL RUN TIME CONTACTS COMFORT BOILER RATE OUTPUT CONTROL BOARD SEQUENCER / BUILDING...
  • Page 11 Service Manual Service (continued) Table 1A Sequence of Operation Sequence of operation Upon a call for heat, the louver relay output will be closed initiating a block that will clear when the louver proving switch closes. Upon resolution of all blockings, the comfort control will send the demand to the boiler control. The boiler control initiates a pre-purge and confirms that all safeties are in their correct state.

  • Page 12: Initial Setup Screen

    Service Manual Service Initial Setup Screen Figure 1-2 Settings Screen 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.

  • Page 13: Viewable And Changeable Control Parameters

    Service Manual Service (continued) Viewable and changeable control parameters Before changing parameters, note the settings so that the unit can be returned to its original operating CAUTION parameters. Set Point Screens Figure 1-3 Set points DHW_Screen A Figure 1-4 Set points DHW_Screen B...
  • Page 14 Service Manual Service Figure 1-5 Set points SH_Screen A Table 1B Set Points (This table lists control module parameters; use the sub-tab under the Setup tab to access them. Default Parameter Name Menu (as shown on the LCD screen) Value Value Value Space Heat 1 Set point: Set point...
  • Page 15 Service Manual Service (continued) Set Points High Limit: MRHL The SMART TOUCH control contains an integral Manual Space Heat 1 Set Point: Set point Reset High Limit (MRHL) on the outlet of the heat exchanger. Once the outlet temperature exceeds the MRHL set point, the The SH set point sets the water temperature set point used boiler will shut down and lock out.

  • Page 16: Outdoor Reset Screen

    Service Manual Service Outdoor Reset Screen Figure 1-6A Outdoor Reset A Figure 1-6B Outdoor Reset B...
  • Page 17 Service Manual Service (continued) Table 1C Outdoor Reset (This table lists control module parameters; use the sub-tab under the Setup tab to access them.) Default Parameter Name Menu (as shown on the LCD screen) Value Value Value Set point: Cold Day Set point: Warm Day Outdoor Temperature: Cold Day Outdoor Temperature: Warm Day...

  • Page 18: Ramp Delay Screen

    Service Manual Service Ramp Delay Screen Figure 1-7A Ramp Delay Figure 1-7B Ramp Delay...
  • Page 19 Service Manual Service (continued) Table 1D Ramp Delay (This table lists control module parameters; use the sub-tab under the Setup tab to access them.) Default Parameter Name Menu (as shown on the LCD screen) Value Value Value Ramp Delay Mode Step 1: Ramp Delay Time Step 1: Ramp Delay Limit (%) Step 2: Ramp Delay Time...

  • Page 20: Bms Screen

    Service Manual Service BMS Screens Figure 1-8 BMS_Screen A Figure 1-9 BMS_Screen B...
  • Page 21 Service Manual Service (continued) Table 1E BMS / BAS (This table lists control module parameters; use the sub-tab under the Setup tab to access them.) Default Parameter Name Menu (as shown on the LCD screen) Value Value Value BMS Status ACTIVE INACTIVE INACTIVE...
  • Page 22 Service Manual Service BMS Set Point at Minimum Volts This parameter is visible only when the BMS Mode is set to BAS Active / Inactive SETPOINT. The value of this parameter determines the set The boiler is capable of being monitored and/or controlled point when the voltage on the 0 - 10V BMS input is equal to by a Building Automation System (BAS) through either a or less than the BMS Volts at Minimum parameter value.

  • Page 23: Advanced Setup Screen

    Service Manual Service (continued) Advanced Setup Screen Figure 1-10 Advanced Setup Screen Table 1F Advanced Setup (This table lists control module parameters; use the sub-tab under the Setup tab to access them.) Default Parameter Name Menu (as shown on the LCD screen) Value Value Value...
  • Page 24 Service Manual Service Advanced Setup Freeze Protection Pump On Anti-Cycling Differential The control will bypass the anti-cycling time if the inlet The SMART TOUCH control will turn on the boiler and system pump outputs whenever the inlet temperature drops water temperature drops too much. The control will use below this setting.

  • Page 25: Night Setback Screen

    Service Manual Service (continued) Night Setback Screen Figure 1-11A SH Night Setback Table 1G DHW/SH Night Setback Default Parameter Name Menu (as shown on the LCD screen) Value Value Value Offset Temperature (F) Offset Temperature Once the internal clock has been set correctly, the 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.
  • Page 26 Service Manual Figure 1-11B SH Night Setback Schedule DWH/SH Night Setback Schedule Add / Delete Active Months Select or deselect active months by checking or unchecking the desired months. Slider or -/+ can be used to select the beginning and ending dates. Active Days Select or deselect active weekdays by checking or unchecking desired days.

  • Page 27: Pump Screen

    Service Manual Service (continued) Pump Screen Figure 1-12 Pump Screen Table 1H Pumps (This table lists control module parameters; use the sub-tab under the Setup tab to access them.) Default Parameter Name Menu (as shown on the LCD screen) Value Value Value Boiler Pump Mode...
  • Page 28 Service Manual Service Pumps DHW System Pump Mode This parameter allows the installer to determine how the System Pump Mode system pump responds to a DHW call for heat. The parameter The SMART TOUCH control is able to control the system can be adjusted through the DHW System Pump Mode pump in 5 different ways.

  • Page 29: Cascade Screens

    Service Manual Service (continued) Cascade Screens Figure 1-13 Cascade Setup Figure 1-14 Cascade Leader Setup...
  • Page 30 Service Manual Service Table 1I Cascade (This table lists control module parameters; use the sub-tab under the Setup tab to access them. Default Parameter Name Menu (as shown on the LCD screen) Value Value Value Cascade Address Cascade Status ENABLE DISABLE DISABLE Cascade Type...
  • Page 31 Service Manual Service (continued) Rate % to Switch off Last Boiler Maximum Cascade Cond and Non-Cond Set point (F) When the Cascade is programmed in the Efficiency Optimization These types of parameters determine the set point used Mode, the currently running boiler will stop at this rate. by the individual boilers in a Cascade.

  • Page 32: Service Screen

    Service Manual Service Service Screens Figure 1-15B Cascade Redundant Leader Selected Figure 1-16 Service Maintenance Th e Service Screen allows the integrated control to override all other heat demands and operates the combustion system manually through the complete modulation range. To place the boiler into Service Mode, press the START button. As specifi ed above the integrated control will override all other heat demands, however, all safeties will be active.

  • Page 33: Graph Screens

    Service Manual Service (continued) Graph Screens Th e Graph Screen consists of two (2) diff erent types of screens. Th e fi rst screen Short Term Data Screen (three minutes in one second intervals) and the Long Term Data Screen (32 days, 233 average minutes). If a parameter is selected by mistake, it can be de-selected by re-selecting the parameter.

  • Page 34: History Screens

    Service Manual Service History Screen Th e History Screen shows the status of various counters and faults. Within the History Screen there are two separate sections, the “Lockout Blocking Fault” and “Runtime History”. Th e left side of the screen refl ects the “Lockout Blocking Fault” section which allows you to view the last 20 lockout/blocking faults. Succeeded by each fault is the date and time of when the fault occurred.

  • Page 35: Maintenance

    Service Manual Maintenance Maintenance and annual startup Table 2A Service and Maintenance Schedules Owner maintenance Service technician (see the Crest User’s Information Manual for (see the following pages for instructions) instructions) General: • Address reported problems, if any • Check boiler area •...
  • Page 36 Service Manual Maintenance Follow the service and maintenance procedures given throughout this manual and in component literature ⚠WARNING 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.
  • Page 37 Service Manual Maintenance (continued) Check expansion tank Inspect ignition and flame sense electrodes 1. Expansion tanks provide space for water to move in and out as the heating system water expands due to temperature 1. Remove the ignition and both flame sense electrodes from increase or contracts as the water cools.
  • Page 38 NOTE: Be sure to pay close attention to the Lochinvar logo. 5. Remove the gas/air manifold burner access cover Align the logo with the Lochinvar GAS/AIR MANIFOLD COVER (FIG. 2-2). logo on the gas/air manifold to ensure proper assembly.
  • Page 39 Service Manual Maintenance (continued) Review with owner 9. Temporarily remove the condensate drain line from the condensate trap and route directly to a drain. 1. Review the Crest User’s Information Manual with the owner. 10. Rinse out debris with a low pressure water supply. The water will drain through the condensate connection.
  • Page 40 Service Manual Maintenance Test low water flow conditions Handling ceramic fiber materials This test is to be carried out once the REMOVAL OF COMBUSTION CHAMBER NOTICE Crest boiler is completely piped in with LINING adequate gas and water flow. Once the test is completed, ensure that the The combustion chamber insulation in this ⚠WARNING...

  • Page 41: Troubleshooting

    Service Manual Troubleshooting Check control module fuses Label all wires prior to disconnection ⚠WARNING when servicing controls. Wiring errors can cause improper and ALWAYS check control module fuses before NOTICE dangerous operation. Always replacing control module or any major disconnect power to the boiler components (blower, etc.).
  • Page 42 Service Manual Troubleshooting Table 3A Troubleshooting Chart - No Display FAULT CAUSE CORRECTIVE ACTION - No power supplied to the unit. • Check external line switch, fuse, or breaker. - No LED’s illuminated on the CON•X•US Interface control board. • Check position of ON/OFF switch. Turn switch to the ON position.
  • Page 43 Service Manual Troubleshooting (continued) 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.
  • Page 44 Service Manual Troubleshooting Table 3F Troubleshooting Chart - Noisy System FAULT CAUSE CORRECTIVE ACTION - Supply problem. Natural pressures should be between 4 inches w.c. • Refer to Section 6 - Gas Connections of the Crest (1.0 kPa) and 14 inches w.c. and LP gas Installation and Operation Manual for detailed pressures should be between 8 inches w.c.
  • Page 45 Service Manual Troubleshooting (continued) Table 3G Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION • Measure the supply gas pressure to determine cause Gas Pressure SW of failure. Natural gas pressures should be between Open 4 inches w.c.
  • Page 46 Service Manual Troubleshooting 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 The main control board has received a call set time period.
  • Page 47 Service Manual Troubleshooting (continued) Table 3G (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION • Inspect flame rods and associated wiring for damage and connection. Reference this manual for removal and cleaning procedures. Replace if necessary. •...
  • Page 48 Service Manual 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. •...
  • Page 49 Service Manual 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. •...
  • Page 50 Service Manual Troubleshooting 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 Fan Speed High Crest Installation...
  • Page 51 Service Manual 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. •...
  • Page 52 Service Manual Troubleshooting Table 3G (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION Flue Sensor • Check the sensor and its associated wiring. Repair Shorted or replace the sensor or wiring if damaged. (will require a manual •...
  • Page 53 Service Manual 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. •...
  • Page 54 Service Manual Troubleshooting Table 3G (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface FAULT DESCRIPTION CORRECTIVE ACTION • Turn the power OFF. Wait 15 seconds, then turn the IO Expander Out power back ON. Error The control board detected an internal fault.

  • Page 55: Combustion Analysis Procedure

    Service Manual Troubleshooting (continued) Combustion Analysis Procedure Once the heater analysis is complete, test the safety shutoff device by turning the manual shutoff valve to the OFF position and ensuring the 1. Turn the main power off to the boiler by placing heater shuts down and registers an alarm.
  • Page 56 Service Manual Troubleshooting Table 3I 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 •...

  • Page 57: Gas Valve Adjustment Procedure

    Service Manual Troubleshooting (continued) Gas valve adjustment procedure Under normal operating conditions the CAUTION gas valve should not need adjusting. Any adjustment should be done in conjunction with the commissioning sequence as detailed in the Start-up Section of the Crest Installation and Operation Manual.
  • Page 58 NOTES...
  • Page 59 NOTES...

  • Page 60: Revision Notes

    Revision Notes: Revision A (PCP #3000047204 / CN #500034581) initial release. MM #100343237_DIR #2000600598_Rev A 10/21...

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