FB-SER Rev B
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.
ƽ WARNING
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.
Service Manual
Please read before proceeding
Installer–Readallinstructions,including
ƽ WARNING
When calling or writing about the boiler
– Please have the boiler model and serial
number from the boiler rating plate.
NOTICE
this manual and the Crest Installation
and Operation Manual, before installing.
Perform steps in the order given.
Consider piping and installation when
determining boiler location (see the Crest
Installation and Operation Manual).
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.
Any claims for damage or shortage
in shipment must be filed immediately
against the transportation company by the
consignee.
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.
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.
ƽ WARNING
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
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.
3
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.
4
Service Manual
What is in this manual?
Service
Maintenance
• Service and maintenance schedules
• Address reported problems
Near boiler piping
• Typical system components
• Inspect boiler area and boiler interior
• Clean condensate trap
• Check all piping for leaks
• Check air openings
The Crest boiler display
• Display panel readout, buttons and their functions
• Flue vent system and air piping
• Check water system
• Check expansion tank
Control module inputs
• Control module inputs and options
• 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
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
• Review with owner
• Cleaning boiler heat exchanger
• Oiled bearing circulators
• Accessing programming mode and locating menus
(See separate guide covering the PC interface.)
Control panel parameter access
Troubleshooting
• Accessing and changing parameters from the display panel
• Troubleshooting table - No display
• Checking temperature sensors
• Sensor tables
• Troubleshooting table - Fault messages displayed on
boiler interface
Quick start information -- parameter
table
• An index of available adjustments and readouts, where to
access them and where to find detailed information.
• Combustion analysis procedure
• Gas valve adjustment procedure
Crest boiler operation
• Initial Setup
• Set Points
• Outdoor Reset
• Ramp Delay
• BMS
• Advanced Setup
• SH Night Setback
• HWG Night Setback
• Cascade
• Pumps
• Service Notification
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