Lochinvar Crest FBD 751, Crest FBD 2001, Crest FBD 1001, Crest FBD 1251, Crest FBD 1501 Supplemental Manual

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Page 1

000508

100268179_2000509263 Rev A

Dual Fuel Supplemental Manual

Models: FBD 751 - 2001

 WARNING

Save this manual for future reference.

DIR #2000508187

IR #2

This manual must only be used by a qualified heating installer / service technician. Read all instructions, including this manual along with the Crest Installation and Operation Manual, and the Crest Service Manual, before installing. Perform steps in the order given. Failure to comply could result in severe personal injury, death, or substantial property damage.

Page 2

CONTENTS

HAZARD DEFINITIONS .................................................... 2

PLEASE READ BEFORE PROCEEDING ........................ 3

THE CREST -- HOW IT WORKS ...................................... 4

RATINGS ........................................................................... 5

1. GAS CONNECTIONS

Check Inlet Gas Supply ..................................................... 6

Gas Pressure ..................................................................... 7

Gas Valve Replacement ................................................... 7

2. START-UP

Start the Boiler ................................................................... 8

Check System and Boiler ....................................................8

Operating Instructions ........................................................ 9

Check Flame and Combustion ......................................... 10

Dual Fuel Switching Instructions ................................ 10-11

3. DIAGRAMS .............................................................12-13

Revision Notes .................................................. Back Cover

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.

Page 3

Please read before proceeding

Dual Fuel Supplemental Manual

 WARNING

NOTICE

Installer – Read all instructions, including this manual, the Crest Installation and Operation Manual and the Crest Service 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 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.

Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.

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.

 WARNING

Factory warranty (shipped with unit) does not apply to units improperly installed or improperly operated.

Failure to adhere to the guidelines on this page can result in severe personal injury, death, or substantial property damage.

If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

This appliance MUST NOT be installed in any location where gasoline or flammable vapors are likely to be present.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electric switch; do not use any phone in your building.

• Immediately call your gas supplier from a near by phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

• Installation and service must be performed by a qualified installer, service agency, or the gas supplier.

Page 4

The Crest Dual Fuel - How it works...

Dual Fuel Supplemental Manual

1. Propane gas connection

The propane gas connection pipe is a threaded black iron pipe connection. This pipe should be connected to the incoming gas supply to deliver propane gas to the boiler.

2. Natural gas connection

The natural gas connection pipe is a threaded black iron pipe connection. This pipe should be connected to the incoming gas

supply to deliver natural gas to the boiler.

3. Fuel selection switch

Switches the unit between natural and propane gas.

4. Natural gas indicator light (green)

Indicates that natural gas operation has been selected.

5. Propane gas indicator light (red)

Indicates that propane gas operation has been selected.

6. Small natural gas valve (Valve 1 Natural)

The small natural gas valve senses the negative pressure created by the blowers, allowing gas to flow only if the gas valves are powered and combustion air is flowing.

7. Small propane valve (Valve 1 Propane)

The small propane gas valve senses the negative pressure

created by the blowers, allowing gas to flow only if the gas valves are powered and combustion air is flowing.

Models FBD 751 - 2001

8. Large natural gas valve (Valve 2 Natural)

The large natural gas valve senses the negative pressure created by the blowers, allowing gas to flow only if the gas valves are powered and combustion air is flowing.

9. Large propane gas valve (Valve 2 Propane)

The large propane gas valve senses the negative pressure created by the blowers, allowing gas to flow only if the gas valves are powered and combustion air is flowing.

10. Natural shutoff valve

The natural shutoff valve is used to isolate the boiler gas train from the gas supply.

11. Propane shutoff valve

The propane shutoff valve is used to isolate the boiler gas train from the gas supply.

DIR #2000508194

DIR #2000508187

Front View

DIR #2000508206

Left Side (inside unit)

Page 5

Ratings

Dual Fuel Supplemental Manual

Crest

AHRI Rating

Model Number

Note: Change “N” to

“L” for L.P. gas models.

Min Max FB(N,L,D)0751 50 750 720 626 FB(N,L,D)1001 50 1000 960 835 FB(N,L,D)1251 62 1250 1200 1043 FB(N,L,D)1501 60 1500 1440 1252 FB(N,L,D)1751 70 1750 1680 1460

FB(N,L,D)2001 80 2000 1920 1670

NOTICE

Maximum allowed working pressure is located on the rating plate.

Input MBH

(Notes 4 - 8)

Notes:

1. The ratings are based on standard test procedures prescribed by the United States Department of Energy.

2. Net AHRI ratings are based on net installed radiation of sufficient quantity for the requirements of the building and nothing need be added for normal piping and pickup. Ratings are based on a piping and pickup allowance of 1.15.

3. Crest boilers require special gas venting. Use only the vent materials and methods specified in the Crest Installation and Operation Manual.

4. Standard Crest boilers are equipped to operate from sea level to 4,500 feet only. The boiler will de-rate by 1.4% for each 1,000 feet above sea level up to 4,500 feet.

5. High altitude Crest Models are equipped to operate from 3,000 to 12,000 feet only.  e boiler will not de-rate up to 5,500 feet and will de-rate by 1.6% for each 1,000 feet above 5,500 feet.  e operation given in this manual remains the same as the standard boilers. A high altitude label (as shown in FIG A.) is also a xed to the unit.

De-rate values are based on proper combustion

calibration and

CO2’s adjusted to the recommended

levels.

Gross

Output

MBH

(Note 1)

Net

AHRI

Ratings

Water,

MBH

(Note 2)

Other Specifications

Appliance

Water Content Gallons

106 4" 4" 1 1/2" 8" 8" 2458 111 4" 4" 1 1/2" 8" 8" 2570

UNIT EQUIPPED FOR

HIGH ALTITUDE

3,000 FT. TO 12,000 FT.

Pipe

Pipe Size Inlet

Gas Inlet

Size

Outlet

73 3" 3" 1 1/4" 6" 6" 1768 77 3" 3" 1 1/4" 6" 6" 1838

87 3" 3" 1 1/4" 6" 8" 1975 94 4" 4" 1 1/2" 8" 8" 2307

Air

Size

Vent Size

(Note 3)

IMG01026

Weight

w/Water

(lbs.)

Figure A High Altitude Label Location

Page 6

1 Gas connections

10 20 30 40 50 60 70 80 90 100 125 150

1/2 2442 1885 1580 1382 1240 1133 1048 979 921 872 775 703 Pipe 3/4 4831 3812 3230 2842 2561 2346 2175 2035 1917 1816 1618 1470 Size 1 8531 6916 5939 5270 4776 4392 4083 3829 3614 3429

3063 2789

(I.D.) 1 1/4 16626 13771 11963 10691 9736 8987 8378 7872 7443 7074 6336 5779

1 1/2 23670 19957 17510 15749 14407 13341 12470 11740 11119 10581 9501 8682 2 42521 36514 32398 29359 27001 25104 23538 22216 21082 20097 18104

16580

Nominal Iron Pi pe

Size Inches

Length of pipe or tubing, fe e t

Max i m um Capacit i es of Pi pe i n K BTUH/Hr

Notice: Capacities shown are for Natural G as. Please consult supplier for proper gas pipe sizing for propane.

10 20 30 40 50 60 70 80 90 100 125 150

1 1/4 2205 1496 1212 1039 913 834 771 724 677 630 567 511 Pi pe 1 1/ 2 3307 2299 1858 1559 1417 1275 1181 1086 1023 976 866 787 Size 2 6221 4331 3465 2992 2646 2394 2205 2047 1921 1811 1606 1496 (I.D.) 2 1/2 10140 7046 5695 4778 4343 3908 3618 3329 3160 2991 2654 2412

3 17990 12510 10110 8481 7708 6936 6422 5908 5608 5309 4711 4281 4 36710 25520 20620 17300 15730 14150 13100 12050 11440 10830 9613 8736

Nominal Iron Pi pe

Size Inches

Length of pipe or tubing, feet

Max i m um Capacit i es of Pi pe i n K BTUH/Hr

Notice: Capacities shown are for Natural G as. Please consult supplier for proper gas pipe sizing for propane.

Table 1A First Stage Piping at High Pressure_10 PSI

Table 1B Second Stage Piping at Low Pressure_1/2 PSI

Dual Fuel Supplemental Manual

Check inlet gas supply

 WARNING

NOTICE

The gas piping must be sized for the proper flow and length of pipe, to avoid excessive pressure drop. Both the gas meter and the gas regulator must be properly sized for the total gas load.

If you experience a pressure drop greater than 1 inch w.c. (249 Pa), the meter, regulator, or gas line is undersized or in need of service. Perform the steps below when checking inlet gas supply:

1. Turn the main power switch to the “OFF” position.

2. Shut off gas supply at the manual gas valve in the gas piping to the appliance.

3. Remove the 1/8" pipe plug on the flange to the factory supplied gas shutoff valve and install a suitable 1/8" fitting (field supplied) for the manometer tubing. Place the tubing of the manometer over the tap once the 1/8" fitting is installed as shown in FIG.’s 1-1 and 1-2.

DO NOT adjust or attempt to measure gas valve outlet pressure. Attempting to alter or measure the gas valve outlet pressure could result in damage to the valve, causing potential severe personal injury, death, or substantial property damage.

The Dual Fuel Crest is equipped with two (2) inlet gas connections. Each connection must be checked to ensure proper operation.

4. Slowly turn on the gas supply at the factory installed manual gas valve.

5. Turn the power switch to the “ON” position.

6. Adjust the temperature set point on the control panel of the SMART TOUCH control module to call for heat or utilize Service Mode, see page 10 of this manual.

7. Observe the gas supply pressure as the burner fires at 100% of rated input. Percent of burner input will be displayed on the Modulation Screen.

8. Ensure inlet pressure is within specified range. Minimum and maximum gas supply pressures are specified in this section of the manual.

9. If gas supply pressure is within normal range and no adjustments are needed, proceed on to Step 11.

10. If the gas pressure is out of range, contact the gas utility, gas supplier, qualified installer or service agency to determine the necessary steps to provide proper gas pressure to the control.

11. Turn the power switch to the “OFF” position.

12. Shut off the gas supply at the manual gas valve in the gas piping to the appliance.

13. Remove the manometer from the pressure tap on top of the gas valve. Remove the 1/8" (3 mm) field supplied fitting and reinstall the pipe plug removed in Step 3.

Page 7

1 Gas connections (continued)

Dual Fuel Supplemental Manual

 WARNING

14. Turn on the gas supply at the manual gas valve.

15. Turn the power switch to the “ON” position.

16. Adjust the temperature set point on the control panel of the SMART TOUCH control module to the desired water temperature so the appliance will call for heat.

17. Check burner performance by cycling the system while you observe burner response. The burner should ignite promptly. Flame pattern should be stable. Turn system off and allow burner to cool, then cycle burner again to ensure proper ignition and flame characteristics.

18. Repeat Steps 1 - 17 for both natural and LP gas supply.

Do not check for gas leaks with an open flame -- use the bubble test. Failure to use the bubble test or check for gas leaks can cause severe personal injury, death, or substantial property damage.

Gas Pressure

The gas pressure must remain between 4 inches w.c. (.99 kPa)

minimum and 14 inches w.c. (3.5 kPa) maximum for Natural

gas and between 4 inches w.c. (.99 kPa) minimum and 14

inches w.c. (3.5 kPa) maximum for LP gas during standby

(static) mode and while in operating (dynamic) mode. If an

in-line regulator is used, it must be a minimum of 10 feet (3 m)

from the Crest boiler. It is very important that the gas line is

properly purged by the gas supplier or utility company. Failure

to properly purge the lines or improper line sizing, will result

in ignition failure.

Ignition problems are especially noticeable in NEW LP installations and also in empty tank situations. This can also occur when a utility company shuts off service to an area to provide maintenance to their lines.

Gas valve replacement

The gas valve MUST NOT be replaced with a conventional gas valve under any circumstances. As an additional safety feature, the gas valves have flanged connections to the venturis and blowers.

 WARNING

Failure to follow all precautions could result in fire, explosion, or death!

Figure 1-1 Inlet Gas Supply Check_Natural

DIR #2000508192

Figure 1-2 Inlet Gas Supply Check_Propane

DIR #2000508193

Page 8

2 Start-up

Dual Fuel Supplemental Manual

Final checks before starting the boiler

 Read the Crest Service Manual to familiarize yourself

with SMART TOUCH control module operation. Read this manual, page 9 for proper steps to start boiler.

 Verify the boiler and system are full of water and all

system components are correctly set for operation.

 Verify the preparation procedures of Section 9 of the

Crest Installation and Operation Manual have been completed.

 Verify electrical connections are correct and securely

attached.

 Inspect vent piping and air piping for signs of deterioration

from corrosion, physical damage or sagging. Verify air piping and vent piping are intact and correctly installed per this manual.

Start the boiler

1. Read and follow the Operating instructions in FIG. 2-1, page 9.

 Check vent piping and air piping

1. Check for gastight seal at every connection, seam of air piping, and vent piping.

 WARNING

 Check gas piping

1. Check around the boiler for gas odor following the procedure in the Crest Installation and Operation Manual (connecting gas supply piping).

 WARNING

Venting system must be sealed gastight to prevent flue gas spillage and carbon monoxide emissions, which will result in severe personal injury or death.

If you discover evidence of any gas leak, shut down the boiler at once. Find the leak source with a bubble test and repair immediately. Do not start the boiler again until corrected. Failure to comply could result in severe personal injury, death, or substantial property damage.

If boiler does not start correctly

1. Check for loose connections, blown fuse or service switch off?

2. Is external limit control (if used) open? Is boiler water temperature above 200°F (93°C)?

3. Is the boiler receiving a call for heat?

4. Is gas turned on at meter and boiler?

5. Is incoming gas pressure less than 4 inches w.c. (.99 kPa)?

If none of the above corrects the problem, refer to the Troubleshooting Section of the Crest Service Manual.

Check system and boiler

 Check water piping

1. Check system piping for leaks. If found, shut down the boiler and repair immediately. (See WARNINGS in the Crest Installation and Operation Manual (startup) regarding failure to repair leaks.)

2. Vent any remaining air from the system using manual vents. Air in the system will interfere with circulation and cause heat distribution problems and noise.

Page 9

2 Start-up (continued)

Figure 2-1 Operating Instructions

FOR YOUR SAFETY READ BEFORE OPERATING

WARNING: If you do not follow these instructions exactly, a fire or explosion

may result causing property damage, personal injury, or loss of life.

Dual Fuel Supplemental Manual

A. T his appliance does not have a pilot. It is

equipped with an ignition device which automatically lights the burner. Do not try

to light the burner by hand.

B. BE FOR E OP ER ATI NG sme ll a ll ar ou nd

the a pp lia nce area fo r gas. B e s u re to smell next to the floor because some gas

is heavie r than air and will settle on the floor.

WHAT T O DO IF YOU SMELL GAS

• D o not tr y to light an y ap pl ian ce.

• Do not touch any electric switch; do

not use an y phon e i n your b ui ldi ng .

OPERATIN G INSTRUCTIONS

1. STOP! Read the safety information

above on this label.

2. Set the thermostat to lowest setting.

3. Turn off all electric power to the app lia nc e.

4. T his appliance is equipped with an ign ition device which automatically lights

the burner. Do not try to light the burner by hand .

5. Remove front door.

6. Turn gas shutoff valve counterclockwise to “ O FF”. H an dle wil l be pe rpen dicula r to

pipe. Do not force.

7. Wait five (5) minutes to clear out any gas. If you then smell gas, ST O P ! Follow “B” in the safety in forma tion above this label.

If you don’t smell gas, go to next step.

• Immediately call your gas supplier from a neig hbor ’s phon e. Fol low t h e gas su pp lier’s

instr uctions.

• If yo u can n ot re ach your ga s sup pl ier , call the fire department.

C. Use only your hand to turn the gas control knob.

Never use tools. If the handle will not turn by hand , do n’t try to re pair i t, call a qua lified se rvice

technician. Force or attempted repair may result in a fire or explosion.

D. Do n ot us e t his app lia nce if any part ha s be en

unde r wa t er. I mm ed iate ly c all a qu al ified ser vice tech nician to in spe ct th e a pplianc e an d to replace any part of the control system and any gas co n trol w hich ha s be en un de r wa t er.

8. Tur n g as sh ut of f val ve clo ck wise to “ O N”. Handle will be paralle l to pi pe.

9. Inst al l fr on t d oor.

10. Turn on all electric power to appliance.

11. Set t h er mostat to desired se tting .

12. If the ap pl iance w ill not oper ate, fol low th e instr uctio ns “T o Tu rn Off G a s To App lia nc e ” and

call your service technician or gas supplier.

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat to lowest setting.

2. T urn off all e le ctr ic po we r to the ap pl ian ce if servic e is t o be perf or me d.

3. Remove front door.

4. Turn gas shut off valve counterclockwise to “OFF”. Handle will be perpendicular to pipe.

Do not force.

5. Inst al l fr on t d oor.

L BL2 0053 RE V B

Page 10

2 Start-up

Dual Fuel Supplemental Manual

Check flame and combustion

1. Turn the main power off to the boiler by placing the “On/Off” switch in the OFF position.

2. Remove the fitting 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” switch in the ON position.

4. Navigate to the Service Maintenance Screen from the Home Screen by pressing the SETUP button, enter the installer password, and then using the scrolling menu feature on the left side, scroll down to the SERVICE MAINTENANCE button.

5. On the Service Maintenance Screen place heater into Service Mode by selecting the START button, then selecting Set Gas Valve 1 - High.

6. Insert the probe from a combustion analyzer into the hole left by the removal of the fitting.

7. Once the boiler has modulated up to rate, measure the combustion. The values should be in the range listed in Table 2A below. CO levels should be less than 200 ppm for a properly installed unit. If the combustion is not within range reference the Troubleshooting Section in the Crest Service Manual for possible causes and corrective actions.

8. Once the heater analysis is complete, test the safety shutoff device by turning the manual shutoff valve to the OFF position and ensuring the heater shuts down and registers an alarm. Open the manual shutoff valve and reset the control.

9. Turn the main power off to the boiler and replace the fitting into the flue pipe connection.

10. Place the boiler back into normal operation.

 WARNING

You must replace the fitting to prevent flue gas spillage into the room. Failure to comply could result in severe personal injury, death, or substantial property damage.

Dual fuel switching instructions

1. Turn the main power off to the boiler by placing the “On/ Off” switch in the OFF position (FIG. 2-2).

2. Using the fuel selector switch (FIG. 2-2), select the desired fuel.

Figure 2-2 Fuel Selector Switch

Table 2A Flue Products Chart

Flue Products

Gas Valve

Valve 1 High 9.2 4.6

Valve 1 Low 9.0 4.9

Valve 2 High 9.3 4.4

Valve 2 Low 8.7 5.5

Natural Gas

CO2 (%) O2 (%)

Propane

Valve 1 High 11.0 4.1

Valve 1 Low 10.0 5.6

Valve 2 High 11.1 4.0

Valve 2 Low 10.7 4.6

**All set points should be within +/- 0.2%**

MAIN POWER SWITCH

NATURAL PERSONALITY I.D.

PROPANE PERSONALITY I.D.

FUEL SELECTION

SWITCH

NATURAL

DIR #2000508194

PROPANE

IMG00063

DETAIL

Page 11

2 Start-up (continued)

Dual Fuel Supplemental Manual

3. Turn off all shutoff valves for the fuel not in use (FIG. 2-3).

Figure 2-3 Shutoff Valves

NATURAL SHUTOFF

VALV E

PROPANE SHUTOFF

VALV E

DIR #2000508189

Figure 2-4 Personality Plug

4. Turn on the shutoff valve for the one in use.

5. Turn the main power ON.

6. Using the Touch Screen, accept the appropriate personality identification as shown in FIG. 2-4.

Page 12

3 Diagrams

PRE-MIX SENSOR 1 (S13)

PRE-MIX SENSOR 1 (S11)

FLUE SENSOR (S10)

OUTLET SENSOR (S1)

-T

FLUE SENSOR

OUTLET SENSOR (S9)

1.5A EACH MAX

WARNING

OPTIONAL USB/WIFI

J3-3

JUNCTION BOX

TERMINAL STRIP 120V SUPPLY "L"

TERMINAL STRIP 120V SUPPLY "N"

120VAC NEUTRAL

INTEGRATED CONTROL

ON/OFF

SWITCH

3.15 A

5.0 A

SYSTEM PUMP

RELAY

BOILER PUMP

RELAY

DHW PUMP

RELAY

X1-1

X1-2

X1-4

X1-8

SMALL GAS

VALVE RELAY

LARGE GAS

VALVE RELAY

X1-6

2-01X1-01X

X10-3

SMALL GAS

VALVE RELAY

LARGE GAS

VALVE RELAY

X10-6

X10-5

X10-4

TERMINAL STRIP

SYSTEM PUMP

CONTACTOR

BOLIER PUMP

CONTACTOR

DHW PUMP

CONTACTOR

BLOWER

RELAY

BLOWER

X6-10

X13-4

X6-1

X2-5

BAS

X1-1

X1-2

X1-3

FLUE DAMPER

TRANSFORMER

24V

TRANSFORMER

FLUE DAMPER

X6-3

X1-12

RIBBON CABLE

BOARD

TEST

SWITCH

LWCO

PROBE

LWCO RESET

J2-2

J3-5

X6-5

X6-15

X6-12

X13-1

X6-6

X3-3

X3-4

X3-1

X3-2

X6-11

X6-2

X1-3

LWCO

CONTROL

BLOCKED FLUE

SWITCH

BLOCKED DRAIN

SWITCH

ALARM CONTACTS

RUN-TIME CONTACTS

TANK THERMOSTAT

LOUVER PROVING

AUX SWITCH 1

AUX SWITCH 2

ENABLE

CN1-12

J3-6

CN1-10

CN1-11

CN1-9

X6-4

CN1-8

CN1-7

CN1-1

CN1-3

X1-3

X1-7

X1-10

X2-3

FLAME

SENSE 2

FLAME

SENSE 1

SPARK

GENERATOR

SPARK

ROD

SHIELD

MODBUS OPTION

RATE OUT

BOILER PUMP OUT

SYSTEM RETURN SENSOR

SYSTEM SUPPLY SENSOR

0-10V

TANK SENSOR

OUTDOOR SENSOR

0-10V

BMS IN

SYSTEM PUMP IN

SHIELD

CASCADE

LARGE

CONNECTION BOARD

CN6-1

CN3-6

CN3-7

CN3-14

CN3-13

CN3-11

CN3-9

CN3-8

CN3-1

CN3-2

CN3-3

CN3-4

CN6-2

CN6-3

CN3-10

X6-14

INTEGRATED

BOARD

X4-1

X4-2

X4-3

X6-3

X6-1

X6-2

X8-20

X8-10

X7-8

X8-13

X8-14

X8-12

INTEGRATED

CONTROL

CN3-4X8-15

X7-7

X8-11

X8-6

X8-16

X8-7

X8-17

X8-1

X8-3

X8-8

X8-2

X8-4

X8-9

X7-1

X7-5

GROUND

X11

LCD

DISPLAY

X5-1

X5-7

X5-2

X5-8

X5-3

X5-9

X5-4

X5-10

X5-5

X5-41

X5-6

CN3-12

BAS

X5-12

J3-2

BOX DEPICTS

SINGLE HOUSING

HIGH VOLTAGE

LOW VOLTAGE

BOX DEPICTS

OPTIONAL ITEMS

X6-8

INLET SENSOR

-T

X6-9 4

BLOWER

120 VAC

locations when using diagrams to troubleshoot unit.

USB

INTERFACE

"X5"

BLOCK WIRING

IS MODEL

DEPENDENT

X8-1

X8-5

100266316 REV A

24 VAC LOUVER RELAY COIL

X6-13

CN1-2

BLOWER

RELAY

CN1-5

CN1-4

HIGH LIMIT

SWITCH

SMALL CONNECTION BOARD

CN-1

CN1-6

CN-2

CN-3

CAM

SWITCH

PROPANE LGPS

NATURAL LGPS

AIR VALVE

PRESS. SWITCH

CAM

SWITCH

PROPANE LIGHT

NATURAL LIGHT

CAM

SWITCH

PROPANE NATURAL

J23

3. Actual connector block locations may vary from those shown on diagrams. Refer to actual components for proper connector blo ck

J3-4

DUAL SENSOR

ETHERNET CABLE

USB CABLE

J17

EXTENSION CABLE

OPTIONAL

GND

J12

J11

J10

24V

BAS

CN-4

DONGLE

AIR VALVE

CN6-1

CN6-3

CN6-2

LG CON BRD

X6-18 1

X6-17

Notes

1. All wiring must be installed in accordance with: local, st ate, provincial and national code requirements per either N.E.C. in USA or C.S.A. in Canada.

2. If any original equipment wire as supplied with the appliance mu st be replaced, it must be replaced with wire having same wire gauge (AWG) and rated for a minimum of 105°C. Exceptions: Replacement high voltage spark lead and ribbon cables must be purchas ed from the factory. Use of a non-approved spark lead or ribbon cables can lead to operational problems which could result in non-repairable damage to the integrated controller or other components.

WIFI

J2-1

DISCONNECT POWER

BEFORE SERVICING

Figure 3-1 Ladder Diagram

Dual Fuel Supplemental Manual

Page 13

3 Diagrams (continued)

Figure 3-2 Wiring Diagram

J10

J2 J11

0-10V

GND

DISPLAY

J12

LARGE CONNECTION BOARD

LCD

USB CABLE

J9 J17

OPTIONAL USB/WIFI EXTENSION CABLE

J23

OPTIONAL ETHERNET CABLE

LWCO

PROBE

OR/BK

CAM

SWITCH

CAM

SWITCH

CN6-3

CN6-2

CN6-1

CN3-4 CN3-6

CN3-7

CN3-14

CN3-13

CN3-12

CN3-11

CN3-10

CN3-9

CN3-8

CN3-1

CN3-2

CN3-3

CN3-5

DONGLE

CN1-4

CN1-5

CN1-6

CN1-12

CN1-10

CN1-11

CN1-9

CN1-8

CN1-7

CN1-1

CN1-2

CN1-3

TEST

SWITCH

LWCO RESET

BLOCKED FLUE

SWITCH

BLOCKED DRAIN

SWITCH

MODBUS

OPTION

BOILER

PUMP OUT

SYSTEM RETURN

SENSOR

SYSTEM SUPPLY

SENSOR

OUTDOOR

SENSOR

SYSTEM PUMP IN

CASCADE

LG CON BRD

CN6-2

CN6-1

CN6-3

CONTACTS

RUN-TIME

CONTACTS

THERMOSTAT

LOUVER

PROVING

24 VAC LOUVER

RELAY COIL

SWITCH 1

SWITCH 2

SHIELD

RATE

OUT

TANK

BMS

SHIELD

BAS

24V

ALARM

TANK

ENABLE

AUX

WIFI

SMALL CONNECTION BOARD

OR/BK

OR OR

PROPANE LGPS

NATURAL LGPS

PROPANE LIGHT

NATURAL LIGHT

BAS

BOARD

X1-1

X1-2

X1-3

X6-3GY

X6-1

X6-2

X4-1

X4-2

X4-3

OR/W

Y/BK

-T

INLET SENSOR

-T

OUTLET SENSOR (S9)

-T

OUTLET SENSOR (S1)

-T

FLUE SENSOR

-T

FLUE SENSOR (S10)

-T

PRE-MIX SENSOR 1 (S11)

-T

PRE-MIX SENSOR 1 (S13)

HIGH LIMIT

SWITCH

LWCO BOARD

J3-6

J3-5

J3-4

J3-3

J3-2

J2-1

J2-2

"X5"

BLOCK WIRING

IS MODEL

DEPENDENT

Dual Fuel Supplemental Manual

BOX DEPICTS

OPTIONAL ITEMS

BOX DEPICTS DUAL SENSOR

SINGLE HOUSING

INTEGRATED CONTROL

X8-20

X8-10

X7-8

X7-7

X8-13

X8-14

X8-12

X8-11

X8-5

X8-15

X8-6

X8-16

X8-7

X8-17

X8-18

X8-1

X8-3

X8-8

R/W

X8-2

X8-4

CAM

SWITCH

X8-9

X7-1

X7-5

X7-2

X7-6

X3-3

X3-4

X3-1

X3-2

X6-1

X6-11

X6-2

X6-14

X6-10

X6-4

X6-3

X6-5

X13-1PR

X6-6

X5-1

X5-7

X5-2

X5-8

X5-3

X5-9

X5-4

X5-10

X5-5

X5-41

X5-6

X5-12

X1-6

X1-3

X1-12

X10-1

X10-4

X1-1

X1-2

X1-4

X10-2

X10-5

X10-3

X10-6

X6-18

X6-8

X1-8

X6-9

X6-17

X2-3

X1-7

X1-10

X1-5

X2-5

X13-4

X6-13

X6-15

X6-12

X11

USB

INTERFAC E

BLOWER

SPARK

GENERATOR

FLUE DAMPER

TRANSFORMER

OR/W

OR/BK

ON/OFF

SWITCH

DISCONNECT POWER

BEFORE SERVICING

LOW VOLTAGE 120 VAC

HIGH VOLTAGE

120V

SUPPLY

GND

OR/W

CAM

SWITCH

CAM

SWITCH

TRANSFORMER

AIR VALVE PRESSURE

SWITCH

WARNING

OR/BK

SMALL

NATURAL

VALVE

R/BK

R/W

LARGE

NATURAL

VALVE

BLOWER

TRANSITION

FLAME SENSE

SPARK ROD

MAIN

FLAME SENSE

FLUE DAMPER

24V

OR/R

1.5A EACH MAX

SYSTEM PUMP CONTACTOR

BOILER PUMP CONTACTOR

DHW PUMP CONTACTOR

JUNCTION

BOX

SMALL

PROPANE

VALVE

LARGE

PROPANE

VALVE

54321

AIR VALVE

GND

Notes:

1. All wiring must be installed in accordance with: local, state, provincial and national code requirements per either N.E.C. in USA or C.S.A. in Canada.

2. If any original equipment wire as supplied with the appliance mu st be replaced, it must be replaced with wire having same wire gauge (AWG) and rated for a minimum of 105°C. Exceptions: Replacement high voltage spark lead and ribbon cables must be purchased from the factory. Use of a non-approved spark lead or ribbon cables can lead to operational problems which could result in non-repairable damage to the integrated controller or o ther components.

3. Actual connector block locations may vary from those shown on diagrams. Refer to actual components for proper connector block locations when using diagrams to troubleshoot unit.

100266353 REV A

Page 14

Notes

Dual Fuel Supplemental Manual

Page 15

Notes

Dual Fuel Supplemental Manual

Page 16

Revision Notes: Revision A (Change #500001029) initial release.

MM #100268179_DIR #2000509263 Rev A

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