Lochinvar Crest FBD 2.5, Crest FBD 3.5, Crest FBD 5.0, Crest FBD 4.0, Crest FBD 3.0 Supplemental Manual
Page 1
FBD-SUP_100161023_2000004585 Rev D
Dual Fuel Supplemental Manual
Models: FBD 2.5 - 5.0
WARNING
Save this manual for future reference.
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 ..................................... 11
3. DIAGRAMS .............................................................12-17
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
2
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
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.
3
Page 4
The Crest Dual Fuel - How it works...
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.
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.
12. Natural ball valve (Valve 1)
The ball valve for natural valve 1 is used to isolate natural valve 1
from the propane gas supply.
13. Propane ball valve (Valve 1)
The ball valve for propane valve 1 is used to isolate propane valve 1
from the natural gas supply.
14. Natural ball valve (Valve 2)
The ball valve for natural valve 2 is used to isolate natural valve 2
from the propane gas supply.
15. Propane ball valve (Valve 2)
The ball valve for propane valve 2 is used to isolate propane valve 2
from the natural gas supply.
Models FBD 2.5 - 5.0
Dual Fuel Supplemental Manual
1
2
IMG00555
5
IMG00062
MODELS 2.5 - 3.5
13
7
5
MODELS 4.0 - 5.0
11
3
10
14
8
9
4
IMG00064
3
4
Front View
4
IMG00061
15
12
6
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)2500 125 2500 2300 2000
FB(N,L,D)3000 150 3000 2760 2400
FB(N,L,D)3500 200* 3500 3220 2800
FB(N,L,D)4000 335 4000 3720 4043
FB(N,L,D)5000 500 5000 4650 3235
Input
MBH
(Notes 4 - 8)
*For LP models the minimum input is 420 MBH.
NOTICE
Maximum allowed working pressure is located on the rating plate.
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 with no adjustments.
5. High altitude Crest Models 2.5, 3.0 and 3.5 boilers are
equipped to operate from 3,000 to 12,000 feet and high
altitude Crest Models 4.0 and 5.0 boilers are equipped to
operate from 3,000 to 5,500 feet. High altitude models
are manufactured with di erent control parameters for
high altitude operation, but the sequence of 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.
6. Standard Crest boilers will de-rate by 2.2% for each 1,000
feet above sea level up to 4,500 feet when combustion
calibration is performed and CO
’s are adjusted to the
2
recommended levels.
Gross
Output
MBH
(Note 1)
Other Specifications
Net
AHRI
Ratings
Water,
MBH
(Note 2)
Appliance
Water
Content
Gallons
161 4" 4" 2" 8" 9" 3650
181 4" 4" 2" 10" 10" 4125
215 4" 4" 2" 10" 10" 4750
291 4" 4" 2 1/2" 12" 12" 6500
380 4" 4" 2 1/2" 14" 14" 8000
Pipe
Size
Outlet
Pipe
Size
Inlet
Gas Inlet
Size
7. High altitude Crest Models 2.5, 3.0 and 3.5 will de-rate by
1.4% for each 1,000 feet above sea level up to 5,500 feet and
1.8% for each 1,000 feet above 5,500 feet.
8. High altitude Crest Models 4.0 and 5.0 will not de-rate up to
5,500 feet.
9. For Crest Models 4.0 and 5.0, installations above 5,500 feet
contact the factory.
10. Ratings have been con rmed by the Hydronics Section of
AHRI.
UNIT EQUIPPED FOR
HIGH ALTITUDE
3,000 FT. TO 12,000 FT.
Air
Size
Vent
Size
(Note 3)
Weight
w/Water
(lbs.)
Figure A High Altitude Label Location
5
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 Gas. 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 Gas. 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.
6
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
WARNING
Failure to follow all precautions
could result in fire, explosion, or
death!
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.
Figure 1-1 Inlet Gas Supply Check_Natural
Figure 1-2 Inlet Gas Supply Check_Propane
IMG00065
7
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.
8
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 O P ER ATI NG sme ll a ll ar ou nd
the app lia nce are a f o r ga s. Be su 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
• Do not tr y to lig ht an y ap pl ian ce.
• Do not touch any electric switch; do
not use any phon e i n you r bui 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 perp endic u lar t o
pipe. D o not force.
7. Wait five (5) minutes to clear out any gas.
If you then smell gas, STO P ! Follow “B”
in the safety information above this label.
If you don’t smell gas, go to next step.
• Immediately call your gas supplier from a
neig hbor ’s ph on e. Fol lo w the g as supp lie r’s
instr uctions.
• If yo u can n ot re ach you r gas 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 lif ied service
technician. Force or attempted repair may
result in a fire or explosion.
D. Do not use this app lia nce if an y pa rt has b e en
unde r wa ter. I mm ed iat e ly call a qu al ified
ser vice technician to in spect the applia nc e an d
to replace any part of the control system and
any gas co n trol w hich has been un der water.
8. Tur n g as sh ut of f val ve clockwise to “ON”.
Handle will be paralle l to pipe.
9. Inst al l fr on t doo r.
10. Turn on all electric power to applianc e.
11. Set t h er mostat to desired setti ng .
12. If the ap pl iance w ill not op er ate , fol lo w the
instr uctio ns “T o Tu rn Off Gas T o A ppliance ” an d
call your ser vice technician or gas supplier.
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to lowest setting.
2. T urn off all electr ic po wer t o t he appl ian ce
if service is t o be pe rf or med.
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 doo r.
L BL2 0053 RE V B
9
Page 10
2 Start-up
Dual Fuel Supplemental Manual
Check flame and combustion
NOTICE
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” 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 flue temperature
sensor.
A flame and combustion check
must be performed on natural gas
and then repeated on propane.
10. Repeat the same procedure for propane gas. Reference the
Dual Fuel Switching Instructions on pages 10 and 11 of this
manual.
11. Turn the main power off to the boiler and replace the
flue temperature sensor into the flue pipe connection.
12. Place the boiler back into normal operation.
WARNING
You must replace the flue gas temperature
sensor 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.’s 2-2A and
2-2B).
2. Using the fuel selector switch (FIG.’s 2-2A and 2-2B),
select the desired fuel.
Figure 2-2A Fuel Selector Switch - Models 2.5 - 3.5
7. Once the heat exchanger has modulated up to
rate, measure the combustion. The values should
be in the range listed in Table 2A. 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.
Table 2A Flue Products Chart
Gas
Valve
1 - High 3.5% - 5.5% 11.2% - 14.8% 5.1% - 6.8% 10.5% - 13.2%
2 - High 7.8% - 8.6% 5.6% - 7.1% 9.4% - 11.0% 4.1% - 6.6%
Natural Gas Propane
CO
2
O
2
CO
2
O
2
8. After Gas Valve 1 is set, repeat the same procedure for the second
gas train by selecting Set Gas Valve 2 - High on the Service
Screen.
9. Once the heater analysis is complete, test the safety shutoff device
by turning the manual shutoff valve to the OFF position and
ensuring that the heater shuts down and registers an alarm. Open
the manual shutoff valve and reset the control.
MAIN POWER
SWITCH
NATURAL PERSONALITY I.D.
PROPANE PERSONALITY I.D.
FUEL SELECTION
SWITCH
NATURAL
IMG00064
PROPANE
IMG00063
DETAIL
10
Page 11
2 Start-up (continued)
Dual Fuel Supplemental Manual
Figure 2-2B Fuel Selector Switch - Models 4.0 - 5.0
PROPANE
PERSONALITY I.D.
NATURAL
PERSONALITY I.D.
IMG00555
MAIN POWER
SWITCH
FUEL SELECTION
SWITCH
NATURAL
PROPANE
IMG00063
DETAIL
3. Turn off all ball valves (3 total) for the fuel not in use (FIG. 2-3).
Figure 2-3 Ball Valves
PROPANE
NATURAL
IMG00061
Figure 2-4 Personality Plug Screen
4. Turn on the ball valves for the ones in use (3 total).
5. Turn the main power ON.
6. Using the Touch Screen, accept the appropriate personality
identification as shown in FIG. 2-4.
11
Page 12
3 Diagrams
Figure 3-1 Wiring Diagram_2.5 - 3.5 Models
Dual Fuel Supplemental Manual
MODBUS
PUMP OUT
SYSTEM RETURN
SYSTEM SUPPLY
SYSTEM
PUMP IN
CASCADE
LG CON BRD
CN6-2
CN6-1
PR
GY
CN6-3
CONTACTS
CONTACTS
THERMOSTAT
24 VAC LOUVER
RELAY COIL
SHIELD
OPTION
SHIELD
RATE
OUT
BOILER
SENSOR
SENSOR
TANK
SENSOR
OUTDOOR
SENSOR
BMS
SHIELD
SHIELD
BAS
R
ALARM
RUN-TIME
TANK
ENABLE
LOUVER
PROVING
SWITCH 1
SWITCH 2
BOX DEPICTS
OPTIONAL ITEMS
BOX DEPICTS
DUAL SENSOR
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
X2-4
X13-2
X13-3
X2-3
X1-7
X1-10
X1-5
X2-5
X13-4
X11
USB
INTERFACE
SINGLE HOUSING
RP
T
RO
RO
R
KB
YG
SMALL
BLOWER
RELAY
W
T
T
LARGE
BLOWER
RELAY
T
R
R
SPARK
GENERATOR
R
P
FLUE DAMPER
TRANSFORMER
KB
KB/W
BAS
YG
R
RP
INLET SENSOR
OUTLET SENSOR (S9)
OUTLET SENSOR (S1)
FLUE SENSOR
FLUE SENSOR (S10)
PRE-MIX SENSOR 1 (S11)
PRE-MIX SENSOR 1 (S13)
PRE-MIX SENSOR 2 (S12)
PRE-MIX SENSOR 2 (S14)
HIGH LIMIT
SWITCH
R
LWCO
BOARD
KB/RO
RO
RO
OR
T
BLOCK WIRING
DEPENDENT
X1-1
X1-2
X1-3
X6-3
X6-1
X6-2
X4-1
X4-2
X4-3
-T
-T
-T
-T
-T
-T
-T
-T
-T
J3-6
J3-5
J3-4
J3-3
J3-2
J2-1
J2-2
GPS2
OR
RO
RP
KB
CAM SWITCH
"X5"
IS MODEL
GPS3
INTEGRATED CONTROL
KB
X8-20
T
X8-10
LB
X7-8
X7-7
R
X8-13
LB
X8-14
R
RB
X8-12
W
X8-11
X8-5
RO
W/RO
X8-15
X8-6
P
X8-16
W
LB
X8-7
KB
X8-17
KB/Y
X8-18
X8-1
LB
X8-3
W/R
X8-8
R
X8-2
X8-4
W
YG
X8-9
YG
X7-1
RB
X7-5
KB
X7-2
T
X7-6
X4
LB
Y
X3-3
R
R
X3-4
X3-1
RO
X3-2
RO
X6-1
LB
X6-11
KB
RB
X6-2
R
X6-14
Y
X6-10
X6-13
RO
LB
X6-4
R
RO
X6-3
X6-5
BR
X6-15
X6-12
X13-1
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
LARGE CONNECTION BOARD
43
USB CABLE
OPTIONAL USB/WIFI
EXTENSION CABLE
OPTIONAL
ETHERNET CABLE
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
WIFI
DONGLE
17
A
18
B
19
20
21
+
0-10V
22
23
+
0-10V
24
25
26
27
28
29
30
31
32
33
+
0-10V
-
IN
24V
34
35
+
0-10V
36
37
A
38
B
39
40
LCD
DISPLAY
COMMUNICATION
CONTROL BOARD
8
SW1
J6
J7
J8
J10
J9
J17
J11
J2
J23
J12
E
GND
SMALL CONNECTION BOARD
1
2
3
4
5
6
R
7
8
W
9
10
11
12
LWCO
PROBE
13
14
15
16
AUX
AUX
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
KB/RO
LWCO RESET
CAM
PROPANE LGPS
SWITCH
NATURAL LGPS
BLOWER PROVING SWITCH (LARGE)
BLOWER PROVING SWITCH (SMALL)
BLOCKED FLUE SWITCH
BLOCKED DRAIN SWITCH
CAM
SWITCH
PROPANE LIGHT
NATURAL LIGHT
WARNI NG
!
DISCONNECT POWER
BEFORE SERVICING
LOW VOLTAGE
120 VAC
HIGH VOLTAGE
120V
SUPPLY
GND
LN
BK
ON/OFF
SWITCH
KB
W
G
OR/W
CAM
SWITCH
LB
R
CAM
SWITCH
LB
W/KB W/G
R/W
BK/W
Y
TRANSFORMER
BL
Y
OR/BK
SMALL
NATURAL
VALVE
R/BK
R/W
LARGE
NATURAL
VALVE
KB
1
BLOWER
(SMALL)
1245
3
BLOWER
(LARGE)
3
12 45
FLAME SENSE 2
SPARK ROD
FLAME SENSE 1
FLUE DAMPER
1
LB
2
3
RO
24V
1.5A EACH MAX
SYSTEM PUMP
CONTACTOR
BOILER PUMP
CONTACTOR
DHW PUMP
CONTACTOR
JUNCTION
BOX
SMALL
PROPANE
VALVE
LARGE
PROPANE
VALVE
32
231
M
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 equipme nt wire as supplied with the ap pliance must be replaced, it m ust be replaced with wire hav ing 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-approv ed spark lead
or ribbon cables can le ad to operational problems whic h could result in non-repairable damage to the integrated co ntroller or other components.
3. Actual connector bloc k locations may vary from thos e shown on diagrams. Refer to actual components for proper c onnector block locations when using
diagrams to troubleshoot unit.
12
100267551 REV A
Page 13
3 Diagrams (continued)
Figure 3-2 Ladder Diagram_2.5 - 3.5 Models
120VAC NEUTRAL
TERMINAL STRIP
120V SUPPLY "L"
INTEGRATED CONTROL
ON/OFF
SWITCH
F2
X1-6
3.15 AF45.0 A
X6-1
X2-5
SMALL BLOWER
RELAY
LARGE BLOWER
RELAY
X1-1
LWCO
PROBE
CAM
SWITCH
PROPANE LIGHT
NATURAL LIGHT
PROPANE LGPS
NATURAL LGPS
CAM SWITCH
BLOWER PROVING
SWITCH (LARGE)
BLOWER PROVING
SWITCH (SMALL)
BLOCKED FLUE
SWITCH
BLOCKED DRAIN
SWITCH
BLOCK WIRING
IS MODEL
DEPENDANT
SMALL GAS
VALVE RELAY
LARGE GAS
VALVE RELAY
LARGE GAS
VALVE RELAY
SMALL GAS
VALVE RELAY
X11
USB
INTERFACE
BAS
FLUE DAMPER
12
TEST
SWITCH
LWCO RESET
GPS2GPS3
"X5"
SYSTEM PUMP
RELAY
BOILER PUMP
RELAY
DHW PUMP
RELAY
SMALL BLOWER
3
X1-3
M
3
J3-6
J3-3
J2-1
J2-2
X6-5
X6-15
X6-12
X13-1
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
JUNCTION BOX
X1-3
X1-12
X1-1
X1-2
X1-4
X1-8
X2-4
X10-3
X10-6
X10-5
X10-4
X1-3
X1-7
X1-10
X2-5
X6-3
X6-10
X13-4
21
X1-2
FLUE DAMPER
TRANSFORMER
24V
TRANSFORMER
LWCO
BOARD
INTEGRATED
CONTROL
TERMINAL STRIP
120V SUPPLY "N"
1.5A EACH MAX
TERMINAL STRIP
SYSTEM PUMP
CONTACTOR
BOLIER PUMP
CONTACTOR
DHW PUMP
CONTACTOR
SMALL BLOWER RELAY
LARGE BLOWER RELAY
2-01X1-01X
PROPANE
NATURAL
PROPANE
NATURAL
SPARK
GENERATOR
LARGE BLOWER
3
J3-5
J3-2
J3-4
X3-3
X3-4
X3-1
X3-2
X6-11
X6-2
X6-14
X6-13
X6-4
Dual Fuel Supplemental Manual
BOX DEPICTS
OPTIONAL ITEMS
BOX DEPICTS
DUAL SENSOR
SINGLE HOUSING
GROUND
INTEGRATED
CONTROL
FLAME
SENSE 2
SPARK
ROD
FLAME
SENSE 1
21
X4
CN1-4
CN1-5
CN1-6
CN1-12
CN1-10
CN1-11
CN1-9
CN1-8
CN1-7
CN1-1
HIGH LIMIT
CN1-2
SWITCH
CN1-3
Notes:
1. All wiring must be insta lled 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 must be replaced, it must be replaced with wire having same wi re 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 other components.
3. Actual connector block locations may vary from those shown on diagrams. Refer to actual components for proper connector blo ck
locations when using diagrams to troubleshoot unit.
X4-1
X8-20
X4-2
X8-10
X8-1
X4-3
X7-8
X7-7
X8-13
X8-14
X8-12
X8-11
X8-5
X8-15
X8-6
X8-16
X8-7
X8-17
X8-1
X8-3
INLET SENSOR
X8-8
OUTLET SENSOR (S9)
X8-2
OUTLET SENSOR (S1)
X8-4
FLUE SENSOR
X8-9
FLUE SENSOR (S10)
X7-1
PRE-MIX SENSOR 1 (S11)
X7-5
PRE-MIX SENSOR 1 (S13)
X7-2
PRE-MIX SENSOR 2 (S12)
X7-6
PRE-MIX SENSOR 2 (S14)
X6-18
X6-9
X6-17
X6-8
X13-2
X13-3
1
2
3
4
5
6
7
R
8
W
9
10
11
12
13
14
15
16
SMALL
CONNECTION BOARD
BAS
CN3-4
-T
-T
-T
-T
-T
-T
-T
-T
-T
1
2
4
5
1
2
4
5
LG CON BRD
CN6-2
CN6-1
CN6-3
24V
RIBBON CABLE
ALARM
CONTACTS
RUN-TIME
CONTACTS
TANK
THERMOSTAT
ENABLE
LOUVER
PROVING
24 VAC LOUVER
RELAY COIL
AUX
SWITCH 1
AUX
SWITCH 2
X6-3
CN6-3
X6-1
CN6-2
CN6-1
X6-2
CN3-6
CN3-7
CN3-14
CN3-13
CN3-12
CN3-11
CN3-10
CN3-9
CN3-8
CN3-1
CN3-2
CN3-3
CN3-4
SMALL BLOWER
LARGE BLOWER
BAS
WARNING
!
DISCONNECT POWER
BEFORE SERVICING
LOW VOLTAGE
120 VAC
HIGH VOLTAGE
LARGE
CONNECTION BOARD
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
8
43
SW1
J7
J6
J8
J10
J9
J17
J11
J2
J23
J12
E
GND
SHIELD
A
B
SHIELD
+
0-10V
+
0-10V
-
SYSTEM RETURN
SENSOR
SYSTEM SUPPLY
SENSOR
TANK
SENSOR
OUTDOOR
SENSOR
+
0-10V
-
+
0-10V
-
SHIELD
A
B
SHIELD
LCD
DISPLAY
USB CABLE
OPTIONAL USB/WIFI
EXTENSION CABLE
OPTIONAL
ETHERNET CABLE
MODBUS
OPTION
RATE
OUT
BOILER
PUMP OUT
BMS
IN
SYSTEM
PUMP IN
CASCADE
WIFI
DONGLE
100267529 REV A
13
Page 14
3 Diagrams (continued)
Figure 3-3 Wiring Diagram_4.0 Model
A
B
+
0-10V
-
+
0-10V
-
R
R
+
0
-
10V
-
+
0
-10V
-
L
D
A
B
LD
D
ISPL
J
J10
J11
J
2
E
GND
E
E
W
IL
X
LARGE CONNECTION BOARD
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
L
C
D
AY
COMMUNICATIO
CONTROL BOARD
8
3
4
USB
S
W1
6
J
7
J
8
J
9
J17
O
PTIO
EXTENSION CABLE
J23
J12
ETHERNET CABLE
SM
ALL
CONNE
1
2
3
4
5
6
R
7
8
9
10
11
12
13
14
15
16
L
WCO
PRO
BE
O
SWITCH
SWITCH
N
CABL
NAL
OPTIONAL
C
R/BK
LWCO RESET
C
AM
BL
B
L
BL
BL
CAM
CN3-14
CN3-13
CN3-12
CN
CN
E
U
SB
TION
CN
CN1
CN
TEST
SWIT
PRO
O
OWER PRO
O
O
CKED DRAIN
PR
O
NATURAL LIGH
M
PUMP OUT
SYSTEM RETURN
SY
STE
SYSTEM
PUM
CASCAD
L
G
CON
BRD
CN
6
-2
CN6
-1
CN6-3
CONTA
C
THER
24
VAC LOUVER
RE
SH
O
DBUS
O
PTION
SHIELD
RATE
OUT
BO
ILE
SENSOR
M
SUPPLY
SENSOR
SENSO
O
UTDOOR
SENSO
BM
P IN
S
S
BAS
R
PR
G
Y
ALARM
RU
N-TIM
ONTACTS
M
OSTAT
ENABL
LO
UVER
PRO
L
AY CO
SWITCH 1
SWITCH 2
TANK
H
TANK
VING
IELD
R
S
IN
H
I
E
E
I
E
24V
CTS
AU
AUX
CN6-3
CN6-2
CN6-1
CN3-4
CN3-6
CN3-7
3
-11
3
-10
CN3-9
CN3-8
CN3-1
CN
3
-2
CN3-3
CN3-5
WI
F
I
DONGLE
/WIFI
BOARD
CN
1
-4
CN
1
-5
CN
1
-6
1
-12
-10
1
-11
CN
1
-9
CN
1
-8
CN
1
-7
CN1
-1
CN
1
-2
CN
1
-3
C
H
PAN
NATUR
WER PRO
CKED FLU
PANE
GY
R
PR
O
OUTLET SENSOR (S1)
FLUE SENSO
PRE-M
PRE-M
PRE-M
PRE-M
O
R
/
BK
OR
O
R
E LG
PS
OR
A
L
LGPS
VING
SWI
VING
SWI
E SWITC
SWITCH
LIGHT
T
BAS
X1-1
X1-2
X1-3
X6-3
X6-1
X6-2
X4-1
X4-2
X4-3
INLET SENSO
UT
LET SENSO
FLU
E SENSO
IX SENSOR 1
IX SENSOR
IX SENSOR
IX SENSOR
HIG
H
L
SWITCH
R
LWCO
B
OARD
J
3
-6
J
3-5
J
3-4
J
3
-3
J
3
-2
J
2
-1
J
2-2
TC
H
TCH
(SM
H
CAM
BL
O
CK WIRING
IS M
DEPENDEN
Dual Fuel Supplemental Manual
BOX D
EPICT
S
OPTIONAL ITEMS
BO
X DEPICTS
D
UAL S
EN
SINGLE HOUSING
INTEG
RATED CONTROL
BK
X8-20
T
X8-10
BL
X7-8
X7-7
R
BL
X8-13
R
X8-14
BR
X8
-12
X8
W
OR
O
R/W
P
W
BL
B
K
Y/
BK
T
-
R
-
T
R
(S9
-
T
-
T
R
T
-
R
(S10)
T
-
(
S11)
T
-
1
(S13)
T
-
2 (S12)
-
T
2
(S14)
-11
X8-5
X8
-15
X8
-6
X8
-16
X8
-7
X8-17
X8
-18
X8
-1
BL
X8
-3
X8-8
R/W
)
R
X8
-2
X8
-4
W
G
Y
X8
-9
G
Y
X7
-1
BR
X7
-5
X7-2
BK
T
X7-
6
X1
X10-1
X10
X10
X10X10-3
X1
-6
X1
-3
-12
-
4
PR
X1
-1
X1
-2
X1
-4
O
-2
5
N
ON/OFF
S
W
ITCH
BK
W
G
T
R
X10-3
X
4
Y
BL
R
R
OR
OR
BL
BK
BR
R
Y
O
R
IM
IT
BL
R
O
R
G
OR
(L
AR
G
E)
ALL
)
SWI
TCH
"X5"
O
DEL
T
X3
X3-4
X3-1
X3
X6
X6
X6
X6-14
X6-10
X6-13
X6
X6
PS3GPS2
BR
X6
OR
X6
-15
T
X6
PR
X13
BK
X6
X5
X5
X5
X5
X5-3
X5
X5
X5
X5
X5
X5
X5
X10-6
R
X6
-18
BK
X6
-8
X1-8
-3
-2
-1
-11
-2
GY
R
1
W
X6
-9
X6
-17
T
T
X2
-4
R2
-4
X13
2
-
W/BK
T
X13-3
R
X2
-3
X1
-7
R
SPARK
G
ENERATO
R
R
X1
-1
-3
0
P
X1
-5
FLUE DAM
PER
TR
ANSFORMER
X2
-5
BK
-5
X13-4
-12
-1
-6
-1
-7
-2
-8
-9
-4
-10
-5
-41
-6
-12
X1
1
US
B
INTE
RFACE
DISCONNECT POWER
S
OR
LOW VOLTAGE
120 VAC
HIGH VOLTAGE
208V 3Ø
L3
L2
L1
R
BL
B
K
CAM
SWI
C
SW
BK/W
BL
Y
OR
T
R
B
L
Y
WARNING
!
BEFORE SERVICING
1.5
A EACH
S
YST
CONTACTOR
B
O
IL
CONTACTOR
DH
W
C
ONTACTOR
OR/BK
OR
/
W
TCH
SMA
L
L
SM
NATURAL
PROPA
VAL
VE
VAL
R/BK
R/W
A
M
ITCH
L
ARGE
L
ARGE
PRO
PA
NA
TURAL
VAL
VAL
VE
R1
1
2
3
BLOW
ER
(SM
ALL)
2
5
1
3
4
R2
R/W
123
4
BLOWE
R
(LARG
E)
2
1
5
43
FLAME
SEN
SE 2
SPARK ROD
FLAME
SEN
SE
1
FL
U
E
D
AM
PER
1
M
2
3
24V
ANSFO
RM
ER
MAX
E
M
PUM
P
E
R
PUM
P
PUM
P
J
UNC
T
IO
N
BOX
G
N
AL
L
N
E
V
E
N
E
VE
G
ND
Note
s
:
1
.
All
w
ring
i
mu
s
t b
2. If an
y
ori
g
i
n
a
l
e
m
n
i
m
i
u
m
o
f 1
0
5
°C
o
r r
i
bbo
n
c
a
b
l
e
s
ca
3
.
A
c
tu
a
c
l
o
n
n
e
c
d
a
i
g
ra
m
s
to tro
u
b
14
e
i
n
s
tal
ed
l
i
n
a
c
cord
a
n
c
e
wi
th
:
loc
a
, sta
l
te
, pro
v
n
i
c
ia
a
l
n
d
n
a
ti
o
n
a
l
co
d
e
re
q
u
i
re
m
e
n
ts p
e
r e
th
i
e
r N.E.C. i
n
USA
o
C.S.A. i
r
n
Ca
n
a
d
a
q
u
i
p
m
e
n
t
wi
re
a
s s
u
p
p
lie
d
with
th
e
a
p
p
a
l
i
n
c
e
m
u
s
t
b
e
re
p
l
a
c
e
d
, i
t
m
u
s
t
b
e
re
p
a
l
c
e
d
w
th
i
w
re
i
h
a
vin
g
sa
m
e
wire
. Ex
c
e
p
t
i
o
n
s
:
Re
p
a
l
c
e
m
e
n
t
h
g
i
h
v
o
ltag
e
s
p
a
rk l
e
a
d
a
n
d
ribb
o
n
ca
b
e
l
s
m
u
s
t
b
e
p
u
rc
h
a
s
e
n
l
e
a
d
to
o
p
e
ra
t
i
o
n
a
l
p
ro
b
e
l
m
s
wh
i
c
h
co
u
l
d
re
s
u
t i
l
n
n
o
n
-re
p
a
ra
i
b
e
l
d
to
r
b
o
l
c
k
l
o
c
a
tio
n
s
m
a
y v
a
ry
fro
m th
o
s
e
sh
o
wn
o
e
l
s
h
o
o
t u
n
i
t.
n d
a
a
i
g
ra
m
s
.
Re
f
e
r to a
c
d
m
a
g
e
to th
e
i
n
te
g
ra
te
tu
a
l
co
m
p
o
n
e
n
ts
fo
r pro
from
t
h
e
fa
c
tory.
Use
d
co
n
tro
le
l
o
r
r o the
r co
p
e
r co
n
n
e
c
to
r b
l
oc
.
ga
u
g
e
(AW
G) a
n
d
ra
t
ed
fo
o
f a
m
p
k
loc
r a
no
n
-a
p
p
ro
v
e
d
s
p
a
rk
lea
o
n
e
n
a
ti
o
n
d
t
s.
s
wh
e
n
u
s
n
i
g
1
00
2
6
75
3
0
R
E
V
C
Page 15
3 Diagrams (continued)
Figure 3-4 Ladder Diagram_4.0 Model
Dual Fuel Supplemental Manual
L
1
2
L
L3
TERMINAL STRIP
208V 3
ON/OFF
SWITCH
N BOX
O
I
JUNCT
SUPPLY
O
INTEGRATED CONTROL
X1-3
X1-12
F4
2
F
X1-6
3.15 A
SYSTEM
5.0 A
RELAY
LER PUMP
BOI
ELAY
R
DHW PUMP
ELAY
R
PUMP
X1-1
X1-2
X1
X1
X2-4
X
VE RE
VAL
LARGE
VALVE
RGE
LA
VE
VAL
SMALL GA
LVE RE
VA
LAY
S
A
G
X10-
Y
A
L
RE
GAS
X10-
LAY
RE
S
X10
Y
A
L
S
SMALL GA
1X10-2
-
10
X10-
X1
X1-7
X1
X2
X6
BLOWER
L
AL
LARGE BLOWER
CONTACTOR
PER
3
T
J3-6
J3-3
J2-1
J2-2
X6-5
6-15
X
6-12
X
13-1
X
-6
X6
X5-1
-7
X5
RANS
X1-1X
21
2-1
24V
F
LWC
ARD
BO
TEGRATE
N
I
CO
X6-10
X13
1
2
3
ORMER
X6-1
-5
X2
L
L
A
M
S
RELA
BLOWER
1
X1
B
US
TERFACE
IN
M
S
Y
3
BAS
X1-3
M
A
LUE D
F
12
M
T
ES
T
WCO
L
P
CA
W
S
ITCH
SW
CAM
BLOW
SWI
LOWER
B
WI
S
LO
B
BLO
RO
I
T
T
T
SW
CK
S
B
M
CH
PRO
N
R
E
CH
CH
K
C
ED
WI
E
LWCO
PROPANE
URA
T
NA
PANE LG
RAL
U
AT
PROV
(LA
OVI
R
P
(SMA
FLUE
D
E
TCH
I
DRA
CH
T
CH
T
I
W
S
RESET
LIGHT
T
H
G
I
L
L
S
P
PS3
2G
PS
G
PS
G
L
NG
I
)
E
RG
NG
LL)
N
I
X5-2
X5-8
-3
X5
WI
NDENT
X5-9
NG
RI
X5-4
5-10
X
"X5"
CK
BLO
MODEL
S
I
E
DEP
-4
-8
3
6
-5
4
-3
-10
-5
-3
-4
LARGE BLO
LUE D
F
RANSFO
T
O
NTROL
ALL
SM
LARGE BLO
SPAR
GENERATOR
AM
R
J
J
J
D
TERMINAL STRI
208V SUPPLY "N"
1.5A EACH MAX
TERMINAL STRIP
SYSTEM PUMP
CONTACTOR
BOILER PUMP
CONTACT
HW PUMP
D
CONTACTOR
BLOWER
WER
NATURAL
PROPANE
ATURA
N
K
E
W
PER
ER
M
5
-
3
2
-
3
4
-
3
X3-3
X3-4
1
X3-
X3-2
X6-11
X6-2
14
X6-
X6-13
X6-4
X5-5
-41
5
X
X5-6
5-12
X
C
PROPANE
L
R
4
Not
1.
in
2.
3.
OR
RELA
NTACTOR
O
FLAM
SENSE
SPARK
FLA
SENSE
HIG
S
:
es
ll wiring m
A
A
US
any
f
I
wire gauge
be purchased
ust
m
h
c
whi
ua
t
c
A
onnect
c
NEUTRAL
P
Y
E
2
ROD
E
M
1
M
LI
H
WITCH
S
C.
or
iginal
or
A
(
could result
onnect
c
l
lock
or b
T
I
us
A
.
WG)
CN1-4
CN1-5
CN1-6
N1-12
C
1-10
N
C
N1-11
C
CN1-9
CN1-8
CN1-7
CN
CN1-2
CN1-3
installed
be
t
Canada
in
.
equipment
and rated
rom
f
n
in
block
r
o
locations
INTEGRA
CO
1-1
he f
t
on-repa
locations
when
.
wire as
N
GROUND
T
OL
R
T
X4
accordanc
in
a
or
f
or
t
ac
irable dam
us
y.
i
ED
upp
s
m
m
ng
X8-20
X8
X8
X8-1
X7
X7
X8-13
X8-14
X8
X8-11
X8-5
X8
X8
X8
X8
X8-17
X8-18
X8
X8-
X8-2
X8-
X8-9
X7-1
X7-5
X
X
X6
X
X6-17
X
X13-2
X13-3
1
2
3
4
5
6
7
8
9
1
1
1
1
1
1
1
inim
Us
ay
diagrams
-
-
I
7
7
6
6-8
0
1
2
3
4
5
6
lied
var
1
1
-12
-15
-16
NLET
-18
um
e
age
X4-1
0
0
-8
-7
-6
-7
-3
8
4
-2
-6
-9
SMA
CONNEC
wit
e
w
of
of
y
B
-3
-2
X4
X4
CN3-4
SENSOR
OUTLET
UTLET SENS
O
FLUE
PRE-M
-M
PRE
PRE-M
-M
PRE
LG
R
W
L
local,
h:
he appli
t
h
it
105
non-
a
he
t
o
t
t
rom
f
o t
t
AS
-1
X6
X6-2
-T
SENSOR
LUE SENSOR
F
SENSOR (S10)
X SENSOR 1
I
X SENSOR
I
X SENSOR
I
X SENSOR
I
1
4
2
5
1
4
2
5
N BRD
CO
6-2
CN
CN6-1
6-3
CN
BO
B
RI
L
N
O
I
T
at
t
s
nc
a
Exc
°C.
approved spark
at
egr
int
show
hose
leshoot
oub
r
D
BOX
PTIONAL ITEM
O
OX DE
B
DUAL
LE HOUS
NG
I
S
X6-3
C
CN6-3
2
-
6
CN
CN6-1
6
-
CN3
7
CN3-
CN3-1
CN3-1
12
-
CN3
CN3-1
CN3-1
-
CN3
-
3
CN
CN3-1
-
CN3
CN3-
-
CN3
T
-
-T
O
T
-
T
-
-T
T
-
T
-
T
-
BA
4V
2
CABLE
N
ALARM
NT
CO
RUN-
NT
CO
K
N
A
T
HERMO
T
ENABLE
UVE
LO
V
PRO
VA
24
RELAY
AUX
T
SWI
AUX
T
SWI
AR
BO
provi
e,
us
m
e
ions:
ept
contro
ed
on di
n
un
SENS
9
8
2
3
4
R
T
CH
CH
EPICTS
O
4
3
1
0
1
2
2
ACT
ACT
I
C
it
S
DISCONNECT POWER
PICTS
OR
ING
LOW VOLTAGE
120 VAC
HIGH VOLTAGE
LARGE
NNECTION BOARD
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
)
(S9
S1)
(
(S11)
(S13)
(S12)
S14)
(
WER
BLO
L
L
A
SM
BLOWER
LARGE
J6
S
10
J
J11
J2
J12
E
GND
S
E
M
I
S
T
A
T
S
R
NG
R
UVE
LO
L
I
CO
1
2
D
ional
nat
and
ial
nc
it
ed,
ac
pl
re
be
t
Replacement
or ribbon
lead
om
c
r
he
or ot
er
ll
er
ef
R
s.
am
agr
.
!
WARNING
BEFORE SERVICING
D
SHIEL
A
MODBU
T
OP
B
ELD
HI
S
+
RATE
0-10V
OUT
-
+
L
BOI
10V
0-
UM
P
-
SYSTEM
SOR
N
SE
SYSTEM
SENSOR
TANK
R
SO
SEN
DOOR
OUT
NSOR
SE
+
BMS
-10V
0
-
N
I
+
SYSTEM
0-10V
M
PU
-
SHIELD
A
CASCADE
B
ELD
SHI
LCD
LAY
SP
DI
8
3
4
CABLE
USB
SW1
7
J
J8
J9
J17
US
OPTIONAL
J23
ode
c
ust
m
high
ables
c
ponent
o
t
voltage
ac
equ
r
be replac
an
c
s
l
ua
t
ON CABLE
I
NS
E
T
EX
A
TION
OP
CAB
ET
RN
HE
ET
e
per
t
s
iremen
wire hav
h
wit
ed
and ribbon
ead
l
park
s
onal problems
i
o operat
lead t
.
or
f
s
ponent
om
c
1
O
I
E
P
RETU
SUPPLY
P
DO
L
her
it
prope
0
0
S
N
R
OUT
RN
N
I
I
WIF
E
L
NG
WIFI
/
B
LE
C.
N.E.
ame
s
ing
es
l
ab
c
r
A
REV
8
2
5
7
6
2
15
Page 16
(
S
13
)
T
T
S
XX4
3 Diagrams (continued)
Figure 3-5 Wiring Diagram_5.0 Model
Dual Fuel Supplemental Manual
MODBUS
PUMP OUT
SYSTEM RETURN
SYSTEM SUPPLY
SYSTEM
PUMP IN
CASCADE
LG CON BRD
CN6-2
CN6-1
PR
GY
CN6-3
CONTACTS
CONTACTS
THERMOSTAT
24 VAC LOUVER
RELAY COIL
SHIELD
OPTION
SHIELD
RATE
OUT
BOILER
SENSOR
SENSOR
TANK
SENSOR
OUTDOOR
SENSOR
BMS
SHIELD
SHIELD
BAS
R
24V
ALARM
RUN-TIME
TANK
ENABLE
LOUVER
PROVING
SWITCH 1
SWITCH 2
BOX DEPICTS
OPTIONAL ITEMS
BOX DEPICTS
DUAL SENSOR
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
X2-4
X13-2
X13-3
X2-3
X1-7
X1-10
X1-5
X2-5
X13-4
X11
USB
INTERFACE
SINGLE HOUSING
ON/OFF
SWITCH
RP
T
RO
RO
LB
R
LB
R
KB
YG
1R
W
T
T
2R
T
R
R
SPARK
GENERATOR
R
P
FLUE DAMPER
TRANSFORMER
KB
KB/W
BAS
LARGE CONNECTION BOARD
17
A
18
B
19
20
21
+
0-10V
22
23
+
0-10V
24
25
26
27
28
29
30
31
32
33
+
0-10V
-
IN
34
35
+
0-10V
36
37
A
38
B
39
40
LCD
DISPLAY
COMMUNICATION
CONTROL BOARD
8
SW1
J6
J7
J8
J10
J9
J17
J11
J2
J23
J12
E
GND
43
USB CABLE
OPTIONAL USB/WIFI
EXTENSION CABLE
OPTIONAL
ETHERNET CABLE
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
WIFI
DONGLE
SMALL CONN ECTION BOARD
1
2
3
4
5
6
R
7
W
8
9
10
11
12
LWCO
PROBE
13
14
15
16
AUX
AUX
KB/RO
LWCO RESET
CAM
SWITCH
BLOWER PROVING
SWITCH (LARGE)
BLOWER PROVING
SWITCH (SMALL)
BLOCKED FLUE
BLOCKED DRAIN
CAM
SWITCH
PROPANE LIGHT
NATURAL LIGHT
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
PROPANE LGPS
NATURAL LGPS
SWITCH
SWITCH
X1-1
X1-2
X1-3
X6-3
YG
X6-1
R
X6-2
RP
X4-1
X4-2
X4-3
-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)
-T
PRE-MIX SENSOR 2 (S12)
-T
PRE-MIX SENSOR 2 (S14)
HIGH LIMIT
SWITCH
R
LWCO
BOARD
J3-6
J3-5
J3-4
J3-3
KB/RO
J3-2
J2-1
RO
RO
J2-2
GPS3
GPS2
OR
OR
RO
T
RP
KB
CAM SWITCH
"X5"
BLOCK WIRING
IS MODEL
DEPENDENT
INTEGRATED CONTROL
X8-20
KB
T
X8-10
X7-8
LB
X7-7
R
LB
X8-13
R
X8-14
RB
X8-12
X8-11
W
RO
X8-5
W/RO
X8-15
P
X8-6
X8-16
W
LB
X8-7
KB
X8-17
KB/Y
X8-18
X8-1
X8-3
LB
X8-8
W/R
R
X8-2
X8-4
W
YG
X8-9
YG
X7-1
RB
X7-5
X7-2
KB
X7-6
T
X4
LB
Y
R
X3-3
R
X3-4
RO
X3-1
RO
X3-2
X6-1
LB
X6-11
KB
RB
X6-2
R
X6-14
X6-10
Y
X6-13
RO
LB
X6-4
R
RO
X6-3
X6-5
BR
X6-15
X6-12
X13-1
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
WARNIN G
!
DISCONNECT POWER
BEFORE SERVICING
LOW VOLTAGE
120 VAC
HIGH VOLTAGE
208V 3
L3
L1
N
L2
BL
R
BK
KB
W
G
CAM
SWITCH
CAM
SWITCH
R/W
BK/W
LB
Y
RO
TRANSFORMER
BL
Y
1.5A EACH MAX
OR/BK
OR/W
SMALL
NATURAL
VALVE
R/BK
R/W
LARGE
NATURAL
VALVE
1R
231
BLOWER
(SMALL)
124
5
3
2R
231
BLOWER
(LARGE)
1245
3
FLAME SENSE 2
SPARK ROD
FLAME SENSE 1
FLUE DAMPER
1
M
2
3
24V
SYSTEM PUMP
CONTACTOR
BOILER PUMP
CONTACTOR
DHW PUMP
CONTACTOR
JUNCTION
BOX
SMALL
PROPANE
VALVE
LARGE
PROPANE
VALVE
GND
NG
16
Notes:
1. All wiring must be installed in accordance with: local, state, provincial and n ational 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 app liance must be replaced, it must be replaced with wire having sam e wire gauge (AWG) and rated for a
minimum of 105°C. Exceptions: Replacement high vo ltage spark lead and ribbon cables must be purchased from the factory. Use o f a non-approved spark lead
or ribbon cables can lead to operational problems which could result in non-repairable dam age to the integrated controller or other components.
3. Actual connector block locations may vary from those shown on di agrams. Refer to actual components for proper connector block locations when using
diagrams to troubleshoot unit.
100267552 REV A
Page 17
3 Diagrams (continued)
Figure 3-6 Ladder Diagram_5.0 Model
Dual Fuel Supplemental Manual
L1
L3
L2
TERMINAL STRIP
208V 3Ø SUPPLY
ON/OFF
SWITCH
X1-6
3.15 AF45.0 A
X10-1 X10-2
X6-1
X2-5
SMALL BLOWER
CONTACTOR
LWCO
PROBE
CAM
SWITCH
PROPANE LGPS
NATURAL LGPS
CAM SWITCH
BLOWER PROVING
SWITCH (LARGE)
BLOWER PROVING
SWITCH (SMALL)
BLOCKED FLUE
SWITCH
BLOCKED DRAIN
SWITCH
BLOCK WIRING
INTEGRATED CONTROL
F2
SMALL GAS
VALVE RELAY
LARGE GAS
VALVE RELAY
LARGE GAS
VALVE RELAY
SMALL GAS
VALVE RELAY
INTERFACE
1
2
3
FLUE DAMPER
12
TEST
SWITCH
LWCO RESET
PROPANE LIGHT
NATURAL LIGHT
GPS2GPS3
"X5"
IS MODEL
DEPENDENT
SYSTEM PUMP
BOILER PUMP
DHW PUMP
X11
USB
SMALL BLOWER
4
BAS
X1-3
M
J3-6
J3-3
J2-1
J2-2
JUNCTION BOX
RELAY
RELAY
RELAY
LARGE BLOWER
CONTACTOR
2-1X1-1X
3
TRANSFORMER
LWCO
BOARD
INTEGRATED
X6-5
X6-15
X6-12
X13-1
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
X1-3
X1-12
X1-1
X1-2
X1-4
X1-8
SMALL BLOWER CONTACTOR
X2-4
LARGE BLOWER CONTACTOR
X10-3
X10-6
X10-5
X10-4
X1-3
X1-7
SPARK
X1-10
GENERATOR
X2-5
X6-3
X6-10
X13-4
LARGE BLOWER
1
2
3
FLUE DAMPER
TRANSFORMER
24V
J3-5
J3-2
J3-4
CONTROL
X6-11
X6-14
X6-13
NEUTRAL
TERMINAL STRIP
208V SUPPLY "N"
1.5A EACH MAX
TERMINAL STRIP
SYSTEM PUMP
CONTACTOR
BOILER PUMP
CONTACTOR
DHW PUMP
CONTACTOR
PROPANE
NATURAL
PROPANE
NATURAL
FLAME
SENSE 2
SPARK
ROD
FLAME
SENSE 1
4
X3-3
X3-4
X3-1
X3-2
X6-2
HIGH LIMIT
X6-4
SWITCH
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 applianc e must 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 other 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.
CN1-4
CN1-5
CN1-6
CN1-12
CN1-10
CN1-11
CN1-9
CN1-8
CN1-7
CN1-1
CN1-2
CN1-3
GROUND
INTEGRATED
CONTROL
X4
X8-20
X8-10
X8-1
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
X8-3
X8-8
X8-2
X8-4
X8-9
X7-1
X7-5
X7-2
X7-6
X6-18
X6-9
X6-17
X6-8
X13-2
X13-3
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
DUAL SENSOR
SINGLE HOUSING
BAS
X4-1
X4-3
X4-2
X6-1
X6-2
CN3-14
CN3-13
CN3-12
CN3-11
CN3-10
CN3-4
-T
INLET SENSOR
OUTLET SENSOR (S9)
OUTLET SENSOR (S1)
FLUE SENSOR
FLUE SENSOR (S10)
PRE-MIX SENSOR 1 (S11)
PRE-MIX SENSOR 1 (S13)
PRE-MIX SENSOR 2 (S12)
PRE-MIX SENSOR 2 (S14)
1
2
4
5
1
2
4
5
LG CON BRD
CN6-2
CN6-1
CN6-3
RIBBON CABLE
ALARM
CONTACTS
RUN-TIME
CONTACTS
TANK
THERMOSTAT
R
ENABLE
W
LOUVER
PROVING
24 VAC LOUVER
RELAY COIL
AUX
SWITCH 1
AUX
SWITCH 2
SMALL
CONNECTION BOARD
BOX DEPICTS
OPTIONAL
ITEMS
BOX DEPICTS
LARGE
X6-3
CONNECTION BOARD
CN6-3
CN6-2
CN6-1
CN3-6
CN3-7
CN3-9
CN3-8
CN3-1
CN3-2
CN3-3
CN3-4
-T
-T
-T
-T
-T
-T
-T
-T
SMALL BLOWER
LARGE BLOWER
BAS
J10
J2
24V
WARNING
!
DISCONNECT POWER
BEFORE SERVICING
LOW VOLTAGE
120 VAC
HIGH VOLTAGE
17
18
19
20
21
0-10V
22
23
0-10V
24
25
26
27
28
29
30
31
32
33
0-10V
34
35
0-10V
36
37
38
39
40
8
43
SW1
J6
J7
J8
J9
J17
J11
GND
OPTIONAL USB/WIFI
J23
J12
E
ETHERNET CABLE
SHIELD
A
MODBUS
OPTION
B
SHIELD
+
RATE
OUT
-
+
BOILER
PUMP OUT
-
SYSTEM RETURN
SENSOR
SYSTEM SUPPLY
SENSOR
TANK
SENSOR
OUTDOOR
SENSOR
+
BMS
-
IN
+
SYSTEM
PUMP IN
-
SHIELD
A
CASCADE
B
SHIELD
LCD
DISPLAY
DONGLE
USB CABLE
EXTENSION CABLE
OPTIONAL
100267527 REV A
WIFI
17
Page 18
Notes
Dual Fuel Supplemental Manual
18
Page 19
Notes
Dual Fuel Supplemental Manual
19
Page 20
Revision Notes: Revision A (ECO #C08841) initial release.
Revision B (EC) #C10391) reflects the update of wiring and
ladder diagrams on pages 12 and 13.
Revision C (ECO C11685) reflects the addition of models
4.0 and 5.0.
Revision D (Change #500001029) reflects the removal of
Models 1.5 and 2.0 along with updates to the control.
FBD-SUP_MM #100161023_DIR #2000004585 Rev D
10/15
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