Lochinvar Crest OFN2001, Crest OFN001, Crest OFN1751, Crest OFN3501, Crest OFN2501 Supplemental Manual

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Page 1

100302418_2000555704 Rev C

Outdoor Crest Supplemental Manual

Models: OF 751 - 6001

⚠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 OUTDOOR CREST -- HOW IT WORKS ............. 4-5

RATINGS .......................................................................... 6

1. DETERMINE BOILER LOCATION

Installation Must Comply With: ............................................ 7

Before Locating the Boiler, Check: .....................................7

Provide Clearances .............................................................8

Prevent Combustion Air Contamination .............................. 8

Remove Boiler from Wood Pallet ........................................ 8

Install Outdoor Vent Kit .......................................................9

Outdoor Venting ................................................................ 10

Outdoor Vent/Air Inlet Location ......................................... 10

2. GAS CONNECTIONS

Gas Supply ........................................................................ 11

Connecting Gas Supply Piping ....................................11-12

Natural Gas: ...................................................................... 12

Propane Gas: .................................................................... 12

Check Inlet Gas Supply .............................................. 13-14

Gas Valve Replacement ................................................. 14

3. START-UP

Pre-Commissioning Cleaning ........................................... 15

Fill Water ........................................................................... 15

Boiler Water...................................................................... 15

Oxygen Prevention .......................................................... 16

Check for Gas Leaks ........................................................16

Check Thermostat Circuit(s) ............................................. 17

Inspect Condensate System .............................................17

Final Checks Before Starting the Boiler ............................17

Start the Boiler .................................................................. 17

If Boiler Does Not Start Correctly ...................................... 17

Check System and Boiler .................................................. 17

Check Flame and Combustion .......................................... 18

Operating Instructions ....................................................... 19

4. DIAGRAMS

Ladder Diagram 751 - 2001 Models .................................20

Wiring Diagram 751 - 2001 Models ..................................21

Ladder Diagram 2501 - 3501 Models ...............................22

Wiring Diagram 2501 - 3501 Models ................................23

Ladder Diagram 4001 - 5001 Models ...............................24

Wiring Diagram 4001 - 5001 Models ................................25

Ladder Diagram 6001 Model ............................................26

Wiring Diagram 6001 Model .............................................27

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

Outdoor Crest 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 Outdoor Crest - How it works...

Outdoor Crest Supplemental Manual

1. Front access panels

Provides access to the controls compartment.

2. Top access panel

Provides access to the burner compartment.

3. Optional outdoor air inlet hood assembly (shipped

separately with outdoor installation kits) The hood assembly is required when installing outdoors for combustion air to prevent rain and debris from entering the air inlet.

4. Boiler drain connection

Location from which the heat exchanger can be drained.

5. Condensate drain connection

The condensate drain connection provides a connection point to install a condensate drain line using flexible hose provided.

6. Condensate trap box (shipped separately with outdoor

installation kits)

The condensate trap box comes assembled inside the outdoor installation kit. The condensate trap box is required for outdoor installations to protect/house the condensate trap.

7. Control module (on control panel assembly)

The control module responds to internal and external signals and controls the blower, gas valves, and pump(s), depending on the application, to meet the heating demand.

8. Electronic display

Digital controls with SMART TOUCH screen technology, full color display, and an 8" user interface screen.

9. Gas connection pipe

The gas connection pipe is a threaded black iron pipe connection (see Gas Connections Section for specific model pipe size requirements). This pipe should be connected to the incoming gas supply to deliver gas to the boiler.

10. Gas shutoff valve (inside unit)

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

11. Gas valves

The gas valves sense the negative pressure created by the blower, allowing gas to flow only if the gas valves are powered and combustion air is flowing.

12. Condensate trap

The condensate trap is sized for a 1" PVC outlet connection pipe.

13. Line voltage junction box

The line voltage junction box contains the connection points for the line voltage power to the boiler (and pumps if used).

14. Line voltage wiring connections

Conduit connection points for the high voltage junction box.

15. Low gas pressure switch

Monitors gas supply pressure to the boiler and shuts the boiler down in the event a low gas pressure condition occurs.

16. High gas pressure switch

Monitors gas supply pressure to the boiler and shuts the boiler down in the event a high gas pressure condition occurs.

17. Low voltage connection board(s)

Connection boards used to connect external low voltage devices.

18. Low voltage wiring connections (knockouts)

Conduit connection points for the low voltage connection

boards.

19. Power switch

The On/Off power switch provides the ability to turn line voltage

power to the boiler on and off.

20. Relief valve

The safety relief valve protects the heat exchanger from an over pressure condition. The boiler comes with a 50 PSI relief valve as

standard equipment. Optional settings are available.

21. Reset switch

Reset switch for the low water cutoff. Hold the switch for 10 seconds to reset.

22. Test switch

The test switch permits manual triggering of the LWCO safety circuit to test the contacts and evaluate the integrity of the circuit. Hold the switch for 10 seconds to test.

23. Firetube heat exchanger

High grade stainless steel WAVETM firetube design that extracts heat from flue gases and transfers it directly into boiler water.

24. Temperature and pressure gauge

Monitors the outlet temperature of the boiler as well as the system water pressure.

25. Venturi (not shown)

The venturi controls air and gas flow into the burner.

26. Water inlet

An ANSI flange connects the return water from the system to the

heat exchanger.

27. Water outlet

An ANSI flange connects the hot water supply from the boiler to

the system.

28. Flame inspection window (not shown)

Two large high temperature quartz observation windows provide views of the burner surface during firing.

29. Air metering valve

The air metering valve is used to control the amount of air used

when firing.

30. Air metering valve air pressure switch

The air metering valve air pressure switch is used to ensure the air metering valve is open when firing gas valve 2.

31. Vent support (shipped in the ship loose parts box with each

unit)

The vent support is required for outdoor installations to support the vent piping.

32. Air pressure switch

The air pressure switch detects blocked flue/vent conditions.

Page 5

Outdoor Crest Supplemental Manual

2000549892 0

The Outdoor Crest - How it works... (continued)

20 24 27

Front View

2000549892 0

DIR #2000549892 0

DIR #2000549906 00

Rear View

13 14

Left Side (inside unit)

DIR #2000549908 00

22 21

Right Side (inside unit)

DIR #2000549910 00

Page 6

Ratings

Outdoor Crest Supplemental Manual

Outdoor Crest

AHRI Rating

Model Number

Note: Change “N” to

“L” for L.P. gas models.

Min Max

OF(N,L)0751 50 750 720 626

OF(N,L)1001 50 999 960 835

OF(N,L)1251 62 1250 1200 1043

OF(N,L)1501 60 1500 1440 1252

OF(N,L)1751 70 1750 1680 1460

OF(N,L)2001 80 1999 1920 1670

OF(N,L)2501 125 2500 2403 2089

OF(N,L)3001 150 3000 2880 2504

OF(N,L)3501 175 3500 3360 2922

OF(N,L)4001 333 3999 3840 3339

OF(N,L)5001 500 4999 4800 4174

OF(N,L)6001 600 6000 5760 5009

Input MBH

(Notes 4 - 8)

Gross

Output

MBH

(Note 1)

Net

AHRI

Ratings

Water,

MBH

(Note 2)

Other Specifications

Boiler Water

Content Gallons

73 3" 1 1/4"

77 3" 1 1/4"

87 3" 1 1/2"

94 4" 1 1/2"

106 4" 1 1/2"

111 4" 1 1/2"

157 4" 2"

156 4" 2"

202 4" 2"

201 4" 2 1/2"

254 6" 2 1/2"

304 6" 2 1/2"

Water

Connections

Gas

Connections

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. Standard Outdoor 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.

4. Ratings have been confirmed by the Hydronics Section of AHRI.

5. Outdoor Crest boilers comply with the requirements of CSD-1 Section CW-400 requirements as a temperature operation control. The manual reset high limit provided with the Outdoor Crest is listed to UL353.

Page 7

1 Determine boiler location

Installation must comply with:

• Local, state, provincial, and national codes, laws, regulations, and ordinances.

• National Fuel Gas Code, ANSI Z223.1 – latest edition.

• Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1, when required.

• National Electrical Code.

NOTICE

⚠WARNING

Before locating the boiler, check:

1. Check for nearby connection to:

• System water piping

• Gas supply piping

• Electrical power

2. - Keep venting areas free of obstructions.

- Keep area clean and free of combustible and flammable

materials.

- To avoid a blocked air inlet or blocked flue condition,

keep the outdoor air inlet and flue outlet clear of leaves, debris, etc.

CAUTION

The Outdoor Crest gas manifold and controls met safe lighting and other performance criteria when the boiler underwent tests specified in ANSI Z21.13 – latest edition.

Outdoor models must be installed outdoors only and must use the outdoor air inlet hood assembly along with the vent termination cap supplied by the manufacturer. Personal injury or product damage may result if any other venting is used or if an outdoor model is used indoors. All covers, doors and jacket panels must be properly installed to ensure proper operation and prevent a hazardous condition.

This product contains a condensate management and disposal system that may be subject to freezing if exposed to sustained temperatures below 32°F. Precautions should be taken to protect the condensate trap and drain lines during extended periods of outdoor temperatures below 32°F.

The Outdoor Crest is NOT suitable for installation in areas which may experience temperatures below 32°F.

Do not install outdoor models directly on the ground. You must install the outdoor unit on a level concrete, brick, block, or pressure-treated wood platform.

Outdoor Crest Supplemental Manual

⚠ CAUTION

⚠CAUTION

CAUTION

⚠WARNING

3. Check area around the boiler. Remove any combustible materials, gasoline and other flammable liquids.

⚠WARNING

4. If a new boiler will replace an existing boiler, check for and correct system problems, such as:

• System leaks causing oxygen corrosion or heat exchanger cracks from hard water deposits.

• Incorrectly-sized expansion tank.

• Debris left from existing piping, if not flushed and cleaned with an appropriate cleaner.

Do not locate unit so that high winds can deflect off of adjacent walls, buildings or shrubbery causing recirculation. Recirculation of flue products may cause operational problems, bad combustion or damage to controls. Locate unit at least 3 feet (0.91m) from any wall or vertical surface to prevent wind conditions from affecting performance.

The unit must not be installed in an area that is enclosed by walls or a fence that will block free wind movement around the appliance. Free movement of wind around the outdoor unit is required to carry away the flue products and provide combustion air. The flue outlet/ combustion air inlet of an outdoor unit must not be installed closer than 10 feet from an inside corner of an L-shaped structure. Walls or enclosed fencing may cause eddy currents which can recirculate the flue products into the combustion air inlet. Recirculation of flue products may cause operational problems, bad combustion or non-warrantable damage to controls.

Locate the unit at least 3 feet (0.91m) outside any overhang.

Do not install in locations where rain from building runo drains will spill onto the unit.

Do not locate the unit so that water from sprinklers may spray directly onto it. Water may damage controls or other electrical components.

Do not install the unit under a deck. Do not install the unit in a well, stairwell,

alcove, courtyard or other recessed area. Do not install outdoor units on stack

frames. Failure to comply with the above may result in severe personal injury, death or substantial property damage.

Failure to keep boiler area clear and free of combustible materials, gasoline, and other flammable liquids and vapors can result in severe personal injury, death, or substantial property damage.

Page 8

1 Determine boiler location

• This unit is not intended for installations where temperatures may reach below 32°F (0°C). Exposure to freezing temperatures will cause the system and boiler to freeze and leak.

5. Check around the boiler for any potential air contaminants that could risk corrosion to the boiler or the boiler combustion air supply (see Table 1A). Prevent combustion air contamination. Remove any of these contaminants from the boiler area.

⚠WARNING

Provide clearances:

Clearances from combustible materials

1. Hot water pipes—at least 1/4" (6 mm) from combustible

materials.

2. Jacket—minimum of 0" from right side and 14" from rear

side for proximity from combustible materials.

3. Vent—minimum of 1" from combustible materials.

Clearances for service access

1. If you do not provide the minimum clearances shown, it

may not be possible to service the boiler without removing it from the space.

Recommended service clearances

Front: 30" (762mm) Top: 24" (610mm) Left side: 24" (610mm) Right side: 24" (610mm) Rear: 24" (610mm)

Flooring and foundation

Flooring

The Outdoor Crest is approved for installation on combustible flooring.

Under no circumstances is the manufacturer to be held responsible for water damage in connection with this appliance, or any of its components. If flooding is possible, elevate the boiler sufficiently to prevent water from reaching the boiler.

Prevent combustion air contamination

Do not install unit in locations that can allow contamination of combustion air. Refer to Table 1A for products and areas which may cause contaminated combustion air.

DO NOT install units in areas that contain corrosive contaminants (see Table 1A). Failure to comply could result in severe personal injury, death, or substantial property damage.

Outdoor Crest Supplemental Manual

Table 1A Corrosive Contaminants and Sources

Products to avoid:

Spray cans containing chloro/fluorocarbons

Permanent wave solutions

Chlorinated waxes/cleaners

Chlorine-based swimming pool chemicals

Calcium chloride used for thawing

Sodium chloride used for water softening

Refrigerant leaks

Paint or varnish removers

Hydrochloric acid/muriatic acid

Cements and glues

Antistatic fabric softeners used in clothes dryers

Chlorine-type bleaches, detergents, and cleaning solvents found in household laundry rooms

Adhesives used to fasten building products and other similar products

Areas likely to have contaminants

Dry cleaning/laundry areas and establishments

Swimming pools

Metal fabrication plants

Beauty shops

Refrigeration repair shops

Photo processing plants

Auto body shops Plastic manufacturing plants

Furniture refinishing areas and establishments

New building construction

Remodeling areas

Garages with workshops

Remove boiler from wood pallet

1. After removing the outer shipping crate and plastic from the boiler, remove the parts package (packaged parts inside the controls compartment of the boiler inside the lower front access panel).

2. To remove the boiler from the pallet:

a. Remove the three (3) shipping bolts located inside the controls compartment securing the boiler to the front of the pallet (see FIG. 1-1 on page 9).

b. Remove the three (3) shipping bolts that fasten the tie-down brackets securing the legs to the rear of the pallet (FIG. 1-1).

c. The boiler can now be removed from the pallet using a lift truck lifting from the front or rear of the boiler. If lifting from the front, the lift truck forks must extend at least half way under the boiler heat exchanger to assure proper lifting technique with no damage to the boiler.

Page 9

1 Determine boiler location (continued)

DIR #2000

⚠WARNING

Failure to assure the truck forks are long enough to extend at least halfway under the boiler heat exchanger will result in the boiler tipping off the lift truck, and potentially falling. This will result in severe personal injury, death, or substantial property damage.

d. If lifting by crane is desired, remove the top access panels to gain access to the lifting lugs located on the boiler. It is also recommended that the upper and lower front panels along with both front side panels be removed (no tools required).

8. Once the condensate hoses are inserted through the terminal plates of the condensate trap box and attached to the condensate trap (both inlet and vent), the condensate trap box can then be re-assembled (FIG. 1-3).

9. Make certain the condensate trap is oriented correctly and that the wiring harness has enough slack to ensure the escutcheons remain seated properly. For proper trap placement, reference the Condensate Disposal Section of the Crest Installation and Operation Manual.

Figure 1-2 Install the Air Inlet Hood Assembly

Outdoor Crest Supplemental Manual

AIR INLET HOOD ASSEMBLY

NOTICE

Do not drop the boiler or bump the jacket on the floor or pallet. Damage to the boiler can result.

Figure 1-1 Boiler Mounted on Shipping Pallet

BOLT, WASHERS, & LOCKNUT (3X)

LAG BOLTS & TABS (3X)

REARFRONT

DIR #2000555479 00

Install outdoor vent kit

In order to properly install the appliance in an outdoor configuration, the optional outdoor kit must be used (see Table 1B).

1. Locate all venting components from the installation kit and carton.

a. Kit Components: Air Inlet Hood Assembly and Condensate Trap Box Assembly

2. Position the air inlet hood assembly to the top of the unit. Make certain the face of the wire screen frame of the hood is set flush with the front leading edge of the top of the unit as shown in FIG. 1-2.

3. Once positioned, use the kit provided self-tapping fasteners to attach the hood to the unit through the holes in the sides of the air inlet hood assembly.

Note: Once the air inlet hood is installed, the top, front and side doors are still removable.

4. Locate the kit provided display cover and place over the electronic display (FIG. 1-2).

5. Locate the kit provided condensate trap box.

6. The outdoor condensate wiring harness has escutcheons built into it which allows a water tight fit into both the rear jacket of the boiler as well as the terminal plates of the condensate trap box. Connect the outdoor condensate wiring harness to the pigtail connector of the condensate trap (see FIG. 1-3).

7. Disassemble the condensate trap box.

MAKE CERTAIN THE FACE OF THE WIRE SCREEN FRAME OF THE HOOD IS SET FLUSH WITH THE LEADING EDGE OF THE TOP OF THE UNIT

PLACE THE DISPLAY COVER OVER THE ELECTRONIC DISPLAY

DIR #2000555428 00

⚠CAUTION

Do NOT use grease or other lubricant on the vent seals. Only water may be used for this purpose. Grease or other lubricant can make the seal brittle or cause tearing of the seal surface which can result in flue gas leakage.

Figure 1-3 Disassemble/Re-assemble outdoor condensate trap

DISASSEMBLE THE CONDENSATE TRAP BOX

CONNECT THE OUTDOOR CONDENSATE WIRING HARNESS TO THE PIGTAIL CONNECTOR

DIR #2000555429 00

Table 1B Outdoor Vent Kits

Model Outdoor Kit Number

751 - 2001 100301827

2501 - 3001 100313289

3501 100308477

4001 - 5001 100313290

6001 100313291

Page 10

1 Determine boiler location

Outdoor venting

Outdoor Crest Supplemental Manual

• Vent materials for outdoor venting are to be field supplied.

• The vent must terminate at least 36 inches above the top of

the unit.

• All vent materials must be supported as recommended by

the vent manufacturer.

NOTICE

Units are self-venting and can be used outdoors when installed with the optional outdoor kit.

⚠WARNING

Combustion air supply must be free of contaminants To prevent recirculation of the  ue products into the combustion air inlet, follow all instructions in this section.

For outdoor models, you must install a flue termination. Do not install outdoor models directly on the ground. You must install the outdoor unit on a concrete, brick, block, or other non-combustible pad.

Before installing a venting system, follow all requirements found in the Outdoor Venting section of this manual.

Only install outdoor models outdoors, and only use the vent caps specified in this manual. Personal injury or product damage may result if any other cap is used, or if an indoor model is used outdoors. Properly install all covers, doors, and jacket panels to ensure proper operation and prevent a hazardous condition.

Keep venting areas free of obstructions. Keep area clean and free of combustible and flammable materials. Maintain minimum clearances to combustible surfaces and a 36" (915 mm) minimum clearance to the air inlet. To avoid a blocked air inlet or blocked flue condition, keep the air inlet, flue outlet, and condensate trap clear of leaves, debris, etc.

Do not locate unit so that high winds can deflect off of adjacent walls, buildings, or shrubbery causing recirculation. Recirculation of flue products may cause operational problems, bad combustion, or damage to controls.

Multiple unit outdoor installations require 48" (1.22 m) clearance between each vent cap. Locate outdoor cap at least 48" (1.22m) below and 48" (1.22 m) horizontally from any window, door, walkway, or gravity air intake.

Locate unit at least 10 feet (3.05 m) away from any forced air inlet.

Locate unit at least 3 feet (0.91 m) outside any overhang.

Clearances around outdoor installations can change with time. Do not allow the growth of trees, shrubs, or other plants to obstruct the proper operation of the outdoor vent system.

Do not install in locations where rain from building runoff drains will spill onto the unit.

Some discoloration to exterior building or unit surfaces can be expected. Adjacent brick or masonry surfaces should be protected with a rust resistant sheet metal plate.

Outdoor vent / air inlet location

Keep venting areas free of obstructions. Keep area clean and free of combustible and  ammable materials. Maintain minimum clearances to combustibles as stated in this manual.

⚠WARNING

DO NOT install units in areas that contain corrosive contaminants (see Table 1A on page 8). Failure to comply could result in severe personal injury, death, or substantial property damage.

Page 11

2 Gas connections

Gas supply

NOTICE

1. It is recommended to install one (1) gas regulator for each

Outdoor Crest boiler.

2. Gas regulators should be installed in a horizontal

orientation unless otherwise recommended by the regulator manufacturer.

3. It is recommended to install a filter at the inlet of a gas

regulator to prevent debris from entering the regulator.

4. Gas regulators should be installed the greater of either 20

inches or 10 pipe diameters from the nearest fitting, elbow, or valve to the outlet of the regulator.

5. It is recommended that the gas regulator outlet size match

the gas inlet size of the boiler and to not change the pipe size between them. If the pipe diameter must be increased, a bell reducer type fitting should be located at the regulator outlet and the boiler inlet, maintaining the distance indicated in Step 4.

6. Gas regulators must be properly vented to ensure proper

function: a. Vent pipe must be no smaller than the regulator vent connection size. b. Each regulator must have a separate vent line. c. Vent lines must not be combined together or with any other equipment that also requires atmospheric vents. d. Excessive gas regulator vent length will detrimentally affect regulator performance:

• Gas regulators must be properly vented according to

the regulator manufacturer’s instructions.

• It is recommended that regulator vent length not

exceed 15 equivalent feet (4.5 m).

• When regulator vent must exceed 15 equivalent feet, it

is recommended to use a ventless regulator equipped with a vent limiter.

• If a ventless regulator cannot be utilized, it is

recommended to increase vent diameter by one pipe size after the initial 15 equivalent feet and every additional 10 equivalent feet. e. Proper measures must be taken to prevent water, snow, insects, or other debris from obstructing the vent.

Connecting gas supply piping

1. Refer to FIG. 2-1 to pipe gas to the boiler.

a. Install ground joint union for servicing, when

required.

Ensure that the high gas pressure regulator is at least 10 feet (3 m) upstream of the appliance.

Outdoor Crest Supplemental Manual

Figure 2-1 Gas Supply Piping

SEDIMENT TRAP / DRIP LEG CLEAN OUT (FACTORY SUPPLIED)

2. Support piping with hangers, not by the boiler or its accessories.

⚠WARNING

The gas valve and blower will not support the weight of the piping. Do not attempt to support the weight of the piping with the boiler or its accessories. Failure to comply could result in severe personal injury, death, or substantial property damage.

3. Purge all air from the gas supply piping.

4. Before placing the boiler in operation, check the boiler and its gas connection for leaks. a. The appliance must be disconnected from the gas supply piping system during any pressure testing of that system at a test pressure in excess of 1/2 PSIG (3.5 kPa).

b. The appliance must be isolated from the gas supply piping system by closing a manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 PSIG (3.5 kPa).

c. The appliance and its gas connection must be leak tested before placing it in operation.

⚠WARNING

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.

5. Use pipe sealing compound compatible with propane gases. Apply sparingly only to male threads of the pipe joints so that pipe dope does not block gas flow.

⚠WARNING

Failure to apply pipe sealing compound as detailed in the Crest Installation and Operation Manual can result in severe personal injury, death, or substantial property damage.

UNION

GAS SUPPLY

DIR #2000555433 00

Table 2A Gas Inlet Size

Model Gas Inlet Size

OF0751 - OF1001 1 1/4"

OF1251 - OF2001 1 1/2"

OF2501 - OF3501 2"

OF4001 - OF6001 2 1/2"

Page 12

2 Gas connections

Outdoor Crest Supplemental Manual

⚠WARNING

Use two wrenches when tightening gas piping at boiler (FIG. 2-2), using one wrench to prevent the boiler gas line connection from turning. Failure to support the boiler gas connection pipe to prevent it from turning could damage gas line components.

Figure 2-2 Inlet Pipe with Backup Wrench

DIR #2000555453 00

USE BACK UP WRENCH TO PREVENT PIPE FROM ROTATING

NOTICE

Maximum inlet gas pressure must not exceed the value specified. Minimum value listed is for the purposes of input adjustment.

Natural gas:

⚠WARNING

Pipe sizing for natural gas

1. Refer to Table 2B for pipe length and diameter. Based on rated boiler input (divide by 1,000 to obtain cubic feet per hour).

a. Table 2B is only for natural gas with specific gravity

0.60, with a pressure drop through the gas piping of 0.3 inches w.c.

b. For additional gas pipe sizing information, refer to

the National Fuel Gas Code, NFPA 54 / ANSI Z223.1

- latest edition, or in Canada CSA B149.1 Installation Code.

Check boiler rating plate to determine which fuel the boiler is set for. Outdoor Crest boilers CANNOT be field converted. Failure to comply could result in severe personal injury, death, or substantial property damage.

3. Install 100% lockup gas pressure regulator in supply line for each boiler if inlet pressure exceeds 14 inches w.c. (3.5 kPa).

4. Gas valves used on Outdoor Crest boilers are rated for at least 27 inches w.c. (6.7 kPa).

Propane Gas:

⚠WARNING

Pipe sizing for propane gas

1. Contact gas supplier to size pipes, tanks, and 100% lockup gas pressure regulator.

Propane Supply Pressure Requirements

1. Target a supply pressure of 11 inches w.c. (2.7 kPa) measured when the boiler is operating at minimum input rate. Gas pressure can be adjusted higher or lower than 11 inches w.c. as needed.

2. Adjust propane supply regulator provided by the gas supplier for 14 inches w.c. (3.5 kPa) maximum pressure.

3. Pressure required at gas valve inlet pressure port:

• Maximum 14 inches w.c. (3.5 kPa) with boiler operating.

• Minimum 4 inches w.c. (.99 kPa) with boiler operating.

Figure 2-3 Gas Supply Piping to Regulator

Check boiler rating plate to determine which fuel the boiler is set for. Outdoor Crest boilers CAN NOT be field converted. Failure to comply could result in severe personal injury, death, or substantial property damage.

10'

MINIMUM

* MANUAL SHUT

(FIELD SUPPLIED)

* REQUIRED FOR INSTALLATION IN THE COMMONW EALTH OF MASSACHUSETTS

OFF VALVE

* GAS PRESSURE

REGULATOR

(FIELD SUPPLIED)

Natural gas supply pressure requirements

1. Target a supply pressure of 7 inches w.c. (1.7 kPa) measured when the boiler is operating at minimum input rate. Gas pressure can be adjusted higher or lower than 7 inches w.c. as needed.

2. Pressure required at the gas valve inlet pressure port:

• Maximum 14 inches w.c. (3.5 kPa) with boiler operating.

• Minimum 4 inches w.c. (.99 kPa) with boiler operating.

DIR #2000555541 00

Page 13

2 Gas connections (continued)

Table 2B Natural Gas Pipe Size Chart

TABLE - 2B

Capacity of Schedule 40 Metallic Pipe in Cubic Feet of Natural Gas Per Hour

(based on .60 specific gravity, 0.30" w.c. pressure drop)

Outdoor Crest Supplemental Manual

Pipe

Size

(Inches)

1 1/4 1,060 726 583 499 442 400 368 343 322 304 269 244 224 209

1 1/2 1,580 1,090 873 747 662 600 552 514 482 455 403 366 336 313

2 3,050 2,090 1,680 1,440 1,280 1,160 1,060 989 928 877 777 704 648 602

2 1/2 4,860 3,340 2,680 2,290 2,030 1,840 1,690 1,580 1,480 1,400 1,240 1,120 1,030 960

3 8,580 5,900 4,740 4,050 3,590 3,260 3,000 2,790 2,610 2,470 2,190 1,980 1,820 1,700

4 17,500 12,000 9,660 8,270 7,330 6,640 6,110 5,680 5,330 5,040 4,460 4,050 3,720 3,460

10 20 30 40 50 60 70 80 90 100 125 150 175 200

Length of Pipe in Straight Feet

Check inlet gas supply

⚠WARNING

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 gas pressure drops more than 1 inch w.c. (249 Pa) between maximum and minimum input rate, the meter, regulator, or gas line may be 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. 2-4.

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.

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.

7. Observe the gas pressure with the burner operating at 100% of rated input. Without turning off the boiler, reduce the burner to the minimum input rate and observe the gas pressure with the burner at the minimum input rate. 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 14

2 Gas connections

Outdoor Crest 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.

Figure 2-4 Inlet Gas Supply Check

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 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 venturi and the blower.

⚠WARNING

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

DIR# 2000549933 00

Page 15

3 Start-up

Outdoor Crest Supplemental Manual

Pre-Commissioning Cleaning

1. Prior to fill and start-up, flush the entire heating system.

2. Clean the entire heating system with an approved precommissioning cleaner (comparable to Sentinel X300 or X400 and Fernox F3 or DS40) in accordance with the manufacturer’s recommendation to remove debris and prolong the life of the heat exchanger.

3. Clean all water filtering devices in the system.

4. Flush the cleaning solution out of the entire system and refill.

Fill water

Check/control fill water chemistry

IMPORTANT

The manufacturer recommends the following for properly filling your boiler with the appropriate water chemistry for closed loop boilers. Good fill water quality will help extend the life of the appliance by reducing the effects of lime scale buildup and corrosion in closed loop systems.

Hardness between 5 and 12 grains per gallon

1. Consult local water treatment companies for hard water areas (above 12 grains per gallon hardness).

2. Hardness levels that are above 12 grains/gallon can lead to lime scale buildup throughout the boiler system. If the fill water is below 5 grains/gallons, usually due to use of a water softener, it is recommended to mix in some potable water at the inlet to increase the hardness of the water to above 5 grains/gallons.

Conduct water quality testing prior to installing the appliance. Various solutions are available to adjust water quality.

Boiler water

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 boiler, personnel, and/or property may result.

Table 3A Boiler Water Chemistry

BOILER WATER CHEMISTRY

Speci cation Range

Dissolved Solids < 2000 ppm

pH Level 6.5 to 9.5

Chloride < 150 ppm

• Monitoring pH, chlorides, TDS, and hardness levels can prolong the life of the appliance by reducing lime scale buildup, corrosion, and erosion. Check for leaks to ensure that fresh water is not entering the system.

• Continual fresh makeup water will reduce boiler life.

• Mineral buildup in the heat exchanger reduces heat transfer, overheats the stainless steel heat exchanger, and causes failure.

• The addition of oxygen carried in by makeup water can cause internal corrosion in system components.

pH between 6.5 and 8.5

1. pH levels below 6.5 can cause an increase in the rate of corrosion. pH of 8.5 or higher can potentially cause lime scale buildup.

Total Dissolved Solids (TDS) less than 350 ppm

1. Total dissolved solids are all minerals, salts, metals, and charged particles that are dissolved in water.

2. The greater the amounts of TDS present, the higher the corrosion potential due to increased conductivity in the water.

Chloride concentration less than 150 ppm

1. Do not fill boiler or operate with water containing chlorine in excess of 150 ppm.

2. Filling with fresh drinking water should be acceptable.

3. Do not use the boiler to directly heat swimming pool or spa water.

• Leaks in the boiler or piping must be repaired at once to prevent excessive makeup water. For this purpose, it is recommended to install a water meter to easily check the amount of makeup water entering the system. Makeup water volume should not exceed 5% of the total system volume per year. Note: When makeup water is added, make sure the chemical additives are added to maintain the correct level.

• An approved multi-metal corrosion inhibitor (comparable to Sentinel X100 or Fernox F1) is recommended at the correct concentration and in the manner recommended by the manufacturer.

Page 16

3 Start-up

Outdoor Crest Supplemental Manual

Oxygen prevention

CAUTION

Dissolved oxygen can have a negative effect on the boiler system. Oxygen can cause iron oxide to generate iron deposits. Oxygen may also increase the rate of corrosion on non-stainless steel parts of the system. A low pH level combined with oxygen further enhances its corrosive effects. After boiler installation, check for air leaks in the following areas:

• Suction gasket

• Pump

• Air valve

• O-ring gaskets

Precautions include installing a water meter to evaluate the fresh water volume entering the system (should be no more than 5% system volume). Additional volumes of fresh water could indicate that a leak is present.

Fill and test water system

1. Fill system only after ensuring the water meets the requirements of this manual.

2. Close automatic and manual air vents and boiler drain valve.

3. Fill to correct system pressure. Correct pressure will vary with each application.

a. The minimum cold water fill pressure for a system is

12 psi.

b. Pressure will rise when the boiler is turned ON and

system water temperature increases.

4. At initial fill and during boiler startup and testing, check the system thoroughly for any leaks. Repair all leaks before proceeding further.

Purge air from water system

1. Purge air from system:

a. Connect a hose to the purge valve. Route the hose to

an area where water can drain and be seen.

b. Close the boiler or system isolation valve between the

purge valve and fill connection to the system.

c. Close zone isolation valves. d. Open the quick-fill valve on the cold water makeup

line.

e. Open purge valve.

Eliminate all system leaks. Continual fresh makeup water will reduce boiler life. Minerals can build up in the heat exchanger, reducing heat transfer, overheating the heat exchanger, and causing heat exchanger failure.

f. Open the isolation valves one zone at a time. Allow

water to run through the zone, pushing out the air. Run until no noticeable air flow is present. Close the zone isolation valves and proceed with the next zone. Follow this procedure until all zones are purged.

g. Close the quick-fill water valve and purge valve and

remove the hose. Open all isolation valves. Watch that system pressure rises to correct cold-fill pressure.

h. After the system has operated for a while, eliminate

any residual air by using the manual air vents located throughout the system.

i. If purge valves are not installed in the system, open the

manual air vents in the system one at a time, beginning with the lowest floor. Close the vent when water squirts out. Repeat with remaining vents.

2. Open the automatic air vent (diaphragm-type or bladder type expansion tank systems only) one turn.

3. Open other vents:

a. Starting on the lowest floor, open air vents one at a

time until water squirts out.

b. Repeat with remaining vents.

4. Refill to correct pressure.

Check for gas leaks

⚠WARNING

Before starting the boiler, and during initial operation, smell near the floor and around the boiler for gas odorant or any unusual odor. Remove the top access panel and smell the interior of the boiler enclosure. Do not proceed with startup if there is any indication of a gas leak. Use an approved leak detection solution. Repair any leaks at once.

DO NOT adjust or attempt to measure gas valve outlet pressure. The gas valve is factory set for the correct outlet pressure. This setting is suitable for natural gas and propane, requiring no field adjustment. 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.

Page 17

3 Start-up (continued)

Outdoor Crest Supplemental Manual

⚠WARNING

Propane boilers only – Your propane supplier mixes an odorant with the propane to make its presence detectable. In some instances, the odorant can fade, and the gas may no longer have an odor. Before startup (and periodically thereafter), have the propane supplier verify the correct odorant level in the gas.

Check thermostat circuit(s)

1. Disconnect the two external wires connected to the enable terminals on the connection board.

2. Connect a voltmeter across these two incoming wires. Close each thermostat, zone valve, and relay in the external circuit one at a time and check the voltmeter reading across the incoming wires.

3. There should NEVER be a voltage reading.

4. If a voltage does occur under any condition, check and correct the external wiring. (This is a common problem when using 3-wire zone valves.)

5. Once the external boiler enable wiring is checked and corrected if necessary, reconnect the external thermostat circuit wires to the connection board. Allow the boiler to cycle.

Inspect condensate system

Inspect/check condensate lines and fittings

1. Inspect the condensate drain line, condensate PVC fittings and condensate trap.

Figure 3-1 Condensate Trap

Final checks before starting the boiler

 Read the Crest Service Manual to familiarize yourself

with SMART TOUCH control module operation. Read this manual, page 19 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 3 pages 15 -

18 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. 3-3, page 19.

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)?

6. 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.

TO FLOOR DRAIN OR NEUTRALIZER KIT 1" PVC / CPVC CONNECTION

FROM CONDENSATE VENT ON BOILER

FROM CONDENSATE DRAIN ON BOILER

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 on pages 15 - 18 (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 18

3 Start-up

Outdoor Crest Supplemental Manual

 Check vent piping and air piping

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

 Check gas piping

1. Check around the boiler for gas odor following the procedure on page 11 of this manual (connecting gas supply piping).

⚠WARNING

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.

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

4. Turn the main power on to the boiler by placing the “On/ Off” switch in the ON position.

5. Navigate to the Setup Screen from the Home Screen by pressing the SETUP button along the left side of the screen. Enter the installer password.

6. Select the Service Maintenance Screen. The tabs will scroll (up and down) to reveal more options.

On the Service Maintenance Screen place heater into

Service Mode by selecting the START button, then selecting Set Gas Valve 1 - High (FIG. 3-2).

7. Once the boiler has modulated up to rate, measure the combustion. The values should be in the range listed in Table 3B (this page). 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 Outdoor Crest Service Manual for possible causes and corrective actions.

Table 3B Flue Products Chart

Flue Products

Units

Gas Valve

Valve 1 High 9.2 4.6 9.2 4.6

Valve 1 Low 9.0 4.9 8.5 5.7

Valve 2 High 9.3 4.4 9.5 4.2

Valve 2 Low 8.7 5.5 8.8 5.4

CO2 (%) O2 (%) CO2 (%) O2 (%)

Natural Gas

751-2001 2501-6001

Propane

Units

Gas Valve

Valve 1 High 11.0 4.1 11 4.1

Valve 1 Low 10.0 5.6 9.9 5.7

Valve 2 High 11.1 4.0 11.1 4

Valve 2 Low 10.7 4.6 10.1 5.5

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

751-2001 2501-6001

CO2 (% O2 (%) CO2 (% O2 (%)

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. Ensure the boiler is placed 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.

Figure 3-2 Service Maintenance Screen

SETUP

Page 19

3 Start-up (continued)

Figure 3-3 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.

Outdoor Crest 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. BEFOR E OPERATI NG sme ll all ar ound

the a pp liance area fo r ga s. Be su re to smell next to the floor because some gas

is heavier than air and will settl e on the floor.

WHAT TO DO IF YOU SMELL GAS

• D o no t try to lig ht any appliance.

• Do not touch any electric switch; do

not use any phone in you r b ui ldi ng .

OPERATING 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 applia nc e.

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

the burner. Do not try to light the burner by ha nd.

5. Remove front door.

6. T urn gas shutoff valve counterclockwise to “OFF”. Handle wil l be perpendicu la r to

pipe. Do 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 la bel.

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

• Immediately call your gas supplier from a neighbor’s ph on e. Fol lo w th e gas supplier’s

instr uctions.

• If you can not reach you r ga s supplier , ca ll 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, ca ll a qua lified s ervice

technician. Force or attempted repair may result in a fire or e xpl osion.

D. Do not use this app liance if any pa rt has been

under water. I mm ed iat ely c all a qu al if ied service techn ician to inspect the applianc e and to replace any part of the control system and any ga s co ntrol w hich has been un de r wat er.

8. Turn gas shut off valve clockwise to “ O N”. Handle will be parallel to pipe.

9. Instal l fr on t door.

10. Turn on all electric power to appliance.

11. Se t thermostat to desired set ti ng.

12. If the ap pl ian ce will not operate , follow the instructions “To Turn Off Gas To Appliance” 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 ctric po we r t o the ap pl iance if se rvice is to be pe rf 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. Instal l fr on t door.

L BL2 005 3 REV B

Page 20

4 Diagrams

TERMINAL STRIP

OUTLET SENSOR (S9)

OUTLET SENSOR (S1)

FLUE SENSOR

FLUE SENSOR (S10)

120VAC

NEUTRAL

ON/OFF

SWITCH

GAS

VALVE

(LARGE)

GAS

VALVE

(SMALL)

CONTACTOR

BOILER PUMP

CONTACTOR

DHW PUMP

CONTACTOR

BLOWER

BAS (AS APPLICABLE)

FLUE DAMPER

TRANSFORMER

FLUE DAMPER

TEST

SWITCH

LWCO

PROBE

LWCO RESET

GPS1 GPS2

BLOCKED FLUE

SWITCH

BLOCKED DRAIN

SWITCH

ALARM CONTACTS

CONTACTS

TANK THERMOSTAT

LOUVER PROVING

AUX SWITCH 1

AUX SWITCH 2

ENABLE

FLAME

SENSE 1

FLAME

SENSE 2

SPARK

GENERATOR

SPARK

ROD

SHIELD

BAS OPTION

RATE OUT

BOILER PUMP OUT

SENSOR

TANK SENSOR

OUTDOOR SENSOR

BMS IN

PUMP IN

SHIELD

CASCADE

INLET SENSOR

GROUND

BLOWER

BOX DEPICTS

OPTIONAL ITEMS

BOX DEPICTS DUAL SENSOR

SINGLE HOUSING

HIGH VOLTAGE

LOW VOLTAGE 120 VAC

"X5"

BLOCK WIRING

IS MODEL

DEPENDENT

AIR VALVE

PRESS. SWITCH

BLOWER

AIR VALVE

HIGH LIMIT

SWITCH

DISCONNECT POWER

BEFORE SERVICING

BOILER PUMP

DHW PUMP

5.0 A

3.15 A

LARGE GAS

SMALL GAS

USB

INTERFACE

X11

WIFI

DONGLE

USB CABLE

SW1

LG CON BRD

OPTIONAL

ETHERNET CABLE

OPTIONAL USB/WIFI EXTENSION CABLE

BAS

GND

BAS

BOARD

(AS

APPLICABLE)

SHIELDED CABLE FROM X4

TO J12 OR J23 AS APPLICABLE

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.

shielded

cables

must be purchased from the factory. Use of a non-approved spark lead or

shielded

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 componen ts for proper connector block locations when using diagrams to troubleshoot unit.

LADDER DIAGRAM 100266646 REV B

Figure 4-1 Ladder Diagram_751 - 2001 Models

Outdoor Crest Supplemental Manual

Page 21

4 Diagrams (continued)

Figure 4-2 Wiring Diagram_751 - 2001 Models

BAS

BOARD

(AS APPLICABLE)

LCD

DISPLAY

LARGE CONNECTION BOARD

COMMUNICATION CONTROL BOARD

SW1

USB CABLE

OPTIONAL USB/WIFI EXTENSION CABLE

OPTIONAL

ETHERNET CABLE

SMALL CONNECTION BOARD

LWCO PROBE

OR/BK

GPS1

WIFI

DONGLE

TO J12 OR J23 AS APPLICABLE

TEST

SWITCH

LWCO RESET

INLET SENSOR

OUTLET SENSOR (S9)

OUTLET SENSOR (S1)

FLUE SENSOR

FLUE SENSOR (S10)

SHIELDED CABLE FROM X4

HIGH LIMIT

SWITCH

LWCO

BOARD

OR/BK

OR OR

GPS2

LG CON BRD

OPTION

RATE

BOILER

PUMP OUT

SENSOR

OUTDOOR

SENSOR

PUMP IN

CASCADE

BAS

CONTACTS

THERMOSTAT

ENABLE

LOUVER

PROVING

SWITCH 1

SWITCH 2

SHIELD

BAS

SHIELD

OUT

BMS

SHIELD

GND

ALARM

TANK

AUX

Outdoor Crest Supplemental Manual

BOX DEPICTS

DUAL SENSOR

SINGLE HOUSING

BOX DEPICTS

OPTIONAL ITEMS

INTEGRATED CONTROL

W OR

OR/W

W BL

R/W

OR BL BK

T OR OR

R BK

BLOWER

GENERATOR

FLUE DAMPER

TRANSFORMER

SPARK

ON/OFF SWITCH

DISCONNECT POWER

BEFORE SERVICING

LOW VOLTAGE 120 VAC HIGH VOLTAGE

120V

GND

FLAME SENSE 2

SPARK ROD

FLAME SENSE 1

WARNING

1.5A EACH MAX

GAS VALVE (SMALL)

GAS VALVE (LARGE)

BLOWER

235

FLUE DAMPER

CONTACTOR

BOILER PUMP CONTACTOR

DHW PUMP CONTACTOR

JUNCTION

BOX

GND

BLOCKED FLUE

BLOCKED DRAIN

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 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 vo ltage spark lead an d shielded cables must be purchased from the facto ry. Use of a non-approved spark lead or shielded 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 t roubleshoot unit.

SWITCH

"X5"

BLOCK WIRING

IS MODEL

DEPENDENT

X11

USB

INTERFACE

OR/W

OR/BK

TRANSFORMER

AIR VALVE PRESSURE SWITCH

OR/R

AIR VALVE

WIRING DIAGRAM 100266647 REV C

Page 22

4 Diagrams

Figure 4-3 Ladder Diagram_2501 - 3501 Models

L2 L3

TERMINAL STRIP

208V 3 SUPPLY

SERVICE

ON/OFF

SWITCH

X1-4

3.15 AF45.0 A

X10-1 X10-2

X6-1

X2-5

X1-1 X1-2

JUNCTION BOX

OUTLET

INTEGRATED CONTROL

SYSTEM PUMP

RELAY

BOILER PUMP

RELAY

DHW PUMP

RELAY

SMALL GAS

VALVE RELAY

LARGE GAS

VALVE RELAY

LARGE GAS

VALVE RELAY

SMALL GAS

VALVE RELAY

X11

USB

INTERFACE

CONTACTOR

BAS

(AS APPLICABLE)

X1-3

BLOWER

X1-3

X1-12

X1-1

X1-2

X1-4

X1-8

X10-3

X10-6

X10-5

X10-4

X1-3

X1-7

X1-10

X2-5

X6-3

X6-10

X13-4

1 2 3

TRANSFORMER

CONTACTOR

VALVE

(LARGE)

GENERATOR

BLOWER

FLUE DAMPER

TERMINAL STRIP 208V SUPPLY "N"

1.5A EACH MAX

TERMINAL STRIP

SYSTEM PUMP

CONTACTOR

BOILER PUMP

CONTACTOR

DHW PUMP

CONTACTOR

GAS

SPARK

GAS

VALVE

(SMALL)

FLAME

SENSE 1

SPARK

ROD

FLAME

SENSE 2

NEUTRAL

GROUND

INTEGRATED

CONTROL

Outdoor Crest Supplemental Manual

BOX DEPICTS

OPTIONAL ITEMS

BOX DEPICTS

DUAL SENSOR

SINGLE HOUSING

BAS

BOARD

(AS APPLICABLE)

X4-1

X4-2

X4-3

X8-20

X8-10

X8-1

X7-8

X7-7

X8-13

X8-14

X8-12

X8-11

X8-5

X8-15

CN3-4

X8-6

X8-16

X8-7

X8-17

X8-18

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)

X6-2

X6-1

-T

X6-3

CONNECTION BOARD

CN6-3

CN6-2

CN6-1

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

-T

LOW VOLTAGE

120 VAC

HIGH VOLTAGE

LARGE

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

0-10V

SHIELD

BAS OPTION

SHIELD

RATE OUT

BOILER PUMP OUT

SYSTEM RETURN SENSOR

SYSTEM SUPPLY SENSOR

TANK SENSOR

OUTDOOR SENSOR

BMS

SYSTEM PUMP IN

SHIELD

CASCADE

SHIELD

GPS1 GPS2

BLOCKED FLUE

SWITCH

BLOCKED DRAIN

SWITCH

BLOCK WIRING

IS MODEL

DEPENDANT

LWCO

PROBE

AIR VALVE

PRESS. SWITCH

"X5"

FLUE DAMPER

TEST

SWITCH

LWCO RESET

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

J3-6

J3-3

J2-1

J2-2

INTEGRATED

TRANSFORMER

CONTROL

24V

LWCO BOARD

X6-18

X6-9

X6-17

X6-8

J3-5

J3-2

J3-4

X6-13

X3-3

X3-4

X3-1

X3-2

X6-11

X6-2

X6-14

X6-4

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 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 must be replaced, it must be replaced wi th wire having same wire gauge (AWG) and rated for a minimum of 105 °C. Exceptions: Replacement high voltage spark lead and must be purchased from the factory. Use of a non-approved spark lead or 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 componen ts for proper connector block locations when using diagrams to troubleshoot unit.

CN-4

CN-1

CN-2

CN-3

SMALL

CONNECTION BOARD

AIR VALVE

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

R W

ALARM CONTACTS

RUN-TIME CONTACTS

TANK THERMOSTAT

ENABLE

LOUVER PROVING

24 VAC LOUVER RELAY COIL

AUX SWITCH 1

AUX SWITCH 2

BLOWER

LG CON BRD

BAS

CN6-2

CN6-1

CN6-3

24V

SHIELDED CABLE FROM X4

TO J12 OR J23 AS APPLICABLE

shielded

LCD

DISPLAY

USB CABLE

SW1

J10

J17

J11

GND

cables can lead to operational problems

OPTIONAL USB/WIFI

J23

J12

EXTENSION CABLE

OPTIONAL

ETHERNET CABLE

shielded

WIFI

DONGLE

cables

LADDER DIAGRAM 100303181 REV B

Page 23

4 Diagrams (continued)

Figure 4-4 Wiring Diagram_2501 - 3501 Models

(AS APPLICABLE)

J10

0-10V

LCD

DISPLAY

J11

GND

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

COMMUNICATION CONTROL BOARD

SW1

USB CABLE

J9 J17

OPTIONAL USB/WIFI

EXTENSION CABLE

J23

J12

OPTIONAL

ETHERNET CABLE

SMALL CONNECTION BOARD

1 2 3 4 5 6 7

9 10 11 12 13 14 15 16

LWCO

PROBE

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

SHIELDED CABLE FROM X4

TO J12 OR J23 AS APPLICABLE

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

GPS1 GPS2

BLOCKED FLUE

SWITCH

BLOCKED DRAIN

SWITCH

INLET SENSOR

OUTLET SENSOR (S9)

OUTLET SENSOR (S1)

FLUE SENSOR

FLUE SENSOR (S10)

PRE-MIX SENSOR 1 (S11)

PRE-MIX SENSOR 1 (S13)

HIGH LIMIT

KB/RO

RO RO

OPTION

PUMP OUT

SYSTEM RETURN

SYSTEM SUPPLY

OUTDOOR

SYSTEM PUMP IN

CASCADE

LG CON BRD

CN6-2

CN6-1

CN6-3

CONTACTS

THERMOSTAT

24 VAC LOUVER

RELAY COIL

SHIELD

BAS

SHIELD

RATE

OUT

BOILER

SENSOR

TANK

SENSOR

BMS

SHIELD

BAS

ALARM

RUN-TIME

TANK

ENABLE

LOUVER

PROVING

SWITCH 1

SWITCH 2

24V

AUX

BOARD

SWITCH R

LWCO

BOARD

J3-6 J3-5 J3-4 J3-3 J3-2 J2-1 J2-2

Outdoor Crest Supplemental Manual

BOX DEPICTS

OPTIONAL ITEMS

BOX DEPICTS

BAS

X1-1 X1-2 X1-3 X6-3 X6-1 X6-2 X4-1 X4-2 X4-3

LB KB

-T

RO LB KB RB

R Y

KB/Y

W/RO

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

W/R

X8-2

X8-4

X8-9

X7-1

X7-5

X3-3 X3-4 X3-1 X3-2 X6-1 X6-11 X6-2 X6-14 X6-10 X6-13

X6-4

X6-3

X6-5

X13-1

X6-6

X1-12 X10-1 X10-4

X10-2

X10-5 X10-3

X10-6 X6-18

X6-9 X6-17

X1-10

X13-4

X1-6 X1-3

X1-1 X1-2 X1-4

X6-8 X1-8

X2-3 X1-7

X1-5

X2-5

DUAL SENSOR

SINGLE HOUSING

SERVICE

OUTLET

ON/OFF SWITCH

SPARK

GENERATOR

R P

FLUE DAMPER

TRANSFORMER

208V 3

KB W G

LOW VOLTAGE 120 VAC HIGH VOL TAGE

R/W

BK/W

FLAME SENSE 2

SPARK ROD

FLAME SENSE 1

FLUE DAMPER

24V

TRANSFORMER

GAS VALVE (SMALL)

GAS VALVE (LARGE)

BLOWER

124

1.5A EACH MAX

SYSTEM PUMP CONTACTOR

BOILER PUMP CONTACTOR

DHW PUMP CONTACTOR

JUNCTION

231

BOX

GND

X5-1 X5-7 X5-2 X5-8

"X5"

BLOCK WIRING

IS MODEL

DEPENDANT

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 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 vo ltage spark lead and shielded cables must be purchased from the factory. Use of a non-approved spark lead or shielded 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.

X5-3 X5-9 X5-4 X5-10 X5-5 X5-41 X5-6 X5-12

X11

USB

INTERFACE

WIRING DIAGRAM

100303303 REV B

Page 24

4 Diagrams

Figure 4-5 Ladder Diagram_4001 - 5001 Models

L2 L3

TERMINAL STRIP

480V 3 SUPPLY

ON/OFF

SWITCH

X1-6

3.15 AF45.0 A

X10-1 X10-2

X6-1

X2-5

X1-1 X1-2

JUNCTION BOX

INTEGRATED CONTROL

SYSTEM PUMP

RELAY

BOILER PUMP

RELAY

DHW PUMP

RELAY

SMALL GAS

VALVE RELAY

LARGE GAS

VALVE RELAY

LARGE GAS

VALVE RELAY

SMALL GAS

VALVE RELAY

X11

USB

INTERFACE

BLOWER

CONTACTOR

BAS

(AS APPLICABLE)

X1-3

480V

TRANSFORMER

FLUE DAMPER

X1-3

X1-12

X1-1

X1-2

X1-4

X1-8

X10-3

X10-6

X10-5

X10-4

X1-3

X1-7

X1-10

X2-5

X6-3

X6-10

X13-4

2 3

SERVICE OUTLET

TRANSFORMER

24V

TRANSFORMER

FLUE DAMPER

1.5A EACH MAX

TERMINAL STRIP

SYSTEM PUMP

CONTACTOR

BOILER PUMP CONTACTOR

CONTACTOR

BLOWER

CONTACTOR

GAS

VALVE

(LARGE)

SPARK

GENERATOR

BLOWER

TERMINAL STRIP 480V SUPPLY "N"

DHW PUMP

GAS

VALVE

(SMALL)

SENSE 1

SENSE 2

FLAME

SPARK

FLAME

ROD

NEUTRAL

GROUND

INTEGRATED

CONTROL

Outdoor Crest Supplemental Manual

BOX DEPICTS

OPTIONAL ITEMS

BOX DEPICTS

DUAL SENSOR

SINGLE HOUSING

BAS

BOARD

(AS APPLICABLE)

X4-1

X4-2

X4-3

X8-20

X8-10

X8-1

X7-8

X7-7

X8-13

X8-14

X8-12

X8-11

X8-5

X8-15

CN3-4

X8-6

X8-16

X8-7

X8-17

X8-18

X8-3

INLET SENSOR

X8-8

OUTLET SENSOR (S9)

X8-2

OUTLET SENSOR (S1)

X8-4

X8-9

FLUE SENSOR (S10)

X7-1

PRE-MIX SENSOR 1 (S11)

X7-5

PRE-MIX SENSOR 1 (S13)

X8-19

AIR VALVE POSITION

X6-18

X6-9

X6-17

X6-8

X6-2

X6-1

-T

FLUE SENSOR

LARGE

X6-3

CONNECTION BOARD

CN6-3

CN6-2

CN6-1

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

-T

BLOWER

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

SHIELD

BAS OPTION

SHIELD

RATE OUT

BOILER PUMP OUT

SYSTEM RETURN SENSOR

SYSTEM SUPPLY SENSOR

TANK SENSOR

OUTDOOR SENSOR

BMS

SYSTEM PUMP IN

SHIELD

CASCADE

SHIELD

LCD

DISPLAY

GPS1 GPS2

BLOCKED FLUE

SWITCH

BLOCKED DRAIN

SWITCH

BLOCK WIRING

IS MODEL

DEPENDANT

LWCO

PROBE

LWCO RESET

AIR VALVE

PRESS. SWITCH

"X5"

TEST

SWITCH

X6-12

X6-5

X13-1

X5-10

X5-41

X5-12

J3-6

J3-3

J2-1

J2-2

INTEGRATED

CONTROL

X6-6

X5-1

X5-7

X5-2

X5-8

X5-3

X5-9

X5-4

X5-5

X5-6

LWCO

BOARD

J3-5

J3-2

J3-4

X6-13

X3-3

X3-4

X3-1

X3-2

X6-11

X6-2

X6-14

X6-4

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 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 must be replaced, it must be replaced wi th wire having same wire gauge (AWG) and rated for a minimum of 105 °C. Exceptions: Replacement high voltage spark lead and must be purchased from the factory. Use of a non-approved spark lead or 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 componen ts for proper connector block locations when using diagrams to troubleshoot unit.

AIR VALVE

SMALL

CONNECTION BOARD

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

LG CON BRD

BAS

CN6-2

CN6-1

CN6-3

24V

SHIELDED CABLE FROM X4

TO J12 OR J23 AS APPLICABLE

ALARM CONTACTS

RUN-TIME CONTACTS

TANK THERMOSTAT

ENABLE

LOUVER PROVING

24 VAC LOUVER RELAY COIL

AUX SWITCH 1

AUX SWITCH 2

shielded

USB CABLE

SW1

J10

J9 J17

J11

GND

cables can lead to operational problems

OPTIONAL USB/WIFI

J23

J12

EXTENSION CABLE

OPTIONAL

ETHERNET CABLE

shielded

LADDER DIAGRAM

WIFI

DONGLE

cables

100303318 REV B

Page 25

4 Diagrams (continued)

Figure 4-6 Wiring Diagram_4001 - 5001 Models

BAS

BOARD

(AS APPLICABLE)

X1-1 X1-2 X1-3 X6-3

X6-1

X6-2

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)

AIR VALVE POSITION

SHIELDED CABLE FROM X4

HIGH LIMIT

SWITCH

LWCO

BOARD

J3-6 J3-5 J3-4 J3-3

KB/RO

J3-2 J2-1

RO RO

J2-2

AIR VALVE

PRESSURE SWITCH

"X5"

BLOCK WIRING

IS MODEL

DEPENDANT

OPTION

PUMP OUT

SYSTEM RETURN

SYSTEM SUPPLY

SYSTEM PUMP IN

CASCADE

LG CON BRD

CN6-2

CN6-1 CN6-3

CONTACTS

THERMOSTAT

24 VAC LOUVER

RELAY COIL

BAS

RATE

OUT

BOILER

SENSOR

OUTDOOR

SENSOR

BMS

BAS R PR

ALARM

RUN-TIME

ENABLE

LOUVER

PROVING

SWITCH 1

SWITCH 2

SHIELD

TANK

SHIELD

24V

TANK

LARGE CONNECTION BOARD

J10

0-10V

DISPLAY

J11

GND

LCD

J12

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

COMMUNICATION CONTROL BOARD

SW1

J9 J17

J23

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

TO J12 OR J23 AS APPLICABLE

SMALL CONNECTION BOARD

1 2 3 4 5 6 7

9 10 11 12

LWCO

PROBE

13 14 15 16

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

GPS1 GPS2

BLOCKED FLUE

SWITCH

BLOCKED DRAIN

SWITCH

Outdoor Crest Supplemental Manual

BOX DEPICTS

OPTIONAL ITEMS

BOX DEPICTS DUAL SENSOR

SINGLE HOUSING

LOW VOLTAGE

ON/OFF

480V 30

KB W G

120 VAC

HIGH VOL TAGE

BK/W

TRANSFORMER

R/W

BLOWER

124

FLAME SENSE 2

SPARK ROD

FLAME SENSE 1

SERVICE OUTLET

FLUE DAMPER

24V

1.5A EACH MAX

GAS VALVE (SMALL)

GAS VALVE (LARGE)

480V

231

SYSTEM PUMP CONTACTOR

BOILER PUMP CONTACTOR

DHW PUMP CONTACTOR

JUNCTION

BOX

GND

INTEGRATED CONTROL

X8-20

X8-10

X7-8

X7-7

X8-13

X8-14

X8-12 X8-11

X8-5

W/RO

X8-15

X8-6 X8-16

W LB

X8-7 X8-17

X8-18

KB/Y

X8-1

X8-3

X8-8

W/R

X8-2

X8-4

X8-9

X7-1

X7-5

X8-19

X3-3

X3-4

X3-1

X3-2 X6-1

X6-11

X6-2

X6-14

X6-10

X6-13

X6-4

X6-3

X6-5

X13-1

X6-6

O/BK

X6-12

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

X11

USB

INTERFACE

X6-13

SWITCH

LB R

SPARK

GENERATOR

R P

FLUE DAMPER TRANSFORMER KB

O/W

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 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 vo ltage spark lead and shielded cables must be purchased from the factory. Use of a non-approved spark lead or shielded 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.

WIRING DIAGRAM

100303313 REV B

Page 26

4 Diagrams

Figure 4-7 Ladder Diagram_6001 Model

L2 L3

TERMINAL STRIP

480V 3 SUPPLY

ON/OFF SWITCH

GPS GPS2

BLOCKED DRAIN

X1-6

3.15 AF45.0 A

X10-1 X10-2

X6-1

X2-5

X6-1

X2-5

X1-1 X1-2

LWCO PROBE

LWCO RESET

POC

AIR VALVE

PRESSURE SWITCH

BLOCKED FLUE

SWITCH

"X5"

BLOCK WIRING

IS MODEL

DEPENDANT

JUNCTION BOX

INTEGRATED CONTROL

SYSTEM PUMP

RELAY

BOILER PUMP

RELAY

DHW PUMP

RELAY

SMALL GAS

VALVE RELAY

LARGE GAS

VALVE RELAY

LARGE GAS

VALVE RELAY

SMALL GAS

VALVE RELAY

X11

USB

INTERFACE

BLOWER

CONTACTOR

BAS

(AS APPLICABLE)

X1-3

480V

TRANSFORMER

FLUE DAMPER

J3-6

TEST

J3-3

SWITCH

J2-1

J2-2

X6-5

INTEGRATED

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

TRANSFORMER

P.O.C. VALVE

CONTROL

1 2 3

SERVICE OUTLET

24V

LWCO

BOARD

X1-3

X1-12

X1-1

X1-2

X1-4

X1-8

CONTACTOR

X10-3

X10-6

X10-5

X10-4

X1-3

X1-7

X1-10

X2-5

X6-3

X6-10

X13-4

BLOWER

FLUE DAMPER

TRANSFORMER

J3-5

X6-13

X3-3

X3-4

X3-1

X3-2

X6-11

X6-2

X6-14

X6-4

Outdoor Crest Supplemental Manual

NEUTRAL

TERMINAL STRIP 480V SUPPLY "N"

1.5A EACH MAX

TERMINAL STRIP

SYSTEM PUMP

CONTACTOR

BOILER PUMP

CONTACTOR

DHW PUMP

CONTACTOR

GAS

VALVE

(LARGE)

GAS

VALVE

(SMALL)

FLAME

SENSE 1

SPARK

ROD

SPARK

GENERATOR

FLAME

SENSE 2

J3-2

J3-4

CN-4

CN-1

CN-2

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 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 must be replaced, it must be replaced wi th wire having same wire gauge (AWG) and rated for a minimum of 105 °C. Exceptions: Replacement high voltage spark lead and must be purchased from the factory. Use of a non-approved spark lead or 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 componen ts for proper connector block locations when using diagrams to troubleshoot unit.

GROUND

INTEGRATED

CONTROL

AIR VALVE

SMALL

CONNECTION BOARD

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

BAS

BOARD

(AS APPLICABLE)

X4-1

X4-2

X4-3

X8-20

X8-10

X8-1

X7-8

X7-7

X8-13

X8-14

X8-12

X8-11

X8-5

X8-15

CN3-4

X8-6

X8-16

X8-7

X8-17

X8-18

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)

X8-19

AIR VALVE POSITION

X6-18

X6-9

X6-17

X6-8

ALARM CONTACTS

RUN-TIME CONTACTS

TANK THERMOSTAT

ENABLE

LOUVER PROVING

24 VAC LOUVER RELAY COIL

AUX SWITCH 1

AUX SWITCH 2

BOX DEPICTS

OPTIONAL ITEMS

BOX DEPICTS DUAL SENSOR

SINGLE HOUSING

LARGE

X6-2

X6-1

X6-3

CONNECTION BOARD

CN6-3

CN6-2

CN6-1

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

-T

BLOWER

LG CON BRD

BAS

CN6-2

J10

CN6-1

CN6-3

SHIELDED CABLE FROM X4

TO J12 OR J23 AS APPLICABLE

24V

shielded

LOW VOLTAGE 120 VAC

HIGH VOLTAGE

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

J11

J12

GND

cables can lead to operational problems

0-10V

SW1

J17

J23

SHIELD

BAS OPTION

SHIELD

RATE OUT

BOILER PUMP OUT

SYSTEM RETURN SENSOR

SYSTEM SUPPLY SENSOR

TANK SENSOR

OUTDOOR SENSOR

BMS

SYSTEM PUMP IN

SHIELD

CASCADE

SHIELD

LCD

DISPLAY

USB CABLE

OPTIONAL USB/WIFI

EXTENSION CABLE

OPTIONAL

ETHERNET CABLE

shielded

LADDER DIAGRAM

100303354 REV B

DONGLE

cables

WIFI

Page 27

4 Diagrams (continued)

Figure 4-8 Wiring Diagram_6001 Model

(AS APPLICABLE)

J10

0-10V

DISPLAY

J11

GND

LCD

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

COMMUNICATION CONTROL BOARD

SW1

USB CABLE

J9 J17

OPTIONAL USB/WIFI EXTENSION CABLE

J23

J12

OPTIONAL

ETHERNET CABLE

SMALL CONNECTION BOARD

1 2 3 4 5 6 7

9 10 11 12 13 14 15 16

LWCO

PROBE

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

SHIELDED CABLE FROM X4

TO J12 OR J23 AS APPLICABLE

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

GPS1 GPS2

BLOCKED FLUE

SWITCH

BLOCKED DRAIN

SWITCH

POC

AIR VALVE

PRESSURE SWITCH

OUTLET SENSOR (S9)

OUTLET SENSOR (S1)

FLUE SENSOR (S10)

PRE-MIX SENSOR 1 (S11)

PRE-MIX SENSOR 1 (S13)

KB/RO

RO RO

BLOCK WIRING

DEPENDANT

OPTION

BOILER

PUMP OUT

SYSTEM RETURN

SYSTEM SUPPLY

OUTDOOR

SYSTEM PUMP IN

CASCADE

LG CON BRD

CN6-2

CN6-1

CN6-3

CONTACTS

RUN-TIME

CONTACTS

THERMOSTAT

24 VAC LOUVER

RELAY COIL

SWITCH 1

SWITCH 2

SHIELD

BAS

SHIELD

RATE

OUT

SENSOR

TANK

SENSOR

BMS

SHIELD

BAS

ALARM

TANK

ENABLE

LOUVER

PROVING

24V

AUX

BAS

BOARD

X1-1 X1-2 X1-3

X6-3 X6-1

X6-2 X4-1 X4-2 X4-3

-T

INLET SENSOR

-T

FLUE SENSOR

-T

AIR VALVE POSITION

HIGH LIMIT

SWITCH R

LWCO

BOARD

J3-6 J3-5 J3-4 J3-3 J3-2 J2-1 J2-2

O/BK

"X5"

IS MODEL

Outdoor Crest Supplemental Manual

BOX DEPICTS

OPTIONAL ITEMS

BOX DEPICTS DUAL SENSOR

SINGLE HOUSING

LOW VOLTAGE

ON/OFF

480V 30

KB W G

120 VAC

HIGH VOL TAGE

R/W

BK/W

FLAME SENSE 2

SPARK ROD

FLAME SENSE 1

SERVICE

OUTLET

24V

TRANSFORMER

GAS VALVE (SMALL)

GAS VALVE (LARGE)

480V

TRANSFORMER

231

BLOWER

124

FLUE DAMPER

1.5A EACH MAX

SYSTEM PUMP CONTACTOR

BOILER PUMP CONTACTOR

DHW PUMP CONTACTOR

JUNCTION

BOX

GND

INTEGRATED CONTROL

X8-20

X8-10

X7-8

LB R

X7-7

X8-13

X8-14

X8-12 X8-11

X8-5

W/RO

X8-15

X8-6 X8-16

X8-7 X8-17

X8-18

KB/Y

X8-1

X8-3

X8-8

W/R

X8-2

X8-4

X8-9

X7-1

X7-5

X8-19

X3-3

X3-4

X3-1

X3-2 X6-1

X6-11

X6-2

X6-14

X6-10

X6-13

X6-4

X6-3

X6-5

X13-1

X6-6

X6-15

X6-12

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

X11

X12-1

X12-2

USB

X12-5

INTERFACE

X12-4

SWITCH

RO RO

LB R

SPARK

GENERATOR

R P

FLUE DAMPER

TRANSFORMER

P.O.C VALVE

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 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 vo ltage spark lead and shielded cables must be purchased from the factory. Use of a non-approved spark lead or shielded 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.

WIRING DIAGRAM

100303308 REV B

Page 28

Revision Notes: Revision A (PCP# 3000023718 / CN# 500013605) initial release. Revision B (PCP #3000027910 / CN #500017507) reflects the addition of the 3501 model, updates made to the Check Flame and Combustion Section on page 18, and the wiring and ladder diagrams.

Revision C (PCP #3000029182 / CN #500018624) reflects the addition of the 2501 - 3001 and 4001 - 6001 models.

MM #100302418_DIR #2000555704 Rev C

11/18