Lochinvar CREST 2.5 Supplemental Manual

CREST 2.5
Lochinvar
Brand
Lochinvar
Model
CREST 2.5
Type
Supplemental Manual

This manual is also suitable for

The Lochinvar CREST 2.5 is a versatile boiler capable of heating homes and other buildings efficiently and reliably. With a maximum input of 125 MBH and a net output of 2000 MBH, it can provide ample warmth even in the coldest climates. Its compact size and flexible venting options make it suitable for a variety of installation scenarios, while its advanced features like the SMART SYSTEM control board and Outdoor Reset capability ensure optimal performance and energy savings. This dual-fuel boiler can operate on either natural gas or propane, providing fuel flexibility and peace of mind.

The Lochinvar CREST 2.5 is a versatile boiler capable of heating homes and other buildings efficiently and reliably. With a maximum input of 125 MBH and a net output of 2000 MBH, it can provide ample warmth even in the coldest climates. Its compact size and flexible venting options make it suitable for a variety of installation scenarios, while its advanced features like the SMART SYSTEM control board and Outdoor Reset capability ensure optimal performance and energy savings. This dual-fuel boiler can operate on either natural gas or propane, providing fuel flexibility and peace of mind.

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.
WARNING
Save this manual for future reference.
FBD-SUP_100161023_2000004585 Rev D
Dual Fuel Supplemental Manual
Models: FBD 2.5 - 5.0
2
CONTENTS
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.
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
Dual Fuel Supplemental Manual
Please read before proceeding
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.
Failure to adhere to the guidelines on this
page can result in severe personal injury,
death, or substantial property damage.
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.
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.
Factory warranty (shipped with unit) does
not apply to units improperly installed or
improperly operated.
3
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.
WARNING
NOTICE
WARNING
WARNING
Dual Fuel Supplemental Manual
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.
IMG00061
14
11
10
8
9
15
12
6
7
13
IMG00064
3
4
5
IMG00555
MODELS 4.0 - 5.0
MODELS 2.5 - 3.5
3
4
5
Models FBD 2.5 - 5.0
IMG00062
1
2
Front View
Left Side (inside unit)
Dual Fuel Supplemental Manual
Ratings
Crest
AHRI Rating
Model Number
Note: Change “N” to
“L” for L.P. gas models.
Input
MBH
(Notes 4 - 8)
Min Max
Gross
Output
MBH
(Note 1)
Net
AHRI
Ratings
Water,
MBH
(Note 2)
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
Maximum allowed working pressure is located on the rating plate.
NOTICE
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
2
’s are adjusted to the
recommended levels.
UNIT EQUIPPED FOR
HIGH ALTITUDE
3,000 FT. TO 12,000 FT.
Figure A High Altitude Label Location
*For LP models the minimum input is 420 MBH.
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.
5
Other Specifications
Appliance
Water
Content
Gallons
Pipe
Size
Outlet
Pipe
Size
Inlet
Gas Inlet
Size
Air
Size
Vent
Size
(Note 3)
Weight
w/Water
(lbs.)
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
6
Table 1A First Stage Piping at High Pressure_10 PSI
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.
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.
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.
WARNING
Check inlet gas supply
1 Gas connections
Dual Fuel Supplemental Manual
The Dual Fuel Crest is equipped with
two (2) inlet gas connections. Each
connection must be checked to ensure
proper operation.
NOTICE
Table 1B Second Stage Piping at Low Pressure_1/2 PSI
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 Pipe
Size Inches
Length of pipe or tubing, feet
Maximum Capacities of Pipe in KBTUH/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
Pipe 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 Pipe
Size Inches
Length of pipe or tubing, feet
Maximum Capacities of Pipe in KBTUH/Hr
7
Dual Fuel Supplemental Manual
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.
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.
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.
Figure 1-1 Inlet Gas Supply Check_Natural
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.
Failure to follow all precautions
could result in fire, explosion, or
death!
WARNING
WARNING
1 Gas connections (continued)
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.
Figure 1-2 Inlet Gas Supply Check_Propane
IMG00065
8
Dual Fuel Supplemental Manual
2 Start-up
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.
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.
Check vent piping and air piping
1. Check for gastight seal at every connection, seam of air
piping, and vent piping.
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 in the Crest Installation and Operation
Manual (connecting gas supply piping).
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.
WARNING
WARNING
9
Dual Fuel Supplemental Manual
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.
A. This 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 OPER ATING sme ll all ar ou nd
th e appliance area for gas. Be su re to
smell next to the floor because some gas
is heavier than air and will settle on the
floor.
WHAT TO DO IF YOU SMELL GAS
• D o not try to light any appl iance.
• Do not touch any electric switch; do
not use any phone i n you r bui ldi ng.
• Immediately call your gas supplier from a
neighb or ’s phone. Fol low the g as supplier’s
instructions.
• If you can not reach you r gas suppl 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 , d on’t try to repair i t, call a qualified service
technician. Force or attempted repair may
result in a fire or explosion.
D. Do not use this appliance if any pa rt has been
unde r water. Imm ediately call a qual ified
ser vice technician to inspect the app lianc e and
to replace any part of the control system and
any ga s control w hich ha s been under water.
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
app lianc e.
4. T his appliance is equipped with an
ignition device which automatically lights
the burner. Do not try to light the burner
by ha nd.
5. Remove front door.
6. Turn gas shutoff valve counterclockwise
to “ OFF”. H andle wil l be perpen dicu lar 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 label.
If you don’t smell gas, go to next step.
8. Tur n gas shutoff val ve clockwise to “ ON”.
Handle will be parallel to pipe.
9. Instal l fr ont door.
10. Turn on all electric power to appliance.
11. Set th er mo stat to desired setti ng.
12. If the appl iance w ill not op er ate , fol low the
instr uctions “T o Turn Off Gas T o Appliance” an d
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 electr ic po wer to the appl iance
if service i s to be perfor med.
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 ont door.
L BL2 005 3 REV B
Figure 2-1 Operating Instructions
2 Start-up (continued)
10
Dual Fuel Supplemental Manual
2 Start-up
Table 2A Flue Products Chart
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.
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.
WARNING
Gas
Valve
Natural Gas Propane
CO
2
O
2
CO
2
O
2
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%
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 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.
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.
NOTICE
A flame and combustion check
must be performed on natural gas
and then repeated on propane.
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.
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
IMG00063
NATURAL
PROPANE
DETAIL
IMG00064
MAIN POWER
SWITCH
NATURAL PERSONALITY I.D.
PROPANE PERSONALITY I.D.
FUEL SELECTION
SWITCH
11
Dual Fuel Supplemental Manual
2 Start-up (continued)
3. Turn off all ball valves (3 total) for the fuel not in use (FIG. 2-3).
Figure 2-3 Ball Valves
NATURAL
PROPANE
IMG00061
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.
Figure 2-4 Personality Plug Screen
Figure 2-2B Fuel Selector Switch - Models 4.0 - 5.0
IMG00063
NATURAL
PROPANE
DETAIL
MAIN POWER
SWITCH
NATURAL
PERSONALITY I.D.
PROPANE
PERSONALITY I.D.
FUEL SELECTION
SWITCH
IMG00555
12
Dual Fuel Supplemental Manual
-T
1
32
1
2
45
3
231
12 45
3
M
1
2
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 with wire having same 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 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.
100267551 REV A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
CN1-12
CN1-5
CN1-10
CN1-11
CN1-6
CN1-9
CN1-8
CN1-7
CN1-1
CN1-2
CN1-3
CN1-4
17
CN3-6
CN6-2
CN3-7
CN3-14
CN6-1
CN3-13
CN3-12
CN3-11
CN3-10
CN3-9
CN3-8
CN6-3
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
CN3-1
CN3-2
CN3-5
CN3-3
X3-2
X3-4
X6-1
X6-11
X3-1
X6-2
X6-14
X6-10
X6-13
X6-4
X3-3
X7-8
X7-7
X8-14
X8-13
X8-12
X8-11
X8-15
X8-5
X8-6
X8-16
X8-7
X8-17
X8-18
X8-1
ALARM
CONTACTS
RUN-TIME
CONTACTS
TANK
THERMOSTAT
LOUVER
PROVING
24 VAC LOUVER
RELAY COIL
AUX
SWITCH 1
AUX
SWITCH 2
SHIELD
SHIELD
A
B
MODBUS
OPTION
+
-
-
+
RATE
OUT
BOILER
PUMP OUT
SYSTEM RETURN
SENSOR
SYSTEM SUPPLY
SENSOR
0-10V
0-10V
TANK
SENSOR
OUTDOOR
SENSOR
+
+
-
-
0-10V
0-10V
BMS
IN
SYSTEM
PUMP IN
SHIELD
SHIELD
A
B
CASCADE
R
R
RO
RO
LB
KB
RB
R
Y
RO
HIGH LIMIT
SWITCH
R
R
X6-1
X6-2
X6-3
YG
R
RP
BAS
LB
R
LB
R
RB
W
RO
W/RO
P
W
LB
KB
J3-5
J3-4
J3-6
LWCO
BOARD
J3-3
J3-2
J2-1
J2-2
X6-3
RO
KB/RO
KB/RO
TEST
SWITCH
LWCO
PROBE
RO
RO
LWCO RESET
X6-5
X6-15
BLOWER PROVING SWITCH (LARGE)
RO
X6-12
BLOWER PROVING SWITCH (SMALL)
T
X13-1
BLOCKED FLUE SWITCH
RP
X6-6
BLOCKED DRAIN SWITCH
KB
ENABLE
X8-3
X8-8
X8-2
X8-4
X8-9
X7-1
X7-5
X7-2
X7-6
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)
R
W
X4-1
X4-2
X4-3
X8-20
X8-10
X5-8
X5-7
X5-3
X5-9
X5-2
X5-4
X5-10
X5-5
X5-41
X5-6
X5-12
X5-1
"X5"
BLOCK WIRING
IS MODEL
DEPENDENT
KB
T
LB
W/R
R
W
YG
YG
RB
T
X10-1
X1-3
X10-4
X1-1
X1-12
X1-2
X1-4
X10-2
X10-5
X10-3
X10-6
X1-6
LN
GND
120V
SUPPLY
ON/OFF
SWITCH
GND
SMALL
PROPANE
VALVE
LARGE
PROPANE
VALVE
KB
W
RP
T
RO
LB
R
LB
X6-18
X6-8
X1-8
G
X6-9
X6-17
SMALL
BLOWER
RELAY
LARGE
BLOWER
RELAY
X2-4
X13-2
X13-3
BLOWER
(SMALL)
BLOWER
(LARGE)
R
KB
YG
W
T
T
KB/W
T
KB
W/KB W/G
R/W
BK/W
X2-3
X1-7
X1-10
X1-5
FLAME SENSE 2
FLAME SENSE 1
SPARK
GENERATOR
SPARK ROD
X2-5
FLUE DAMPER
TRANSFORMER
X13-4
FLUE DAMPER
24V
TRANSFORMER
LB
R
R
R
P
KB
LB
Y
RO
BL
Y
BK
X1-2
X1-3
X1-1
INTEGRATED CONTROL
LARGE CONNECTION BOARD
SMALL CONNECTION BOARD
JUNCTION
BOX
X11
X4
USB
INTERFACE
BOILER PUMP
CONTACTOR
SYSTEM PUMP
CONTACTOR
DHW PUMP
CONTACTOR
KB
HIGH VOLTAGE
LOW VOLTAGE
120 VAC
1.5A EACH MAX
RO
OR
BR
OR
GPS3
GPS2
CAM
SWITCH
PROPANE LGPS
NATURAL LGPS
CAM SWITCH
SMALL
NATURAL
VALVE
LARGE
NATURAL
VALVE
OR/BK
OR/W
CAM
SWITCH
CAM
SWITCH
R/BK
R/W
CAM
SWITCH
PROPANE LIGHT
NATURAL LIGHT
CN3-4
KB/Y
E
GND
LG CON BRD
WIFI
DONGLE
SW1
J2
8
43
J9
J17
J23
J12
J11
J8
USB CABLE
OPTIONAL USB/WIFI
EXTENSION CABLE
J10
R
J6
J7
COMMUNICATION
CONTROL BOARD
OPTIONAL
ETHERNET CABLE
PR
GY
24V
CN6-3
CN6-1
CN6-2
BAS
DISCONNECT POWER
BEFORE SERVICING
!
BOX DEPICT S
DUAL SENSOR
SINGLE HOUSING
BOX DEPICTS
OPTIONAL ITEMS
WARNING
LCD
DISPLAY
Y
LB
-T
-T
-T
-T
-T
-T
-T
-T
3 Diagrams
Figure 3-1 Wiring Diagram_2.5 - 3.5 Models
13
Dual Fuel Supplemental Manual
PRE-MIX SENSOR 1 (S11)
FLUE SENSOR (S10)
FLUE SENSOR
OUTLET SENSOR (S1)
-T
-T
-T
-T
-T
-T
-T
-T
PRE-MIX SENSOR 2 (S14)
PRE-MIX SENSOR 2 (S12)
PRE-MIX SENSOR 1 (S13)
OUTLET SENSOR (S9)
1.5A EACH MAX
WARNING
OUT
100267529 REV A
JUNCTION BOX
TERMINAL STRIP
120V SUPPLY "L"
TERMINAL STRIP
120V SUPPLY "N"
120VAC NEUTRAL
INTEGRATED CONTROL
ON/OFF
SWITCH
F2
3.15 A
F4
5.0 A
SYSTEM PUMP
RELAY
BOILER PUMP
RELAY
DHW PUMP
RELAY
X1-1
X1-2
X1-4
X1-8
X2-4
SMALL BLOWER RELAY
LARGE BLOWER RELAY
SMALL GAS
VALVE RELAY
LARGE GAS
VALVE RELAY
X1-6
2-01X1-01X
X10-3
SMALL GAS
VALVE RELAY
LARGE GAS
VALVE RELAY
X10-6
X10-5
X10-4
TERMINAL STRIP
SYSTEM PUMP
CONTACTOR
BOLIER PUMP
CONTACTOR
DHW PUMP
CONTACTOR
SMALL BLOWER
RELAY
LARGE BLOWER
RELAY
SMALL BLOWER
LARGE BLOWER
X6-10
X13-4
X6-1
X2-5
21
3
21
3
BAS
X1-1
X1-2
X1-3
FLUE DAMPER
TRANSFORMER
12
3
24V
TRANSFORMER
FLUE DAMPER
X6-3
X1-12
X1-3
LWCO
BOARD
TEST
SWITCH
LWCO
PROBE
LWCO RESET
J3-6
J3-3
J2-1
J2-2
J3-5
J3-2
J3-4
X6-5
X6-15
X6-12
X13-1
X6-6
X3-3
X3-4
X3-1
X3-2
X6-11
X6-2
X6-14
INTEGRATED
CONTROL
BLOWER PROVING
SWITCH (LARGE)
BLOWER PROVING
SWITCH (SMALL)
BLOCKED FLUE
SWITCH
BLOCKED DRAIN
SWITCH
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
ALARM
CONTACTS
RUN-TIME
CONTACTS
TANK
THERMOSTAT
LOUVER
PROVING
24 VAC LOUVER
RELAY COIL
AUX
SWITCH 1
AUX
SWITCH 2
ENABLE
R
W
SMALL
CONNECTION BOARD
CN1-4
CN1-5
CN1-6
CN1-12
CN1-10
X6-13
X6-4
CN1-11
CN1-9
CN1-8
CN1-7
CN1-1
CN1-2
CN1-3
HIGH LIMIT
SWITCH
X1-3
X1-7
X1-10
X2-5
FLAME
SENSE 2
FLAME
SENSE 1
SPARK
GENERATOR
SPARK
ROD
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
SHIELD
SHIELD
A
B
MODBUS
OPTION
+
-
-
+
RATE
X6-17
BOILER
PUMP OUT
SYSTEM RETURN
SENSOR
SYSTEM SUPPLY
SENSOR
0-10V
0-10V
TANK
SENSOR
OUTDOOR
SENSOR
+
+
-
-
0-10V
0-10V
BMS
IN
SYSTEM
PUMP IN
SHIELD
SHIELD
A
B
CASCADE
LARGE
CONNECTION BOARD
CN6-1
CN3-6
CN3-7
CN3-14
CN3-13
CN3-11
CN3-9
CN3-8
CN3-1
CN3-2
CN3-3
CN3-4
CN6-2
CN6-3
CN3-10
CN3-12
BAS
X4-1
X4-2
X4-3
X6-3
X6-1
X6-2
X8-20
X8-10
X7-8
X8-13
X8-14
X8-12
INTEGRATED
CONTROL
X8-5
X8-15
X7-7
X8-11
X8-6
X8-16
X8-7
X8-17
X8-1
-T
INLET SENSOR
X8-3
X8-8
X8-2
X8-4
X8-9
X7-1
X7-5
X7-2
X7-6
GROUND
X6-18
X6-9
M
X6-8
X13-2
X13-3
1
2
4
5
1
2
4
5
SMALL BLOWER
LARGE BLOWER
X11
X4
X5-1
X5-7
X5-2
X5-8
X5-3
X5-9
X5-4
X5-10
X5-5
X5-41
X5-6
X5-12
HIGH VOLTAGE
LOW VOLTAGE
OPTIONAL ITEMS
DUAL SENSOR
DISCONNECT POWER
non-repairable damage to the integrated controller or other components.
BEFORE SERVICING
CN6-2
3. Actual connector block locations may vary from those show n on diagrams. Refer to actual components for proper connector blo ck
SINGLE HOUSING
120 VAC
locations when using diagrams to troubleshoot unit.
USB
INTERFACE
"X5"
BLOCK WIRING
IS MODEL
DEPENDANT
CAM
SWITCH
PROPANE LIGHT
NATURAL LIGHT
NATURAL LGPS
PROPANE LGPS
CAM SWITCH
GPS2 GPS3
PROPANE
NATURAL
PROPANE
NATURAL
CN3-4
X8-1
OPTIONAL
ETHERNET CABLE
E
GND
WIFI
DONGLE
RIBBON CABLE
SW1
J2
8
43
J6
J9
J17
J23
J12
J11
LG CON BRD
J8
LCD
DISPLAY
USB CABLE
OPTIONAL USB/WIFI
EXTENSION CABLE
J10
J7
BAS
CN6-1
CN6-3
24V
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 wi re gauge
(AWG) and rated for a minimum of 105°C. Exceptions: Replac ement 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
BOX DEPICTS
BOX DEPICTS
!
3 Diagrams (continued)
Figure 3-2 Ladder Diagram_2.5 - 3.5 Models
14
Dual Fuel Supplemental Manual
PRE-M
IX SENSOR 1
(
S11)
PRE-M
IX SENSOR
1
(S13)
PRE-M
IX SENSOR
2 (S12)
-
T
-
T
-
T
-
T
-
T
-
T
-
T
-
T
O
UT
LET SENSO
R
(S9
)
OUTLET SENSOR (S1)
FLU
E SENSO
R
FLUE SENSO
R
(S10)
PRE-M
IX SENSOR
2
(S14)
BOX D
EPICT
S
OPTIONAL ITEMS
BO
X DEPICTS
D
UAL S
EN
S
OR
SINGLE HOUSING
WARNING
DISCONNECT POWER
BEFORE SERVICING
!
1.5
A EACH
MAX
VAL
V
E
L
ARGE
-
T
1
2
5
43
2
1
4
3
d
i
a
g
ra
m
s
to tro
u
b
l
e
s
h
o
o
t u
n
i
t.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
CN
1
-12
CN
1
-5
CN1
-10
CN
1
-11
CN
1
-6
CN
1
-9
CN
1
-8
CN
1
-7
CN1
-1
CN
1
-2
CN
1
-3
CN
1
-4
17
CN3-6
CN6-2
CN3-7
CN3-14
CN6-1
CN3-13
CN3-12
CN
3
-11
CN
3
-10
CN3-9
CN3-8
CN6-3
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
CN3-1
CN
3
-2
CN3-5
CN3-3
X3
-2
X3-4
X6
-1
X6
-11
X3-1
X6
-2
X6-14
X6-10
X6-13
X6
-4
X3
-3
X7-8
X7-7
X8-14
X8-13
X8
-12
X8
-11
X8
-15
X8-5
X8
-6
X8
-16
X8
-7
X8-17
X8
-18
X8
-1
ALARM
CONTA
CTS
RU
N-TIM
E
C
ONTACTS
TANK
THER
M
OSTAT
LO
UVER
PRO
VING
24
VAC LOUVER
RE
L
AY CO
IL
AU
X
SWITCH 1
AUX
SWITCH 2
SH
IELD
SHIELD
A
B
M
O
DBUS
O
PTION
+
-
-
+
RATE
OUT
BO
ILE
R
PUMP OUT
SYSTEM RETURN
SENSOR
SY
STE
M
SUPPLY
SENSOR
0-10V
0-10V
TANK
SENSO
R
O
UTDOOR
SENSO
R
+
+
-
-
0
-
10V
0
-10V
BM
S
IN
SYSTEM
PUM
P IN
S
H
I
E
L
D
S
H
I
E
LD
A
B
CASCAD
E
R
R
OR
OR
BL
BK
BR
R
Y
O
R
HIG
H
L
IM
IT
SWITCH
R
R
X6-1
X6-2
X6-3
GY
R
PR
BAS
BL
R
BL
R
BR
W
OR
O
R/W
P
W
BL
B
K
Y/
BK
J
3-5
J
3-4
J
3
-6
LWCO
B
OARD
J
3
-3
J
3
-2
J
2
-1
J
2-2
X6
-3
O
R
O
R
/
BK
O
R/BK
TEST
SWIT
C
H
L
WCO
PRO
BE
OR
O
R
LWCO RESET
X6
-5
X6
-15
BL
O
WER PRO
VING
SWI
TC
H
(L
AR
G
E)
OR
X6
-12
B
L
OWER PRO
VING
SWI
TCH
(SM
ALL
)
T
X13
-1
BL
O
CKED FLU
E SWITC
H
PR
X6
-6
BL
O
CKED DRAIN
SWITCH
BK
ENABL
E
X8
-3
X8-8
X8
-2
X8
-4
X8
-9
X7
-1
X7
-5
X7-2
X7-
6
INLET SENSO
R
R
W
X4-1
X4-2
X4-3
X8-20
X8-10
X5
-8
X5
-7
X5-3
X5
-9
X5
-2
X5
-4
X5
-10
X5
-5
X5
-41
X5
-6
X5
-12
X5
-1
BK
T
BL
R/W
R
W
G
Y
G
Y
BR
T
X10-1
X1
-3
X10
-
4
X1
-1
X1
-12
X1
-2
X1
-4
X10
-2
X10-
5
X10-3
X10-6
X1
-6
ON/OFF
S
W
ITCH
G
ND
BK
W
PR
T
O
R
X6
-18
X6
-8
X1-8
G
X6
-9
X6
-17
X2
-4
X13
-
2
X13-3
BLOW
ER
(SM
ALL)
BLOWE
R
(LARG
E)
R
BK
GY
W
W/BK
T
M
T
G
N
R/W
BK/W
X2
-3
X1
-7
X1
-1
0
X1
-5
FLAME
SEN
SE 2
FLAME
SEN
SE
1
SPARK
G
ENERATO
R
SPARK ROD
X2
-5
FLUE DAM
PER
TR
ANSFORMER
X13-4
FL
U
E
D
AM
PER
24V
T
R
ANSFO
RM
ER
BL
R
R
R
P
BK
BL
Y
OR
B
L
Y
B
K
X1-2
X1-3
X1-1
INTEG
RATED CONTROL
LARGE CONNECTION BOARD
SM
ALL
CONNE
C
TION
BOARD
J
UNC
T
IO
N
BOX
X1
1
X
4
US
B
INTE
RFACE
B
O
IL
E
R
PUM
P
CONTACTOR
S
YST
E
M
PUM
P
CONTACTOR
DH
W
PUM
P
C
ONTACTOR
BK
HIGH VOLTAGE
LOW VOLTAGE
120 VAC
1
00
2
6
75
3
0
R
E
V
C
R2
R
BL
R
1
R2
L1
L2
L3
208V 3Ø
R1
N
CN3-4
OR
BR
OR
G
PS3GPS2
C
AM
SWITCH
PRO
PAN
E LG
PS
NATUR
A
L
LGPS
"X5"
BL
O
CK WIRING
IS M
O
DEL
DEPENDEN
T
CAM
SWI
TCH
CAM
SWITCH
PR
O
PANE
LIGHT
NATURAL LIGH
T
SM
AL
L
PROPA
N
E
T
Y
PRO
PA
N
E
VAL
VE
SMA
L
L
NATURAL
VAL
VE
L
ARGE
NA
TURAL
VAL
VE
OR/BK
OR
/
W
CAM
SWI
TCH
C
A
M
SW
ITCH
R/BK
R/W
X10-3
E
GND
L
G
CON
BRD
WI
F
I
DONGLE
S
W1
J
2
8
4
3
J
9
J17
J23
J12
J11
J
8
USB
CABL
E
O
PTIO
NAL
U
SB
/WIFI
EXTENSION CABLE
J10
L
C
D
D
ISPL
AY
R
J
6
J
7
COMMUNICATIO
N
CONTROL BOARD
OPTIONAL
ETHERNET CABLE
PR
G
Y
24V
CN6-3
CN6
-1
CN
6
-2
BAS
1
2
3
1
2
3
4
5
12 3
Note
s
:
1
.
All
w
i
ring
mu
s
t b
e
i
n
s
tal
l
ed
i
n
a
c
cord
a
n
c
e
wi
th
:
loc
a
l
, sta
te
, pro
v
i
n
c
ia
l
a
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
i
th
e
r N.E.C. i
n
USA
o
r
C.S.A. i
n
Ca
n
a
d
a
.
2. If an
y
ori
g
i
n
a
l
e
q
u
i
p
m
e
n
t
wi
re
a
s s
u
p
p
lie
d
with
th
e
a
p
p
l
i
a
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
l
a
c
e
d
w
i
th
w
i
re
h
a
vin
g
sa
m
e
wi re
ga
u
g
e
(AW
G) a
n
d
ra
t
ed
fo
r a
m
i
n
i
m
u
m
o
f 1
0
5
°C
. Ex
c
e
p
t
i
o
n
s
:
Re
p
l
a
c
e
m
e
n
t
h
i
g
h
v
o
ltag
e
s
p
a
rk l
e
a
d
a
n
d
ribb
o
n
ca
b
l
e
s
m
u
s
t
b
e
p
u
rc
h
a
s
e
d
from
t
h
e
fa
c
tory.
Use
o
f a
no
n
-a
p
p
ro
v
e
d
s
p
a
rk
lea
d
o
r r
i
bbo
n
c
a
b
l
e
s
ca
n
l
e
a
d
to
o
p
e
ra
t
i
o
n
a
l
p
ro
b
l
e
m
s
wh
i
c
h
co
u
l
d
re
s
u
l
t i
n
n
o
n
-re
p
a
i
ra
b
l
e
d
a
m
a
g
e
to th
e
i
n
te
g
ra
te
d
co
n
tro
l
le
r
o
r o the
r co
m
p
o
n
e
n
t
s.
3
.
A
c
tu
a
l
c
o
n
n
e
c
to
r
b
l
o
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
n d
i
a
g
ra
m
s
.
Re
f
e
r to a
c
tu
a
l
co
m
p
o
n
e
n
ts
fo
r pro
p
e
r co
n
n
e
c
to
r b
l
oc
k
loc
a
ti
o
n
s
wh
e
n
u
s
i
n
g
BL
3 Diagrams (continued)
Figure 3-3 Wiring Diagram_4.0 Model
15
Dual Fuel Supplemental Manual
O
UTLET SENS
O
R
(
S1)
-
T
-
T
-
T
-T
-
T
-
T
-T
-
T
F
LUE SENSOR
PRE
-M
I
X SENSOR
2
(
S14)
PRE-M
I
X SENSOR
2
(S12)
PRE
-M
I
X SENSOR
1
(S13)
PRE-M
I
X SENSOR 1
(S11)
FLUE
SENSOR (S10)
OUTLET
SENSOR
(S9
)
1.5A EACH M AX
WARNING
L
2
L
1
JUNCT
I
O
N BOX
TERMINAL STRIP
208V 3
O
SUPPLY
TERMINAL STRI
P
208V SUPPLY "N"
NEUTRAL
INTEGRATED CONTROL
ON/OFF
SWITCH
F
2
3.15 A
F4
5.0 A
SYSTEM
PUMP
RELAY
BOI
LER PUMP
R
ELAY
DHW PUMP
R
ELAY
X1-1
X1-2
X1
-4
X1
-8
X2-4
SM
ALL
BLOWER
RELA
Y
LARGE BLO
WER
C
O
NTACTOR
SMALL GA
S
VAL
VE RE
LAY
LARGE
G
A
S
VALVE
RE
L
A
Y
X1-6
X
10
-
1X10-2
X10-
3
SMALL GA
S
VA
LVE RE
L
A
Y
LA
RGE
GAS
VAL
VE
RE
LAY
X10-
6
X10
-5
X10-
4
TERMINAL STRIP
SYSTEM PUMP
CONTACTOR
BOILER PUMP
CONTACT
OR
D
HW PUMP
CONTACTOR
S
M
A
L
L
BLOWER
RELA
Y
LARGE BLOWER
CONTACTOR
S
M
AL
L
BLOWER
LARGE BLO
W
E
R
X6-10
X13
-4
X6-1
X2
-5
21
3
BAS
2-1
X1-1X
X1-3
F
LUE D
AM
PER
T
RANSFO
R
M
ER
12
3
24V
T
RANS
F
ORMER
F
LUE D
A
M
PER
X6
-3
X1-12
X1-3
LWC
O
BO
ARD
T
ES
T
S
W
I
T
CH
L
WCO
P
RO
B
E
LWCO
RESET
J3-6
J3-3
J2-1
J2-2
J
3
-
5
J
3
-
2
J
3
-
4
X6-5
X
6-15
X
6-12
X
13-1
X6
-6
X3-3
X3-4
X3-
1
X3-2
X6-11
X6-2
X6-
14
I
N
TEGRATE
D
CO
NTROL
BLOW
E
R
PROV
I
NG
SWI
T
CH
(LA
RG
E
)
B
LOWER
P
R
OVI
NG
S
WI
T
CH
(SMA
LL)
B
LO
C
K
E
D
FLUE
SW
I
TCH
BLO
CK
ED
DRA
I
N
S
WI
T
CH
1
2
3
4
5
6
7
8
9
1
0
1
1
1
2
1
3
1
4
1
5
1
6
ALARM
CO
NT
ACT
S
RUN-
T
I
M
E
CO
NT
ACT
S
T
A
N
K
T
HERMO
S
T
A
T
LO
UVE
R
PRO
V
I
NG
24
VA
C
LO
UVE
R
RELAY
CO
I
L
AUX
SWI
T
CH
1
AUX
SWI
T
CH
2
ENABLE
R
W
SMA
L
L
CONNEC
T
I
O
N
BO
AR
D
CN1-4
CN1-5
CN1-6
C
N1-12
C
N
1-10
X6-13
X6-4
C
N1-11
CN1-9
CN1-8
CN1-7
CN
1-1
CN1-2
CN1-3
HIG
H
LI
M
I
T
S
WITCH
X1
-3
X1-7
X1
-10
X2
-5
FLAM
E
SENSE
2
FLA
M
E
SENSE
1
SPAR
K
GENERATOR
SPARK
ROD
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
SHIEL
D
S
HI
ELD
A
B
MODBU
S
OP
T
I
O
N
+
-
-
+
RATE
OUT
BOI
L
E
R
P
UM
P
OUT
SYSTEM
RETU
RN
SE
N
SOR
SYSTEM
SUPPLY
SENSOR
0-10V
0-
10V
TANK
SEN
SO
R
OUT
DOOR
SE
NSOR
+
+
-
-
0
-10V
0-10V
BMS
I
N
SYSTEM
PU
M
P
I
N
SHIELD
SHI
ELD
A
B
CASCADE
LARGE
C
O
NNECTION BOARD
CN6-1
CN3
-
6
CN3-
7
CN3-1
4
CN3-1
3
CN3-1
1
CN3
-
9
CN
3
-
8
CN3-1
CN3
-
2
CN3-
3
CN3
-
4
CN
6
-
2
CN6-3
CN3-1
0
CN3
-
12
B
AS
X4-1
X4
-2
X4
-3
X6-3
X6
-1
X6-2
X8-20
X8
-
1
0
X7
-8
X8-13
X8-14
X8
-12
INTEGRA
T
ED
CO
N
T
R
OL
X8-5
X8
-15
X7
-7
X8-11
X8
-6
X8
-16
X8
-7
X8-17
X8-18
-T
I
NLET
SENSOR
X8
-3
X8-
8
X8-2
X8-
4
X8-9
X7-1
X7-5
X
7
-2
X
7
-6
GROUND
X6
-18
X
6
-9
X6-17
X
6-8
X13-2
X13-3
1
4
2
5
1
4
2
5
SM
A
L
L
BLO
WER
LARGE
BLOWER
X1
1
X4
X5-1
X5
-7
X5-2
X5-8
X5
-3
X5-9
X5-4
X
5-10
X5-5
X
5
-41
X5-6
X
5-12
HIGH VOLTAGE
LOW VOLTAGE
L3
M
O
PTIONAL ITEM
S
DUAL
SENS
OR
DISCONNECT POWER
whi
c
h
could result
in
n
on-repa
irable dam
age
t
o
t
he
int
egr
at
ed
contro
ll
er
or ot
he
r
c
om
ponent
s
.
BEFORE SERVICING
CN
6-2
120 VAC
c
onnect
or b
lock
locations
when
us
i
ng
diagrams
t
o t
r
oub
leshoot
un
it
.
US
B
IN
TERFACE
1
2
3
4
1
0
0
2
6
7
5
2
8
REV
A
X8
-
1
0
X8-1
CN3-4
PROPANE
NATURAL
PROPANE
N
ATURA
L
CA
M
S
W
I
T
CH
PROPANE
LIGHT
NA
T
URA
L
L
I
G
H
T
N
AT
U
RAL
L
G
PS
PRO
PANE LG
P
S
CAM
SW
ITCH
G
PS
2G
PS3
"X5"
BLO
CK
WI
RI
NG
I
S
MODEL
DEP
E
NDENT
OP
TION
A
L
ET
HE
RN
ET
CAB
LE
E
GND
WIF
I
DO
NG
L
E
RI
B
BO
N
CABLE
SW1
J2
8
4
3
J6
J9
J17
J23
J12
J11
LG
CO
N BRD
J8
LCD
DI
SP
LAY
USB
CABLE
OPTIONAL
US
B
/
WIFI
EX
T
E
NS
I
ON CABLE
J
10
J
7
BA
S
CN6-1
CN
6-3
2
4V
S
I
NG
LE HOUS
ING
3.
A
c
t
ua
l
c
onnect
o
r
block
locations
m
ay
var
y
f
rom
t
hose
show
n
on di
agr
am
s.
R
ef
er
t
o
ac
t
ua
l
c
om
ponent
s
f
or
prope
r
Not
es
:
1.
A
ll wiring m
us
t
be
installed
in
accordanc
e
wit
h:
local,
s
t
at
e,
provi
nc
ial
and
nat
ional
c
ode
r
equ
iremen
t
s
per
e
it
her
N.E.
C.
in
US
A
or
C.
S
.
A
.
in
Canada
.
2.
I
f
any
or
iginal
equipment
wire as
s
upp
lied
w
it
h
t
he appli
a
nc
e
m
us
t
be
re
pl
ac
ed,
it
m
ust
be replac
ed
wit
h
wire hav
ing
s
ame
wire gauge
(
A
WG)
and rated
f
or
a
m
inim
um
of
105
°C.
Exc
ept
ions:
Replacement
high
voltage
s
park
l
ead
and ribbon
c
ab
l
es
m
ust
be purchased
f
rom
t
he f
ac
t
or
y.
Us
e
of
a
non-
approved spark
lead
or ribbon
c
ables
c
an
lead t
o operat
i
onal problems
B
OX DE
PICTS
BOX
D
EPICTS
!
PR
3 Diagrams (continued)
Figure 3-4 Ladder Diagram_4.0 Model
16
Dual Fuel Supplemental Manual
-T
M
1
2
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 with wire having same 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 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.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
CN1-12
CN1-5
CN1-10
CN1-11
CN1-6
CN1-9
CN1-8
CN1-7
CN1-1
CN1-2
CN1-3
CN1-4
17
CN3-6
CN6-2
CN3-7
CN3-14
CN6-1
CN3-13
CN3-12
CN3-11
CN3-10
CN3-9
CN3-8
CN6-3
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
CN3-1
CN3-2
CN3-5
CN3-3
X3-2
X3-4
X6-1
X6-11
X3-1
X6-2
X6-14
X6-10
X6-13
X6-4
X3-3
X7-8
X7-7
X8-14
X8-13
X8-12
X8-11
X8-15
X8-5
X8-6
X8-16
X8-7
X8-17
X8-18
X8-1
ALARM
CONTACTS
RUN-TIME
CONTACTS
TANK
THERMOSTAT
LOUVER
PROVING
24 VAC LOUVER
RELAY COIL
AUX
SWITCH 1
AUX
SWITCH 2
SHIELD
SHIELD
A
B
MODBUS
OPTION
+
-
-
+
RATE
OUT
BOILER
PUMP OUT
SYSTEM RETURN
SENSOR
SYSTEM SUPPLY
SENSOR
0-10V
0-10V
TANK
SENSOR
OUTDOOR
SENSOR
+
+
-
-
0-10V
0-10V
BMS
IN
SYSTEM
PUMP IN
SHIELD
SHIELD
A
B
CASCADE
R
R
RO
RO
LB
KB
RB
R
Y
RO
HIGH LIMIT
SWITCH
R
R
X6-1
X6-2
X6-3
YG
R
RP
BAS
LB
R
LB
R
RB
W
RO
W/RO
P
W
LB
KB
KB/Y
J3-5
J3-4
J3-6
LWCO
BOARD
J3-3
J3-2
J2-1
J2-2
X6-3
RO
KB/RO
KB/RO
TEST
SWITCH
LWCO
PROBE
RO
RO
LWCO RESET
X6-5
X6-15
BLOWER PROVING
SWITCH (LARGE)
RO
X6-12
BLOWER PROVING
SWITCH (SMALL)
T
X13-1
BLOCKED FLUE
SWITCH
RP
X6-6
BLOCKED DRAIN
SWITCH
KB
ENABLE
X8-3
X8-8
X8-2
X8-4
X8-9
X7-1
X7-5
X7-2
X7-6
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)
R
W
X4-1
X4-2
X4-3
X8-20
X8-10
X5-8
X5-7
X5-3
X5-9
X5-2
X5-4
X5-10
X5-5
X5-41
X5-6
X5-12
X5-1
KB
T
LB
W/R
R
W
YG
YG
RB
T
X10-1
X1-3
X10-4
X1-1
X1-12
X1-2
X1-4
X10-2
X10-5
X10-3
X10-6
X1-6
ON/OFF
SWITCH
GND
KB
W
RP
T
RO
X6-18
X6-8
X1-8
G
X6-17
X2-4
X13-2
X13-3
BLOWER
(SMALL)
BLOWER
(LARGE)
R
KB
YG
W
T
T
KB/W
T
NG
R/W
BK/W
X2-3
X1-7
X1-10
X1-5
FLAME SENSE 2
FLAME SENSE 1
SPARK
GENERATOR
SPARK ROD
X2-5
FLUE DAMPER
TRANSFORMER
X13-4
FLUE DAMPER
24V
TRANSFORMER
LB
R
R
R
P
KB
LB
Y
RO
BL
Y
BK
X1-2
X1-3
X1-1
INTEGRATED CONTROL
LARGE CONNECTION BOARD
SMAL L CONNECTION BOARD
JUNCTION
BOX
X11
USB
INTERFACE
BOILER PUMP
CONTACTOR
SYSTEM PUMP
CONTACTOR
DHW PUMP
CONTACTOR
KB
HIGH VOLTAGE
LOW VOLTAGE
120 VAC
1.5A EACH MAX
1R
2R
R
BL
1R
2R
L1
L2
L3
208V 3
N
231
1
2
45
3
231
1
2
4
5
3
100267552 REV A
CN3-4
SMALL
PROPANE
VALVE
LARGE
PROPANE
VALVE
LB
R
LB
RO
SMALL
NATURAL
VALVE
LARGE
NATURAL
VALVE
OR/BK
OR/W
CAM
SWITCH
CAM
SWITCH
R/BK
R/W
CAM SWITCH
CAM
SWITCH
PROPANE LIGHT
NATURAL LIGHT
OR
BR
OR
GPS3
GPS2
CAM
SWITCH
PROPANE LGPS
NATURAL LGPS
E
GND
LG CON BRD
WIFI
DONGLE
SW1
J2
8
43
J9
J17
J23
J12
J11
J8
USB CABLE
OPTIONAL USB/WIFI
EXTENSION CABLE
J10
R
J6
J7
COMMUNICATION
CONTROL BOARD
OPTIONAL
ETHERNET CABLE
PR
GY
24V
CN6-3
CN6-1
CN6-2
BAS
X4
X6-9
"X5"
BLOCK WIRING
IS MODEL
DEPENDENT
DISCONNECT POWER
BEFORE SERVICING
!
BOX DEPICTS
DUAL SENSOR
SINGLE HOUSING
BOX DEPICTS
OPTIONAL ITEMS
WARNING
-T
-T
-T
-T
-T
-T
-T
-T
LCD
DISPLAY
LB
Y
(
S
13
)
T
T
S
14
X
X
2
-
4
3 Diagrams (continued)
Figure 3-5 Wiring Diagram_5.0 Model
17
Dual Fuel Supplemental Manual
OUTLET SENSOR (S1)
PRE-MIX SENSOR 2 (S12)
PRE-MIX SENSOR 2 (S14)
PRE-MIX SENSOR 1 (S13)
PRE-MIX SENSOR 1 (S11)
FLUE SENSOR (S10)
FLUE SENSOR
OUTLET SENSOR (S9)
-T
-T
-T
-T
-T
-T
-T
-T
1.5A EACH MAX
WARNING
M
L1
L2
JUNCTION BOX
TERMINAL STRIP
208V 3Ø SUPPLY
TERMINAL STRIP
208V SUPPLY "N"
NEUTRAL
INTEGRATED CONTROL
ON/OFF
SWITCH
F2
3.15 A
F4
5.0 A
SYSTEM PUMP
RELAY
BOILER PUMP
RELAY
DHW PUMP
RELAY
X1-1
X1-2
X1-4
X1-8
X2-4
SMALL BLOWER CONTACTOR
LARGE BLOWER CONTACTOR
SMALL GAS
VALVE RELAY
LARGE GAS
VALVE RELAY
X1-6
X10-1 X10-2
X10-3
SMALL GAS
VALVE RELAY
LARGE GAS
VALVE RELAY
X10-6
X10-5
X10-4
TERMINAL STRIP
SYSTEM PUMP
CONTACTOR
BOILER PUMP
CONTACTOR
DHW PUMP
CONTACTOR
SMALL BLOWER
CONTACTOR
LARGE BLOWER
CONTACTOR
SMALL BLOWER
LARGE BLOWER
X6-10
X13-4
X6-1
X2-5
4
BAS
2-1X1-1X
X1-3
FLUE DAMPER
TRANSFORMER
12
3
24V
TRANSFORMER
FLUE DAMPER
X6-3
X1-12
X1-3
LWCO
BOARD
TEST
SWITCH
LWCO
PROBE
LWCO RESET
J3-6
J3-3
J2-1
J2-2
J3-5
J3-2
J3-4
X6-5
X6-15
X6-12
X13-1
X6-6
X3-3
X3-4
X3-1
X3-2
X6-11
X6-2
X6-14
INTEGRATED
CONTROL
BLOWER PROVING
SWITCH (LARGE)
BLOWER PROVING
SWITCH (SMALL)
BLOCKED FLUE
SWITCH
BLOCKED DRAIN
SWITCH
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
ALARM
CONTACTS
RUN-TIME
CONTACTS
TANK
THERMOSTAT
LOUVER
PROVING
24 VAC LOUVER
RELAY COIL
AUX
SWITCH 1
AUX
SWITCH 2
ENABLE
R
W
SMALL
CONNECTION BOARD
CN1-4
CN1-5
CN1-6
CN1-12
CN1-10
X6-13
X6-4
CN1-11
CN1-9
CN1-8
CN1-7
CN1-1
CN1-2
CN1-3
HIGH LIMIT
SWITCH
X1-3
X1-7
X1-10
X2-5
FLAME
SENSE 2
FLAME
SENSE 1
SPARK
GENERATOR
SPARK
ROD
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
SHIELD
SHIELD
A
B
MODBUS
OPTION
+
-
-
+
RATE
OUT
BOILER
PUMP OUT
SYSTEM RETURN
SENSOR
SYSTEM SUPPLY
SENSOR
0-10V
0-10V
TANK
SENSOR
OUTDOOR
SENSOR
+
+
-
-
0-10V
0-10V
BMS
IN
SYSTEM
PUMP IN
SHIELD
SHIELD
A
B
CASCADE
LARGE
CONNECTION BOARD
CN6-1
CN3-6
CN3-7
CN3-14
CN3-13
CN3-11
CN3-9
CN3-8
CN3-1
CN3-2
CN3-3
CN3-4
CN6-2
CN6-3
CN3-10
CN3-12
BAS
X4-1
X4-2
X4-3
X6-3
X6-1
X6-2
X8-20
X8-10
X7-8
X8-13
X8-14
X8-12
INTEGRATED
CONTROL
X8-5
X8-15
X7-7
X8-11
X8-6
X8-16
X8-7
X8-17
X8-18
-T
INLET SENSOR
X8-3
X8-8
X8-2
X8-4
X8-9
X7-1
X7-5
X7-2
X7-6
GROUND
X6-18
X6-9
X6-17
X6-8
X13-2
X13-3
1
2
4
5
1
2
4
5
SMALL BLOWER
LARGE BLOWER
X11
X4
X5-1
X5-7
X5-2
X5-8
X5-3
X5-9
X5-4
X5-10
X5-5
X5-41
X5-6
X5-12
HIGH VOLTAGE
ITEMS
BOX DEPICTS
!
BEFORE SERVICING
CN6-2
SINGLE HOUSING
which could result in non-repairable damage to the integrated controller or other components.
24V
LOW VOLTAGE
120 VAC
connector block locations when using diagrams to troubleshoot unit.
USB
INTERFACE
1
2
3
4
1
2
3
100267527 REV A
X8-1
CN3-4
PROPANE
NATURAL
PROPANE
NATURAL
"X5"
BLOCK WIRING
IS MODEL
DEPENDENT
CAM
SWITCH
PROPANE LIGHT
NATURAL LIGHT
NATURAL LGPS
PROPANE LGPS
CAM SWITCH
GPS2 GPS3
OPTIONAL
ETHERNET CABLE
E
GND
WIFI
DONGLE
RIBBON CABLE
SW1
J2
8
43
J6
J9
J17
J23
J12
J11
LG CON BRD
J8
LCD
DISPLAY
USB CABLE
OPTIONAL USB/WIFI
EXTENSION CABLE
J10
J7
BAS
CN6-1
CN6-3
DISCONNECT POWER
DUAL SENSOR
3. Actual connector block locations may vary from those shown on diagrams. Refer to actual components for proper
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. E xceptions: 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
BOX DEPICTS
OPTIONAL
L3
3 Diagrams (continued)
Figure 3-6 Ladder Diagram_5.0 Model
Dual Fuel Supplemental Manual
Notes
18
19
Dual Fuel Supplemental Manual
Notes
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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Lochinvar CREST 2.5 Supplemental Manual

CREST 2.5
Lochinvar
Brand
Lochinvar
Model
CREST 2.5
Type
Supplemental Manual
This manual is also suitable for

The Lochinvar CREST 2.5 is a versatile boiler capable of heating homes and other buildings efficiently and reliably. With a maximum input of 125 MBH and a net output of 2000 MBH, it can provide ample warmth even in the coldest climates. Its compact size and flexible venting options make it suitable for a variety of installation scenarios, while its advanced features like the SMART SYSTEM control board and Outdoor Reset capability ensure optimal performance and energy savings. This dual-fuel boiler can operate on either natural gas or propane, providing fuel flexibility and peace of mind.

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