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12

        

Dual Fuel Supplemental Manual

 

-T

1

3

2

1 2

4 5

3

2 3

1

1 2

4 5

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

 

 

R

O

 

 

R

O

 

 

L

B

 

 

K

B

 

 

R

B

 

  R

 

  Y

 

 

R

O

HIGH LIMIT

SWITCH

 

  R

 

  R

X6-1

X6-2

X6-3

 

 

Y

G

 

  R

 

 

R

P

BAS

 

 

L

B

 

  R

 

 

L

B

 

  R

 

 

R

B

 

  W

 

 

R

O

 

 

W

/

R

O

 

  P

 

  W

 

 

L

B

 

 

K

B

J3-5

J3-4

J3-6

LWCO

BOARD

J3-3

J3-2

J2-1

J2-2

X6-3

 

 

R

O

 

 

K

B

/

R

O

 

 

K

B

/

R

O

TEST

SWITCH

LWCO

PROBE

 

 

R

O

 

 

R

O

LWCO RESET

X6-5

X6-15

BLOWER PROVING SWITCH (LARGE)

 

 

R

O

X6-12

BLOWER PROVING SWITCH (SMALL)

 

  T

X13-1

BLOCKED FLUE SWITCH

 

 

R

P

X6-6

BLOCKED DRAIN SWITCH

 

 

K

B

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

 

 

K

B

 

  T

 

 

L

B

 

 

W

/

R

 

  R

 

  W

 

 

Y

G

 

 

Y

G

 

 

R

B

 

  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

L

N

GND

120V

SUPPLY

ON/OFF

SWITCH

GND

SMALL

PROPANE

VALVE

LARGE

PROPANE

VALVE

 

 

K

B

 

  W

 

 

R

P

 

  T

 

 

R

O

 

 

L

B

 

  R

 

 

L

B

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

 

 

K

B

 

 

Y

G

 

  W

 

  T

 

  T

 

 

K

B

/

W

 

  T

 

 

K

B

 

 

W

/

K

B

 

 

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

 

 

L

B

 

  R

 

  R

 

  R

 

  P

 

 

K

B

 

 

L

B

 

  Y

 

 

R

O

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

 

 

K

B

HIGH VOLTAGE

LOW VOLTAGE
120 VAC

1.5A EACH MAX

 

 

R

O

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

 

 

K

B

/

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 DEPICTS

DUAL SENSOR

SINGLE HOUSING

BOX DEPICTS

OPTIONAL ITEMS

WARNING

LCD

DISPLAY

 

  Y

 

 

L

B

-T

-T

-T

-T

-T

-T

-T

-T

3  

Diagrams 

Figure 3-1 Wiring Diagram_2.5 - 3.5 Models

Summary of Contents for CREST 2.5

Page 1: ...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 ...

Page 2: ...us 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 BE...

Page 3: ...ternal 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 ...

Page 4: ...s 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 bytheblowers allowinggastoflowonlyifthegasvalvesarepowered and combustion a...

Page 5: ...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 different 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 affixed to the unit 6 Standard Crest boilers will de rate by...

Page 6: ...g 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 p...

Page 7: ...es 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 damag...

Page 8: ...coming 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 re...

Page 9: ...o inspect the appliance and to replace any part of the control system and any gas control which has 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 appliance 4 This appliance is equipped with an ignition device which automatically lights the burner Do not try to light the burn...

Page 10: ...ice 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 ...

Page 11: ...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 ...

Page 12: ...J3 6 LWCO BOARD J3 3 J3 2 J2 1 J2 2 X6 3 R O K B R O K B R O TEST SWITCH LWCO PROBE R O R O LWCO RESET X6 5 X6 15 BLOWER PROVING SWITCH LARGE R O X6 12 BLOWER PROVING SWITCH SMALL T X13 1 BLOCKED FLUE SWITCH R P X6 6 BLOCKED DRAIN SWITCH K B 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 SE...

Page 13: ...0V 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...

Page 14: ...0 5 X10 3 X10 6 X1 6 ON OFF SWITCH GND BK W PR T OR X6 18 X6 8 X1 8 G X6 9 X6 17 X2 4 X13 2 X13 3 BLOWER SMALL BLOWER LARGE R BK GY W W BK T M T GN 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 BL R R R P BK BL Y OR BL Y BK X1 2 X1 3 X1 1 INTEGRATED CONTROL LARGE CONNECTION BOARD SMALL CONNECTION B...

Page 15: ...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 ...

Page 16: ... R O K B R O K B R O TEST SWITCH LWCO PROBE R O R O LWCO RESET X6 5 X6 15 BLOWER PROVING SWITCH LARGE R O X6 12 BLOWER PROVING SWITCH SMALL T X13 1 BLOCKED FLUE SWITCH R P X6 6 BLOCKED DRAIN SWITCH K B 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 ...

Page 17: ...NSOR 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 ...

Page 18: ...Dual Fuel Supplemental Manual Notes 18 ...

Page 19: ...19 Dual Fuel Supplemental Manual Notes ...

Page 20: ...ts 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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