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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

-

0

1

X

1

-

0

1

X

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

2

1

3

2

1

3

BAS

X1-1

X1-2

X1-3

FLUE DAMPER

TRANSFORMER

1

2

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

 

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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