Lochinvar CREST 102 Series Owner's manual

DIR #2000508187
D
IR
#
2
000508
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.
100268179_2000509263_Rev K
Dual Fuel Supplemental Manual
Models: FBD 751 - 6001
Series: 102 & 112

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.
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 ................................ 10-11
3. DIAGRAMS.............................................................12-19
Revision Notes .................................................. Back Cover
⚠DANGER
⚠WARNING
⚠CAUTION

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.
5
4
3
DIR #2000508194
2
1
DIR #2000508187
Front View
Left Side (inside unit)
1
2
10
8
6
11
7
9
DIR #2000508206
DIR #2000562004
Series 102 Series 112
DIR #2000562008
2
1
6
8
Series 102 Series 112

Dual Fuel Supplemental Manual
Ratings
5
Crest
AHRI Rating
Model Number
Note: Change “N” to
“L” for L.P. gas models.
Input
MBH
(Notes 4 - 6)
Min Max
Gross
Output
MBH
(Note 1)
Net
AHRI
Ratings
Water,
MBH
(Note 2)
FB(N,L,D)0751 50 750 721 626
FB(N,L,D)1001 50 999 961 834
FB(N,L,D)1251 62.5 1250 1203 1043
FB(N,L,D)1501 60 1500 1443 1252
FB(N,L,D)1751 70 1750 1684 1461
FB(N,L,D)2001 80 1999 1923 1699
FB(N,L,D)2501 125 2500 2400 2087
FB(N,L,D)3001 150 3000 2883 2507
FB(N,L,D)3501 175 3500 3364 2925
FB(N,L,D)4001 333.3 3999 3843 3342
FB(N,L,D)5001 499.9 4999 4804 4177
FB(N,L,D)6001 600 6000 5766 5014
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.)
73 3" 3" 1 1/4" 6" 6" 1768
77 3" 3" 1 1/4" 6" 6" 1838
87 3" 3" 1 1/2" 6" 8" 1975
94 4" 4" 1 1/2" 8" 8" 2307
106 4" 4" 1 1/2" 8" 8" 2458
111 4" 4" 1 1/2" 8" 8" 2570
157 4" 4" 2" 8" 9" 3600
156 4" 4" 2" 10" 10" 3900
202 4" 4" 2" 10" 10" 4600
201 4" 4" 2 1/2" 12" 12" 5200
254 6" 6" 2 1/2" 14" 14" 5900
304 6" 6" 3" 14" 14" 6900
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. The boiler will de-rate by 1.4%
for each 1,000 feet above sea level up to 4,500 feet.
5. High altitude Crest Models are equipped to operate from
3,000 to 12,000 feet only. e boiler will not de-rate up
to 5,500 feet and will de-rate by 1.6% for each 1,000 feet
above 5,500 feet. e 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.
De-rate values are based on proper combustion
calibration and CO2 ’s adjusted to the recommended
levels.
UNIT EQUIPPED FOR
HIGH ALTITUDE
3,000 FT. TO 12,000 FT.
IMG01026
Figure A High Altitude Label Location
6. High altitude Crest Models 4.0 and 5.0 will not de-rate up to
5,500 feet.
7. e high altitude Crest 6.0 model will de-rate by 2.0% for
each 1000 feet above sea level up to 5,500 feet.
8. For Crest Models 4.0, 5.0 and 6.0, installations above 5,500
feet contact the factory.
9. Ratings have been conrmed by the Hydronics Section of
AHRI.

Table 1A First Stage Piping at High Pressure_10 PSI
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 18531 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
242521 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 show n are f or 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 26221 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
317990 12510 10110 8481 7708 6936 6422 5908 5608 5309 4711 4281
436710 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
Notice: Capacities show n are f or Natural Gas. Please consult supplier for proper gas pipe sizing for propane.
Ensure that the high gas pressure regulator
is at least 10 feet (3 m) upstream of the
appliance.
NOTICE
The gas inlet size has been designed to allow
the minimum of 10 feet between the boiler
and regulator and for a maximum pressure
drop of 1"w.c.
NOTICE
The gas piping must be sized for the proper flow and length
of pipe, to avoid excessive pressure drop. Both the gas meter
and the gas regulator must be properly sized for the total gas
load.
If you experience a pressure drop greater than 1 inch w.c.
(249 Pa), the meter, regulator, or gas line is undersized or
in need of service. Perform the steps below when checking
inlet gas supply:
1. Turn the main power switch to the “OFF” position.
2. Shut off gas supply at the manual gas valve in the gas
piping to the appliance.
3. For Crest models 751-2001: Remove the 1/8"pipe
plug on the gas manifold before the gas 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. 1-1, 1-2, 1-3, and 1-4.
For Crest models 2501-6001: Remove the 1/8"pipe
plug on the large gas valve flange before the gas 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. 1-1, 1-2, 1-3, and 1-4.
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.

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.
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 - Models
751-2001
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 8 inches w.c. (1.99 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 - Models
751-2001
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 the
gas manifold or gas valve flange, depending on model
size. Remove the 1/8"(3mm) field supplied fitting and
reinstall the pipe plug removed in Step 3.
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.
2000611004 00
2000611003 00
Figure 1-3 Inlet Gas Supply Check_Natural - Models
2501-6001
Figure 1-4 Inlet Gas Supply Check_Propane - Models
2501-6001
2000611142 00

8
Dual Fuel Supplemental Manual
2 Start-up
Final checks before starting the boiler
qRead the Crest Service Manual to familiarize yourself
with SMART TOUCH control module operation. Read
this manual, page 9 for proper steps to start boiler.
qVerify the boiler and system are full of water and all
system components are correctly set for operation.
qVerify the preparation procedures of Section 9 of the
Crest Installation and Operation Manual have been
completed.
qVerify electrical connections are correct and securely
attached.
qInspectventpipingandairpipingforsignsofdeterioration
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)
(NATURAL) or 8 inches w.c. (1.99 kPa) (PROPANE)?
If none of the above corrects the problem, refer to the
Troubleshooting Section of the Crest Service Manual.
Check system and boiler
qCheck 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.
qCheck 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.
qCheck 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 instru ctions 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
automati cally lights th e burner. Do not try
to light the burner by hand.
B. BEFOR E OPER ATING smell all ar ound
the appliance area for gas. Be sure 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
•Do not tr y to light any ap pl iance.
•Do not to uch an y electric switch; do
not use any phon e in your buildi ng .
•Im mediatel y call your gas supplier from a
neighb or ’s phone. Follow the gas supplier’s
instructions.
•If you cannot reach your gas supplier , call
th e fire department.
C. Use only your hand to tu rn the gas control knob.
Never use tools. If the handle will not turn by
hand, don’t try to repair it, call a qualified service
te chnician. Force or attempted repair may
result in a fire or expl osion.
D. Do not use this appliance if any pa rt has been
under water. Immediately call a qual ified
service technician to inspect th e applianc e and
to replace any part of the control system and
any gas control which has be en under water.
OPERATING INSTRUCTIONS
1. STOP!Read the safety information
above on this label.
2. Set the thermostat to lowest sett ing.
3. Turn off all electr ic power to the
applianc e.
4. This appliance is equi pp ed with an
ignition device which automatically lights
the burner . Do not try to light th e burner
by hand.
5. Remove fron t door.
6. Turn gas shutoff valve counterclockwise
to “OFF”. Handle will be perpendicular to
pipe. Do not force.
7. Wait five (5) minutes to clear out an y gas.
If you then smell gas, STOP!Follow “B”
in the safety information above this label.
If you don’t smell gas, go to next step.
8. Turn gas shutoff valve clockwise to “ON”.
Handle will be pa rallel to pi pe .
9. In stal l front door.
10. Turn on al l electric power to applianc e.
11. Se t ther mo stat to desired setting.
12. If the ap pl iance will not oper ate, follow the
instructions “T o Turn Off Gas To Appliance” and
call yo ur service technician or gas supplier .
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to lowest sett ing.
2. Turn off all electr ic power to the ap pl iance
if service is to be perfor med.
3. Remove fron t door.
4. Turn gas shut off valve counterclockwise to
“OFF”. Handle wi ll be perpendi cular to pipe.
Do not force.
5. In stal l front door.
LBL2 0053 REV B
Figure 2-1 Operating Instructions
2 Start-up (continued)

10
Dual Fuel Supplemental Manual
2 Start-up
Dual fuel switching instructions
1. Turn the main power off to the boiler by placing the “On/
Off” switch in the OFF position (FIG. 2-2).
2. Using the fuel selector switch (FIG. 2-2), select the desired
fuel.
Figure 2-2 Fuel Selector Switch
IMG00063
NATURAL PROPANE
DETAIL
FUEL SELECTION
SWITCH
NATURAL PERSONALITY I.D.
PROPANE PERSONALITY I.D.
MAIN POWER
SWITCH
DIR #2000508194
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
select Set Gas Valve 1 - High.
7. Once the boiler has modulated up to rate, measure the
combustion. The values should be in the range listed
in Table 2A below. CO levels should be less than 200
ppm for a properly installed unit. If the combustion is
not within range reference the Troubleshooting Section
in the Crest Service Manual for possible causes and
corrective actions.
Table 2A Flue Products Chart
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. Place the boiler back into normal operation.
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.
⚠WARNING
Flue Products Natural Gas
Units
751-2001 2501-6001
Gas Valve
CO2 (%) O2 (%) CO2 (%) O2 (%)
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
Propane
Units
751-2001 2501-6001
Gas Valve
CO2 (% O2 (%) CO2 (% O2 (%)
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%**

11
Dual Fuel Supplemental Manual
2 Start-up (continued)
3. Turn off all shutoff valves for the fuel not in use (FIG. 2-3).
4. Turn on the shutoff valve for the one in use.
Figure 2-3 Shutoff Valves
NATURAL
SHUTOFF
VALVE
PROPANE
SHUTOFF
VALVE
DIR #2000508189
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
Series 102
NATURAL
SHUTOFF
VALVE
PROPANE
SHUTOFF
VALVE
DIR #2000562011
Series 112

12
Dual Fuel Supplemental Manual
3 Diagrams
Figure 3-1 Ladder Diagram_751 - 2001 Models
FLUE SENSOR
FLUE SENSOR (S10)
OUTLET SENSOR (S1)
OUTLET SENSOR (S9)
JUNCTION BOX
TERMINAL STRIP
TERMINAL STRIP
120VAC
NEUTRAL
INTEGRATED CONTROL
ON/OFF
SWITCH
F2
3.15 A
5.0 A
BOILER PUMP
DHW PUMP
SMALL GAS
LARGE GAS
SMALL GAS
LARGE GAS
TERMINAL STRIP
CONTACTOR
BOLIER PUMP
CONTACTOR
DHW PUMP
CONTACTOR
BLOWER
BLOWER
12
3
BAS
FLUE DAMPER
TRANSFORMER
12
3
TRANSFORMER
FLUE DAMPER
LWCO
BOARD
TEST
SWITCH
LWCO
PROBE
LWCO RESET
INTEGRATED
CONTROL
BLOCKED FLUE
SWITCH
BLOCKED DRAIN
SWITCH
ALARM
CONTACTS
CONTACTS
TANK
THERMOSTAT
LOUVER
PROVING
AUX
SWITCH 1
AUX
SWITCH 2
ENABLE
R
W
FLAME
SENSE 2
FLAME
SENSE 1
SPARK
GENERATOR
SPARK
ROD
SHIELD
SHIELD
A
B
MODBUS
OPTION
RATE
OUT
BOILER
PUMP OUT
SENSOR
SENSOR
TANK
SENSOR
OUTDOOR
SENSOR
BMS
IN
PUMP IN
SHIELD
SHIELD
A
B
CASCADE
LARGE
CONNECTION BOARD
BAS
BOARD
INTEGRATED
CONTROL
GROUND
X11
LCD
DISPLAY
BOX DEPICTS
OPTIONAL ITEMS
BOX DEPICTS
DUAL SENSOR
SINGLE HOUSING
HIGH VOLTAGE
LOW VOLTAGE
120 VAC
Notes
C.S.A. in Canada.
locations when using diagrams to troubleshoot unit.
USB
INTERFACE
"X5"
BLOCK WIRING
IS MODEL
DEPENDENT
BLOWER
HIGH LIMIT
SWITCH
SMALL
CONNECTION BOARD
19
20
21
22
23
25
26
29
30
31
32
33
35
36
39
1
2
3
5
6
9
10
11
12
13
15
16
CAM
SWITCH
PROPANE LGPS
NATURAL LGPS
AIR VALVE
PRESS. SWITCH
CAM
SWITCH
PROPANE LIGHT
NATURAL LIGHT
CAM
SWITCH
PROPANE
NATURAL
PROPANE
NATURAL
M
WARNING
!
OPTIONAL USB/WIFI
EXTENSION CABLE
OPTIONAL
ETHERNET CABLE
USB CABLE
E
GND
BAS
WIFI
DONGLE
AIR VALVE
M
LG CON BRD
1
2
5
BLOWER
INLET SENSOR
DISCONNECT POWER
BEFORE SERVICING
100267386 REV B
SHIELDED CABLE FROM X4
TO J12 OR J23 AS APPLICABLE
1.5A EACH MAX

13
Dual Fuel Supplemental Manual
3 Diagrams (continued)
Figure 3-2 Wiring Diagram_751 - 2001 Models
BLOWER
1
OUTLET SENSOR (S9)
OUTLET SENSOR (S1)
FLUE SENSOR
FLUE SENSOR (S10)
DISCONNECT POWER
BEFORE SERVICING
!
WARNING
1
2
3
Notes:
diagrams to troubleshoot unit.
1
2
3
5
6
9
10
11
12
13
15
16
19
20
21
22
23
25
26
29
30
31
32
33
35
36
39
ALARM
CONTACTS
CONTACTS
TANK
THERMOSTAT
LOUVER
PROVING
AUX
SWITCH 1
AUX
SWITCH 2
SHIELD
SHIELD
A
B
MODBUS
OPTION
RATE
OUT
BOILER
PUMP OUT
SENSOR
SENSOR
TANK
SENSOR
OUTDOOR
SENSOR
BMS
IN
PUMP IN
SHIELD
SHIELD
A
B
CASCADE
R
R
OR
OR
BL
BK
BR
R
HIGH LIMIT
SWITCH
R
R
R
PR
BAS
BOARD
BL
R
BL
R
BR
W
OR
OR/W
P
W
BL
BK
LWCO
BOARD
OR
OR/BK
OR/BK
TEST
SWITCH
LWCO
PROBE
OR
OR
LWCO RESET
BR
PR
BK
ENABLE
INLET SENSOR
R
W
"X5"
BLOCK WIRING
IS MODEL
DEPENDENT
T
BK
BL
R/W
R
W
BR
L N
GND
120V
ON/OFF
SWITCH
GND
CAM
SWITCH
BK
W
PR
T
OR
OR
BL
R
BL
G
BLOWER
R
BK
W
T
BK
TRANSITION
FLAME SENSE
MAIN
FLAME SENSE
SPARK
GENERATOR
SPARK ROD
FLUE DAMPER
TRANSFORMER
FLUE DAMPER
TRANSFORMER
BL
R
R
R
P
BK
BL
OR
BK
INTEGRATED CONTROL
LARGE CONNECTION BOARD
SMALL
CONNECTION
BOARD
JUNCTION
BOX
X11
USB
INTERFACE
BOILER PUMP
CONTACTOR
CONTACTOR
DHW PUMP
CONTACTOR
HIGH VOLTAGE
LOW VOLTAGE
120 VAC
1.5A EACH MAX
OR
OR/BK
OR
AIR VALVE
OR/W
BL
BL
BL
OR/R
OR/W
SMALL
PROPANE
VALVE
SMALL
NATURAL
VALVE
OR/BK
R/W
LARGE
PROPANE
VALVE
LARGE
NATURAL
VALVE
R/BK
CAM
SWITCH
CAM
SWITCH
PROPANE LIGHT
NATURAL LIGHT
AIR VALVE
PRESSURE
SWITCH
CAM
SWITCH
PROPANE LGPS
NATURAL LGPS
BLOCKED FLUE
SWITCH
BLOCKED DRAIN
SWITCH
CAM
SWITCH
M
M
BOX DEPICTS
DUAL SENSOR
SINGLE HOUSING
BOX DEPICTS
OPTIONAL ITEMS
USB CABLE
WIFI
DONGLE
OPTIONAL USB/WIFI
EXTENSION CABLE
OPTIONAL
ETHERNET CABLE
LG CON BRD
E
GND
BAS
R
PR
LCD
100267387 REV C
SHIELDED CABLE FROM X4
TO J12 OR J23 AS APPLICABLE
23

Dual Fuel Supplemental Manual
14
Figure 3-3 Ladder Diagram_2501 - 3501 Models
3 Diagrams
JUNCTION BOX
TERMINAL STRIP
208V 3 SUPPLY
TERMINAL STRIP
208V SUPPLY "N"
NEUTRAL
INTEGRATED CONTROL
ON/OFF
SWITCH
F2
3.15 A
F4
5.0 ASYSTEM PUMP
RELAY
BOILER PUMP
RELAY
DHW PUMP
RELAY
X1-1
X1-2
X1-4
X1-8
CONTACTOR
SMALL GAS
VALVE RELAY
LARGE GAS
VALVE RELAY
X1-4
X10-1X10-2
X10-3
SMALL GAS
VALVE RELAY
LARGE GAS
VALVE RELAYX10-6
X10-5
X10-4
TERMINAL STRIP
SYSTEM PUMP
CONTACTOR
BOILER PUMP
CONTACTOR
DHW PUMP
CONTACTOR
BLOWER
CONTACTORBLOWER
X6-10
X13-4
X6-1
X2-5
FLUE DAMPER
TRANSFORMER
M
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
OPTIONAL
ETHERNET CABLE
X1-3
X1-7
X1-10
X2-5
FLAME
SENSE 1
FLAME
SENSE 2
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
BAS
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
BOARD
(AS APPLICABLE)
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
-T
-T
-T
-T
-T
-T
INLET SENSOR
OUTLET SENSOR (S9)
OUTLET SENSOR (S1)
FLUE SENSOR
FLUE SENSOR (S10)
PRE-MIX SENSOR 1 (S11)
PRE-MIX SENSOR 1 (S13)
X8-3
X8-8
X8-2
X8-4
X8-9
X7-1
X7-5
GROUND
X6-18
X6-9
X6-17
X6-8
1
4
2
5
BLOWER
E
GND
1.5A EACH MAX
X11
WIFI
DONGLE
X4
BOX DEPICTS
OPTIONAL ITEMS
BOX DEPICTS
DUAL SENSOR
SINGLE HOUSING
HIGH VOLTAGE
LOW VOLTAGE
120 VAC
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 voltage 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.
USB
INTERFACE
L1 L2 L3
1
2
3
4
LADDER DIAGRAM
100309296 REV A
X8-10
X8-1
CN3-4
SW1
J2
843
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
CN6-2
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
CN1-4
CN1-5
CN1-6
CN1-12
CN1-10
CN1-11
CN1-9
CN1-8
CN1-7
CN1-2
CN1-3
HIGH LIMIT
SWITCH
SMALL
CONNECTION BOARD
X13-1
X6-6
X3-3
X3-4
X3-1
X3-2
X6-11
X6-2
X6-14
INTEGRATED
CONTROL
BLOCKED FLUE
SWITCH
BLOCKED DRAIN
SWITCH
X6-4
X5-2
X5-8
X5-3
X5-9
X5-4
X5-10
X5-5
X5-41
X5-6
X5-12
"X5"
BLOCK WIRING
IS MODEL
DEPENDANT
CN1-1
X6-15
X6-12
PRESS. SWITCH
AIR VALVE
X6-13
AIR VALVE
CN-1
CN-4
CN-2
CN-3
M
SERVICEOUTLET
BAS (AS APPLICABLE)
X1-1 X1-2
X1-3
SHIELDED CABLE FROM X4
TO J12 OR J23 AS APPLICABLE
O
PROPANE
PROPANE
NATURAL
NATURAL
X5-1
X5-7
X6-5
PROPANE HGPS
NATURAL HGPS
CAM
SWITCH
PROPANE LGPS
PROPANE LIGHT
NATURAL LIGHT
CAM
SWITCH
CAM
SWITCH

15
Dual Fuel Supplemental Manual
3 Diagrams (continued)
Figure 3-4 Wiring Diagram_2501 - 3501 Models
-T
-T
-T
-T
-T
-T
-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 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.
BOX DEPICTS
OPTIONAL ITEMS
BOX DEPICTS
DUAL SENSOR
SINGLE HOUSING
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
BAS
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
A
B
CASCADE
R
R
RO
RO
LB
KB
RB
R
Y
BL
HIGH LIMIT
SWITCH
R
R
X6-1
X6-2
X6-3
YG
R
RP
BAS
BOARD
(AS APPLICABLE)
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
RB
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
INLET SENSOR
OUTLET SENSOR (S9)
OUTLET SENSOR (S1)
FLUE SENSOR
FLUE SENSOR (S10)
PRE-MIX SENSOR 1 (S11)
PRE-MIX SENSOR 1 (S13)
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
DEPENDANT
KB
T
LB
W/R
R
W
YG
YG
RB
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
RO
LB
R
LB
X6-18
X6-8
X1-8
G
X6-9
X6-17
BLOWER
KB
YG
W
T
NG
R/W
BK/W
X2-3
X1-7
X1-10
X1-5
FLAME SENSE 2
FLAME SENSE 1
SPARK
GENERATORSPARK 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
HIGH VOLTAGE
LOW VOLTAGE
120 VAC
1.5A EACH MAX
WIRING DIAGRAM
100309297 REV A
1R
RBL
1R
L1 L2 L3
208V 3
N
231
1245
3
4
CN3-4
E
GND
LG CON BRD
WIFI
DONGLE
SW1
J2
843
J9
J17
J23
J12
J11
Y
J8
USB CABLE
OPTIONAL USB/WIFI
EXTENSION CABLE
J10
LCD
DISPLAY
BL
R
J6 J7
COMMUNICATION
CONTROL BOARD
OPTIONAL
ETHERNET CABLE
PR
GY
24V
SHIELD
CN6-3
CN6-1
CN6-2BAS
R
SERVICE
OUTLET
SHIELDED CABLE FROM X4
TO J12 OR J23 AS APPLICABLE
0
CAM
SWITCH
PROPANE LGPS
NATURAL LGPS
PROPANE LIGHT
NATURAL LIGHT
CAM
SWITCH
CAM
SWITCH
CAM SWITCH
CAM SWITCH
LARGE
NATURAL
VALVE
SMALL
NATURAL
VALVE
SMALL
PROPANE
VALVE
LARGE
PROPANE
VALVE

Dual Fuel Supplemental Manual
3 Diagrams
Figure 3-5 Ladder Diagram_4001 - 5001 Models
JUNCTION BOX
TERMINAL STRIP
480V 3 SUPPLY
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
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
BLOWER
CONTACTOR
BLOWER
X6-10
X13-4
X6-1
X2-5
BAS (AS APPLICABLE)
X1-1 X1-2
X1-3
FLUE DAMPER
TRANSFORMER
M
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
OPTIONAL
ETHERNET CABLE
X1-3
X1-7
X1-10
X2-5
FLAME
SENSE 1
FLAME
SENSE 2
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
BAS
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
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
-T
-T
-T
-T
-T
-T
INLET SENSOR
OUTLET SENSOR (S9)
OUTLET SENSOR (S1)
FLUE SENSOR
FLUE SENSOR (S10)
PRE-MIX SENSOR 1 (S11)
PRE-MIX SENSOR 1 (S13)
X8-3
X8-8
X8-2
X8-4
X8-9
X7-1
X7-5
GROUND
X6-18
X6-9
X6-17
X6-8
1
4
2
5
BLOWER
E
GND
1.5A EACH MAX
X11
WIFI
DONGLE
X4
BOX DEPICTS
OPTIONAL ITEMS
BOX DEPICTS
DUAL SENSOR
SINGLE HOUSING
HIGH VOLTAGE
LOW VOLTAGE
120 VAC
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 voltage 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.
USB
INTERFACE
L1 L2 L3
1
2
3
4
LADDER DIAGRAM
100340973 REV A
X8-10
X8-1
CN3-4
SW1
J2
843
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
CN6-2
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
CN1-4
CN1-5
CN1-6
CN1-12
CN1-10
CN1-11
CN1-9
CN1-8
CN1-7
CN1-2
CN1-3
HIGH LIMIT
SWITCH
SMALL
CONNECTION BOARD
X13-1
X6-6
X3-3
X3-4
X3-1
X3-2
X6-11
X6-2
X6-14
INTEGRATED
CONTROL
BLOCKED FLUE
SWITCH
BLOCKED DRAIN
SWITCH
X6-4
X5-2
X5-8
X5-3
X5-9
X5-4
X5-10
X5-5
X5-41
X5-6
X5-12
"X5"
BLOCK WIRING
IS MODEL
DEPENDANT
CN1-1
X6-13
AIR VALVE
M
480V
TRANSFORMER
X8-19
AIR VALVE POSITION
RP
SERVICE OUTLET
BAS
BOARD
(AS APPLICABLE)
SHIELDED CABLE FROM X4
TO J12 OR J23 AS APPLICABLE
O
PROPANE
PROPANE
NATURAL
NATURAL
PROPANE LIGHT
NATURAL LIGHT
CAM
SWITCH
X6-5
X6-15
X6-12
POC
AIR VALVE
PRESSURE SWITCH
NATURAL HGPS
CAM
SWITCH
PROPANE LGPS
CN-4
CN-1
CN-2
CN-3
X5-1
X5-7
CAM
SWITCH
16

Dual Fuel Supplemental Manual
3 Diagrams (continued)
Figure 3-6 Wiring Diagram_4001 - 5001 Models
-T
-T
-T
-T
-T
-T
-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 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.
BOX DEPICTS
OPTIONAL ITEMS
BOX DEPICTS
DUAL SENSOR
SINGLE HOUSING
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
BAS
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
A
B
CASCADE
R
R
RO
RO
LB
KB
RB
R
Y
BL
HIGH LIMIT
SWITCH
R
R
X6-1
X6-2
X6-3
YG
R
RP
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
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
INLET SENSOR
OUTLET SENSOR (S9)
OUTLET SENSOR (S1)
FLUE SENSOR
FLUE SENSOR (S10)
PRE-MIX SENSOR 1 (S11)
PRE-MIX SENSOR 1 (S13)
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
DEPENDANT
KB
T
LB
W/R
R
W
YG
YG
RB
GND
KB
W
RO
LB
R
LB
G
X6-9
X6-17
BLOWER
KB
YG
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
X1-2
X1-3
X1-1
INTEGRATED CONTROL
LARGE CONNECTION BOARD
SMALL CONNECTION BOARD
X11
X4
USB
INTERFACE
HIGH VOLTAGE
LOW VOLTAGE
120 VAC
WIRING DIAGRAM
100340974 REV A
1R
1R
2 31
1245
3
4
CN3-4
E
GND
LG CON BRD
WIFI
DONGLE
SW1
J2
843
J9
J17
J23
J12
J11
Y
J8
USB CABLE
OPTIONAL USB/WIFI
EXTENSION CABLE
J10
LCD
DISPLAY
BL
R
J6 J7
COMMUNICATION
CONTROL BOARD
OPTIONAL
ETHERNET CABLE
PR
GY
24V
SHIELD
CN6-3
CN6-1
CN6-2 BAS
R
ON/OFF
SWITCH
BK
JUNCTION
BOX
BOILER PUMP
CONTACTOR
SYSTEM PUMP
CONTACTOR
DHW PUMP
CONTACTOR
1.5A EACH MAX
R
L1 L2 L3
G
BL
480V
TRANSFORMER
X10-1
X1-3
X10-4
X1-1
X1-12
X1-2
X1-4
X10-2
X10-5
X10-3
X10-6
X1-6
X6-18
X6-8
X1-8
RO
T
RP
AIR VALVE
PRESSURE SWITCH
O/BK X6-12
X6-13
W
O/W
X8-19
AIR VALVE POSITION
PU
RP
SERVICE
OUTLET
BAS
BOARD
(AS APPLICABLE)
SHIELDED CABLE FROM X4
TO J12 OR J23 AS APPLICABLE
480V 30
X6-5RB
CAM
SWITCH
PROPANE LGPS
NATURAL LGPS
PROPANE LIGHT
NATURAL LIGHT
CAM
SWITCH
CAM
SWITCH
CAM SWITCH
CAM SWITCH
LARGE
NATURAL
VALVE
SMALL
NATURAL
VALVE
SMALL
PROPANE
VALVE
LARGE
PROPANE
VALVE
17

Dual Fuel Supplemental Manual
3 Diagrams
Figure 3-7 Ladder Diagram_6001 Model
JUNCTION BOX
TERMINAL STRIP
480V 3 SUPPLY
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
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
BLOWER
CONTACTOR
BLOWER
X6-10
X13-4
X6-1
X2-5
BAS (AS APPLICABLE)
X1-1 X1-2
X1-3
FLUE DAMPER
TRANSFORMER
M
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
OPTIONAL
ETHERNET CABLE
X1-3
X1-7
X1-10
X2-5
FLAME
SENSE 1
FLAME
SENSE 2
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
BAS
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
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
-T
-T
-T
-T
-T
-T
INLET SENSOR
OUTLET SENSOR (S9)
OUTLET SENSOR (S1)
FLUE SENSOR
FLUE SENSOR (S10)
PRE-MIX SENSOR 1 (S11)
PRE-MIX SENSOR 1 (S13)
X8-3
X8-8
X8-2
X8-4
X8-9
X7-1
X7-5
GROUND
X6-18
X6-9
X6-17
X6-8
1
4
2
5
BLOWER
E
GND
1.5A EACH MAX
X11
WIFI
DONGLE
X4
BOX DEPICTS
OPTIONAL ITEMS
BOX DEPICTS
DUAL SENSOR
SINGLE HOUSING
HIGH VOLTAGE
LOW VOLTAGE
120 VAC
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 voltage 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.
USB
INTERFACE
L1 L2 L3
1
2
3
4
LADDER DIAGRAM
100340982 REV A
X8-10
X8-1
CN3-4
SW1
J2
843
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
CN6-2
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
CN1-4
CN1-5
CN1-6
CN1-12
CN1-10
CN1-11
CN1-9
CN1-8
CN1-7
CN1-2
CN1-3
HIGH LIMIT
SWITCH
SMALL
CONNECTION BOARD
X13-1
X6-6
X3-3
X3-4
X3-1
X3-2
X6-11
X6-2
X6-14
INTEGRATED
CONTROL
BLOCKED FLUE
SWITCH
BLOCKED DRAIN
SWITCH
X6-4
X5-1
X5-7
X5-2
X5-8
X5-3
X5-9
X5-4
X5-10
X5-5
X5-41
X5-6
X5-12
"X5"
BLOCK WIRING
IS MODEL
DEPENDANT
CN1-1
X6-5
X6-15
X6-12
POC X6-13
AIR VALVE
CN-1
CN-4
CN-2 M
480V
TRANSFORMER
X6-1
X2-5
R3
AIR VALVE
PRESSURE SWITCH
X8-19
R3
AIR VALVE POSITION
RP
SERVICE OUTLET
BAS
BOARD
(AS APPLICABLE)
SHIELDED CABLE FROM X4
TO J12 OR J23 AS APPLICABLE
O
CAM SWITCH
CAM SWITCH
LARGE
NATURAL
VALVE
LARGE
NATURAL
VALVE
SMALL
NATURAL
VALVE
SMALL
NATURAL
VALVE
CAM SWITCH
P.O.C. VALVE
P.O.C. VALVE
PROPANE LIGHT
NATURAL LIGHT
CAM
SWITCH
PROPANE HGPS
NATURAL HGPS
CAM
SWITCH
PROPANE LGPS
PROPANE LGPS
CAM
SWITCH
18

19
Dual Fuel Supplemental Manual
3 Diagrams (continued)
Figure 3-8 Wiring Diagram_6001 Model
-T
-T
-T
-T
-T
-T
-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 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.
BOX DEPICTS
OPTIONAL ITEMS
BOX DEPICTS
DUAL SENSOR
SINGLE HOUSING
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
BAS
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
A
B
CASCADE
R
R
RO
RO
LB
KB
RB
R
Y
BL
HIGH LIMIT
SWITCH
R
R
X6-1
X6-2
X6-3
YG
R
RP
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
RB
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
INLET SENSOR
OUTLET SENSOR (S9)
OUTLET SENSOR (S1)
FLUE SENSOR
FLUE SENSOR (S10)
PRE-MIX SENSOR 1 (S11)
PRE-MIX SENSOR 1 (S13)
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
DEPENDANT
KB
T
LB
W/R
R
W
YG
YG
RB
GND
KB
W
RO
LB
R
LB
G
X6-9
X6-17
BLOWER
KB
YG
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
X1-2
X1-3
X1-1
INTEGRATED CONTROL
LARGE CONNECTION BOARD
SMALL CONNECTION BOARD
X11
X4
USB
INTERFACE
HIGH VOLTAGE
LOW VOLTAGE
120 VAC
WIRING DIAGRAM
100340980 REV A
1R
1R
2 31
1245
3
4
CN3-4
E
GND
LG CON BRD
WIFI
DONGLE
SW1
J2
843
J9
J17
J23
J12
J11
Y
J8
USB CABLE
OPTIONAL USB/WIFI
EXTENSION CABLE
J10
LCD
DISPLAY
BL
R
J6 J7
COMMUNICATION
CONTROL BOARD
OPTIONAL
ETHERNET CABLE
PR
GY
24V
SHIELD
CN6-3
CN6-1
CN6-2 BAS
R
ON/OFF
SWITCH
BK
JUNCTION
BOX
BOILER PUMP
CONTACTOR
SYSTEM PUMP
CONTACTOR
DHW PUMP
CONTACTOR
1.5A EACH MAX
R
L1 L2 L3
480V 30
G
BL
480V
TRANSFORMER
X10-1
X1-3
X10-4
X1-1
X1-12
X1-2
X1-4
X10-2
X10-5
X10-3
X10-6
X1-6
X6-18
X6-8
X1-8
RO
T
RP
X12-1
X12-2
X12-5
X12-4
3R
P.O.C.
VALVE
(NATURAL)
3R
RP
AIR VALVE
POSITION
X8-19
PU
X6-15
POC
BR
AIR VALVE
PRESSURE SWITCH
O/BK X6-12
BK
W
SERVICE
OUTLET
BAS
BOARD
(AS APPLICABLE)
SHIELDED CABLE FROM X4
TO J12 OR J23 AS APPLICABLE
CAM SWITCH
CAM SWITCH
LARGE
NATURAL
VALVE
SMALL
NATURAL
VALVE
SMALL
PROPANE
VALVE
LARGE
PROPANE
VALVE
PROPANE HGPS
NATURAL HGPS
CAM
SWITCH
PROPANE LGPS
NATURAL LGPS
PROPANE LIGHT
NATURAL LIGHT
CAM
SWITCH
CAM
SWITCH
P.O.C.
VALVE
(PROPANE)
CAM
SWITCH

Revision Notes: Revision A (Change #500001029) initial release.
Revision B (PCP# 3000007468 / CN# 500007726) reflects the addition
of the Energy Star logo.
Revision C (PCP# 3000027158 / CN# 500016862) reflects the addition
of Models 2501 - 6001 as well as gas valve changes to series 112 that
were originally on TLA #27116.
Revision D (PCP# 3000027116 / CN# 500016865) reflects the addition
of series 112 on the front cover.
Revision E (PCP #3000028279 / CN #500017755) reflects an update
to the Check Flame and Combustion Section on page 10, along with
updates to the wiring and ladder diagrams.
Revision F (PCP #3000033824 / CN #500022616) reflects an update
to the ratings table.
Revision G (PCP #3000035711 / CN #500024133) reflects an update
to the Ratings Table and the addition of notices on page 6.
Revision H (PCP #3000040404 / CN #500028531) reflects an update
to the propane minimum inlet gas pressure.
Revision J (PCP #3000042364 / CN #500030203) reflects updates to
the wiring and ladder diagrams.
Revision K (PCP #3000049089 / CN #5000036206) reflects updates
to the gas supply instrcutions on pages 6-7 and new images for FIG.
1-1 and 1-2.
100268179_2000509263 Rev K
02/22