ECR International 95M-200 User's Manual And Troubleshooting Manual

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95M-200

GAS-FIRED DIRECT VENT

MODULATING HOT WATER BOILER

WARNING

Revise boiler control parameters only if you fully un-

derstand the purpose and result of the changes. T am-

pering without understanding the control settings in

this manual will void the warranty and can result in

unreliable operation, with possible severe personal

injury , death, or substantial property damage.

WARNING

This document must only be used by a qualied

heating installer or service technician. Read all instructions, including the Installation Manual (P/N# 240006103), the Parameter Guide (P/N#

240006105), the User’s Information Manual (P/N#

240006106), and this Control Manual and Operating Instructions before attempting to program the control, and be sure to perform all steps in the order specied. Failure to comply could result in severe personal injury, death, or substantial property damage.

Control manual and troubleshooting guide

IMPORTANT: Installation must comply with local requirements and with the National Fuel Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 or B149.2 for Canadian installations.

DO NOT DESTROY THESE INSTRUCTIONS!!

Please read carefully and keep in a safe place

for future reference.

P/N 240006104, Rev. B [06/08]

95-200M GAS FIRED DIRECT VENT MODULATING HOT WATER BOILER

Control manual and oPerating instruCtions

Printed in USA • Made In USA

TABLE OF CONTENTS

I - Safety Symbols and Warnings ................................................................................................... 3

II - Operating Information................................................................................................................4

iii - modulating Control Features ....................................................................................................6

iV - Boiler startup ........................................................................................................................... 6

V - Checkout Procedures and Adjustments ....................................................................................9

Vi - detailed sequence of operation ............................................................................................ 12

Vii- service Hints ..........................................................................................................................13

VIII - Troubleshooting ...................................................................................................................14

iX - user interface Quick reference.............................................................................................20

Keep this manual near boiler

and retain for future reference.

I - SAFETY SYMBOLS AND WARNINGS

The following dened symbols are used throughout this manual to notify the reader of

potential hazards of varying risk levels.

DANGER

Indicates an imminently hazardous situation which, if not avoided, will result in death, seri-

ous injury or substantial property damage.

WARNING

Indicates a potentially hazardous situation which, if not avoided, could result in death, serious in-

jury or substantial property damage.

CAUTION

indicates a potential hazardous situation which,

if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe

practices.

IMPORTANT: read the following instructions

completely before installing!!

II - OPERATING INFORMATION

This boiler is controlled by a microprocessor electronic control that senses outlet water temperature, return water tem-

perature, and outdoor temperature (when a factory supplied, eld installed outdoor sensor is installed). This information (plus input from external limit and operating controls) is used

to regulate boiler on/off operation and will modulate boiler r-

ing rate to more closely match output to demand.

ELECTRICAL SPECIFICATIONS

Boilers require 120 vac/60 HZ power supply and are not polarity sensitive.

CONTROL SPECIFICATIONS

supply voltage 120 vac/60 hz Electrical demand 10 va Prepurge timing 10 seconds

Postpurge timing 15 seconds

Min. off time, space heating 10.2 seconds

Pump on after space htg. 0 minutes

Min. off time, DHW 10.2 seconds Pump on after DHW 30.6 seconds

line voltage fuse, F1 5 amp fast-blow low voltage fuse, F3 4 amp slow-blow

BOILER CIRCULATOR

The circulator has sufcient head to handle the boiler pressure drop plus reasonable pressure drop in the connecting piping. See the separate Installation Manual (P/N# 240006103) for piping and ow rate information.

The boiler control’s internal relay contact is suitable for handling only the boiler circulator provided. Do not wire addi-

tional pumps in parallel with the boiler circulator. To operate a system circulator when the boiler circulator is running, see the section on “Electrical Wiring” in the Installation Manual for

wiring required.

BOILER TEMPERATURE REGULATION

OPERATING TEMPERATURE (TARGET): The boiler con-

trol senses outlet water temperature and regulates the boiler ring rate to achieve a target temperature, set by installer with Parameter 4. Temperature can be set between 120°F and 194°F.

SPACE HEATING: • Target temperature is xed (equal to Parameter 4) when outdoor reset is not installed or calculated as described under “Outdoor Reset Operation”

when outdoor sensor is connected.

ExCEPTION: • See explanation of “Supply Temperature Boost.”

DHW HEATING: • Target temperature is determined by

adding Parameter 1 to Parameter 33 (default 150°F and

30°F). Do not change Parameter 1 from the factory de-

fault setting of 150°F unless the application is specially engineered for other temperature. DHW heating default setting is 180°F.

High limit operation: If outlet water temperature exceeds target temperature (or 180°F, whichever is lower), high limit ac-

tion occurs. The control module shuts the burner off showing “b 9” followed by “26” on the display.

DHW operation (if used): The boiler is factory set to immedi-

ately change target outlet water temperature to 180°F on a call for heat from the DHW aquastat.

Additional Thermal Overrun Protection: High limit operation

shuts down the burner when the outlet water temperature ex-

ceeds the target temperature. However, adverse conditions could cause the water temperature to rise too quickly and overshoot this temperature. The boiler control’s advanced

technology provides protection in the event of thermal over-

run. using its electronics, the control provides two additional

levels of overrun protection:

LEVEL 1:• Indication would occur if supply water tem-

perature reached 183°F. The control would display a soft lockout code (“b 9” followed by “18” if on the supply or “19” if on the return). The control would not operate the burner again until the water temperature dropped 9°F below target temperature.

LEVEL 2:•

Lockout would occur if supply water tempera-

ture reached 200°F or if the return water reached 193°F.

the control would enter hard lockout and display an error

code (“E” followed by “18” if on the supply or “19” if on the return).

NOTE: Hard lockout requires manually pressing the display

panel reset button to restart operation. Service technician must

troubleshoot the cause of the problem and correct it before placing

the boiler back in operation.

LOW WATER PROTECTION

This boiler comes factory equipped with a manual reset

low water cutoff. In addition, the boiler control uses tem-

peratures sensed at both supply and return areas of the heat exchanger. If the ow rate is too low (temperature difference too high) or either temperature is too high, the

control shuts the boiler down. This ensures boiler shut-

down in the event of low water or low ow conditions.

Some codes and jurisdictions may accept these integral features of the control in lieu of requiring an additional limit

control or low water cutoff. Consult your local jurisdiction

for more information on low water cutoff requirements.

Target Outlet Temperature, °F

Outside Temperature, °F

Outdoor Reset Target Temperature

210

60 50 40

10 0

-10

-20

110

130

150

170

160

190

120

Parameter 4 = 190°F

Parameter 4 = 150°F

Parameter 4 = 170°F

Reset Curve Calculations

Target Outlet Temperature, °F

Outside Temperature, °F

Default Reset Curve

Outdoor Reset Target Temperature

210

60 50 40

10 0

-10

-20

110

130

150

170

160

190 180

120

Parameter 7 = 60°F

Parameter 4 = 180°F

Parameter 6 = 0°F

II - OPERATING INFORMATION

FREEZE PROTECTION

Do not install the boiler in a room likely to freeze.

NOTE: The following integral feature of the boiler control pro-

vides some protection for the boiler only, not for the system.

The control module provides freeze-up protection as follows when the boiler water temperature drops below 45° F:

•

Below 45° F, the boiler circulator operates constantly.

Below 37° F, the boiler turns on at low re.•

Boiler and circulator turn off if boiler water temperature • rises above 50° F.

CAUTION

This feature of the boiler control does not eliminate the

possibility of freezing. The installation must still use rec-

ognized design, installation and maintenance practice to

prevent freeze potential for the boiler and system.

SUPPLY TEMPERATURE BOOST

In outdoor reset operation (factory supplied, eld installed outdoor sensor connected), the boiler control automatically increases the target outlet water temperature if a call for heat exceeds 10 minutes. At each 10 minutes of a continuous call for heat, the control module increases the target temperature

by 18°F. The module will continue increasing target tempera-

ture until it reaches the value set in Parameter 4.

Reset cuRve: The graph below shows how the boiler con-

trol calculates target temperature.

•

For outdoor temperature at or below 0°F, the target tem-

perature equals Parameter 4 and never higher.

•

For outdoor temperature above 0°F, the target tempera-

ture is reduced on a curve that would result in 60°F supply temperature at 70°F outdoor temperature.

Summer/winter switch option: Install a summer/winter switch, if desired, to disable the boiler (space heating) circulator during non-heating months. Connect switch across the outdoor sensor terminals. When switch closes, the boiler circulator is disabled and the boiler operates only on call for DHW heating.

When the call for heat ends while target temperature is “boosted,” the target temperature drops about 2°F for each minute the thermostat is open.

Purpose of “boosting”

: If the target temperature happens to be too low, the control “boosts” the target temperature until the supply water meets the system’s needs.

OUTDOOR RESET OPERATION (IF USED)

Target temperature with outdoor reset:

shipped with an outdoor temperature sensor. When this sen-

sor is installed (low voltage terminal strip terminals A1 and

A2), the boiler control regulates target outlet water temper-

ature based on outside temperature. Set the temperature curve by setting Parameter 4 to:

•

ODT (outdoor design temperature for the area).

For ODT of 0°F or lower, set Parameter 4 to the desired • supply temperature at the ODT.

•

For ODT above 0°F, set Parameter 4 to the desired sys-

tem temperature when outdoor temperature is 0°F.

All boilers are

II - OPERATING INFORMATION

DHW OPERATION (IF USED)

The boiler control allows connection of a DHW aquastat to low voltage terminal strip terminals DHW T1 and DHW T2. When the DHW aquastat calls for heat, the module shuts down the boiler circulator activated the DHW circulator and

III - MODULATING CONTROL FEATURES

BOILER CONTROL DESIGN

The integrated modulating boiler control is designed for cen-

tral heating (CH) hot water boilers with modulating fan and gas-air control. Options for domestic hot water (DHW) and outdoor reset are available. Modulation is based upon data

relayed to the control by specic temperature sensors. To ig-

nite the burner, a direct spark igniter (DSI) is used.

The modulating boiler control is intended for use in combina-

tion with a display/user interface unit for both information and

operation purposes. the control is designed for installation

with a conventional on/off dry contact room thermostat. The

control is able to provide hot water and outdoor reset func-

tions.

MAIN CONTROLLER FUNCTIONS

Central Heat (CH):

water, return water and outside air to determine the heat load of the heating system. This results in the boiler supplying just enough heat to satisfy the demand which results in fewer

the control uses sensors on the supply

immediately sets target outlet water temperature to 180°F.

This provides automatic priority heat allocation to the indi-

rect water heater for maximum response and recovery. The DHW circulator continues for 30.6 seconds after the heating cycle to deliver the most possible heat.

overshoots and less short cycling than a conventional on/off boiler.

Domestic Hot Water (DHW):

with an indirect hot water heater this boiler has the capability to provide domestic hot water. An on/off dry contact aquastat is used to activate the call for domestic hot water.

Outdoor Reset:

air temperature using a factory supplied, eld installed sensor. the controller detects the presence of the sensor and acts according to the parameters programmed into the controller.

This control has the ability to sense outside

When used in conjunction

DISPLAY/USER INTERFACE

By means of the display/user interface, the installer and home owner can scroll through the control settings and customize the boiler to the heat delivery system used in the location of installation. See the “User Interface Quick Reference” in Section X of this manual for more information on using and programming the boiler control.

IV - BOILER STARTUP

STARTUP

NOTE: Instructions in this manual are based on factory

default parameter settings.

Start the boiler only after completing all instructions 1.

in the installation manual.

To start the boiler, follow the 2. “Operating Instructions”

in this manual.

Once the boiler has started and is operating, continue the startup procedure by performing all of

the following steps to set and verify operation of the controls.

SET SPACE HEATING OPERATION

VERIFY SPACE HEATING MODE

Press the “Mode” button until the display shows a. [PARA]. This is the parameter mode.

Press the “Step” button until the rst digit of the dis-

play shows “3.”

The last digit must show a “1.” If any other number displays, press the “+” button until a “1” shows in the right-hand digit, then press the “Store” button to save

this setting.

SET SPACE HEATING TARGET TEMPERATURE

Press the “Step” button until the rst digit of the dis-a. play shows “4.” The last three digits will show the out-

let water temperature setting.

Press the “+” or “-” buttons to change the setting to

the desired outlet water temperature. The factory de-

fault setting is 180°F.

OUTDOOR SENSOR INSTALLED:• setting is the

target temperature for outdoor temperature at or below the factory setting (32°F). At higher outside temperatures, the control module calculates the target temperature.

IV - BOILER STARTUP

When a summer/winter switch is used, closing the •

switch will disable the boiler (space heating) circu-

lator during summer operation.

OUTDOOR SENSOR NOT INSTALLED: • setting

is the target temperature at all times.

Press the “Store” button to save the setting.

CHECK DHW OPERATION SETUP

NOTE: If the control is already in parameter mode , skip

step 1 (below) and proceed to step 2.

Press the “Mode” button until the display shows

(parameter mode).

Press the “Step” button until the rst digit of the display shows a “2.”

The last digit must show a “1.” If any other number dis-

plays, press the “+” button until a “1” shows in the right-

hand digit, then press the “Store” button to save this set-

ting.

The control module turns on the DHW circulator when

the indirect water heater operating control closes. the

control module shuts off the boiler circulator (stops space heating) during calls for DHW heating.

VERIFY OPERATION – SPACE HEATING

[PARA]

[2180]• Ignition. After prepurge, the control module

opens the gas valve and starts ignition spark.

•

If burner ame proves within 4.5 seconds, burner con-

tinues to re. Burner will re at startup rate for about 10 seconds to allow ame to stabilize.

•

If burner ame does not prove within 4.5 seconds, con-

trol module attempts ignition sequence again. Flame must prove within 6 attempts or control will lockout

(display will show [E 02]).

•

Verify ame failure operation by closing boiler manual gas cock to prevent gas ow. Open manual gas valve

after testing.

• Burner on, space heating. Once ame is prov-

[3180]

en and stable, the burner turns down to low re for approximately 2 minutes.

•

After this low re period, the burner is allowed to modulate. Firing rate depends on actual outlet water tem-

perature versus target temperature.

Allow boiler to bring water temperature to target temperature.

• Target temperature reached. The burner will

[6180]

shut down. The blower will run in postpurge (see be-

low), then turn off. Boiler circulator continues to run as

long as there is a call for heat.

NOTE: Information below presented in brackets “[ ]” represents the actual display on the boiler control panel with the first digit indicating boiler status and the last three digits showing the measured boiler water temperature. (Ex.- [A180] indicates a status of “A” and a boiler water temperature of 180°F.)

Turn down DHW aquastat on DHW tank (if used). If

necessary, turn off power and remove one of the DHW aquastat wires to ensure boiler will not receive a DHW

heat call.

Turn off power to boiler at service switch.

Wait a few seconds, then turn on power to boiler.

[180]• self-check on power-up for a few seconds. [0180]• no call for heat.

Raise room thermostat to call for heat.

4. [5180] • Blower/boiler circulator on. Blower and boiler

circulator energize and control checks for air ow.

• Prepurge. Blower speed will increase to igni-

[1180]

tion speed. The blower will run in prepurge for 10 seconds.

Lower room thermostat to stop call for heat.

[1180]• Postpurge. When room thermostat is satised (call for heat ended), burner turns off. Blower will con-

tinue for 15-second postpurge, then turn off. If another call for heat occurs, boiler will remain off for ten seconds

before starting again, and the display will show [6180].

[0180]

• No call for heat. Boiler is now in standby mode (waiting for heat call).

Repeat steps 1-6 several times to verify operation.

Return the room thermostat to normal setting.

VERIFY OPERATION – DHW

If necessary, reconnect DHW aquastat wiring to boiler.

Turn off power to boiler at service switch.

Wait a few seconds, then turn on power to boiler.

[A150] self-check on power-up for a few

seconds.

[0150]

no call for heat.

IV - BOILER STARTUP

Raise DHW aquastat above tank temperature to call for heat.

[5150] • Blower/DHW circulator on. Blower and DHW cir-

culator energize and control checks for air ow.

• Prepurge. Blower speed will increase to ignition

[1150]

speed. The blower will run in prepurge for 10 seconds.

• ignition. After prepurge, the control module

[2150]

opens the gas valve and starts ignition spark.

•

If burner ame proves within 4.5 seconds, burner con-

tinues to re. Burner will re at startup rate for about 10 seconds to allow ame to stabilize.

•

If burner ame does not prove within 4.5 seconds, con-

trol module attempts ignition sequence again. Flame

must prove within 5 attempts or control will lockout (display will show [E 02]).

•

Verify ame failure operation by closing boiler manual gas valve to prevent gas ow. Open gas valve after

testing.

• Burner on, DHW. Once ame is proven and

[4150]

stable, the burner is allowed to modulate. Firing rate depends on actual outlet water temperature versus target temperature.

Allow boiler to bring water temperature to target temperature.

• Target temperature reached. The burner will

[6150]

shut down. The blower will run in postpurge (see be-

low), then turn off. DHW circulator continues to run as long as there is a call for DHW heating.

Lower DHW aquastat to stop call for heat.

[1150] • Postpurge. When room thermostat is satised

(call for heat ended), burner turns off. Blower will con-

tinue for 15 second postpurge, then turn off. If another DHW heat call occurs, boiler will begin heating cycle

after 10 second delay. if a CH call for heat occurs after

a DHW demand, the heating cycle will begin after a 30

second delay.

• DHW circulator run-on. The DHW circulator

[8150]

continues to run for 30 seconds.

• No call for heat. Boiler is now in standby mode

[0150]

(waiting for heat call).

Repeat steps 1-6 several times to verify operation.

Return the DHW aquastat to normal setting.

OPERATING INFORMATION

To check operating conditions (Ex.- actual or target tem-

perature), see “User Interface Quick Reference” in sec- tion X of this manual for an explanation of the boiler

control’s “Information” mode.

During normal operation (no shutdown or lockout), the

right 3 display digits show actual boiler outlet water tem-

perature.

PERFORM CHECK-OUT PROCEDURES

Complete the “Checkout Procedures and Adjustments” as in-

dicated in Section VI of this manual.

WARNING

Replace boiler front jacket panel after

performing any service to the boiler.

V - CHECKOUT PROCEDURES AND ADjUSTMENTS

VERIFY SEqUENCE OF OPERATION

a detailed sequence of operation containing potential faults

can be found in Sections VII, “Detailed Sequence of Opera-

tion.” Refer to this section and Section XVIII, “Service Hints,” for more information.

INSPECT VENTING AND AIR INTAKE

Operate the boiler and verify that all vent/air intake connections are gastight and watertight. Repair any leaks immedi-

ately.

INSPECT CONDENSATE DRAIN AND

SYSTEM PIPING

Verify that condensate ows freely and all connections are watertight. Repair any leaks immediately.

TEST IGNITION SYSTEM SAFETY SHUTOFF DE-

VICE

Remove front panel from appliance.

Turn off manual gas ball valve.

Set thermostat for a call for heat.

Boiler begins normal sequence of operation.

After approximately 30 seconds of pre-purge the appli-

ance will attempt to light.

TEST OTHER FIELD INSTALLED SAFETY CON-

TROLS (IF USED)

If the boiler is equipped with any additional safety controls, test for operation as outlined by the control manufacturer. Burner should be operating and should go off when controls are tested. When safety controls are restored, burner should

reignite.

SET FIELD INSTALLED THERMOSTAT

HEAT ANTICIPATOR (IF USED)

For a single thermostat connected to the T-T screw terminals on the low voltage terminal strip on the control board of the

boiler, the heat anticipator should be set at 0.1 amps. For oth-

er wiring congurations, refer to the instructions provided by

the thermostat manufacturer regarding heat anticipator ad-

justment. Cycle boiler with thermostat. Raise the thermostat to the highest setting and verify boiler goes through normal start up cycle. Lower thermostat to lowest setting and verify boiler goes off.

BOILER ADjUSTMENT

NOTE: It is important that this appliance operate as speci-

fied in the table below. The following steps can be used to

verify that the appliance is operating in this range.

after 4 seconds the gas valve closes and the control

retries 5 time, before entering lockout mode.

to reset the control, follow the instructions in section iV

of this manual, “Putting The Boiler In Operation.”

Return thermostat to previous setting.

TEST AND ADjUST HIGH LIMIT CONTROL

While burner is operating, adjust setting on high limit control below actual boiler water temperature. Burner should go off while circulator continues to operate. Raise limit setting above boiler water temperature and burner should reignite after pre purge and igniter warm-up period. Set the high limit control to at least 10°F above parameter 4 setting as described in

the separate “Parameter Guide” (P/N# 240006105). Maxi-

mum high limit setting is 200°F. Minimum high limit setting is 100°F.

TEST LOW WATER CUT OFF

Disconnect the wire from the LWCO sensor probe.

Set thermostat for call for heat.

Boiler should not begin normal sequence of operation.

Check incoming gas pressure to the appliance using a pressure

gauge with a resolution of 0.1” w.c. or better and a range from 0” to at least 14” w.c. Close the gas shutoff inside the boiler jacket.

Locate the inlet pressure tap on the gas valve (see Figure 1) and

open the inlet pressure tap screw ½ turn. Connect the positive side of the gauge to the inlet pressure tap, then open the gas shut-

off. The gas pressure at high re should read between 4” and 10” w.c. for natural gas and between 10” and 14” w.c. for LP gas.

Figure #1

Gas valve

Attach wire to the sensor probe.

Return thermostat to previous setting.

V - CHECKOUT PROCEDURES AND ADjUSTMENTS

Drill a ½” hole in the plastic CPVC vent pipe or exhaust

tee, just large enough to allow access for the sample probe of your combustion analyzer.

Turn the thermostat to the closed position so the appliance is activated.

Set appliance to high re mode as described in the “User Interface Quick Reference” section of this manual and allow it to run for approximately 5 minutes.

Insert the sample probe of your combustion analyzer into the hole you drilled in Step 2 about halfway into the exhaust gas stream. Take a ue gas reading and observe the % CO2 and CO values. Adjust the throttle

screw until the correct readings are reached. turning the throttle screw clockwise decreases the rate and the Co2 value. turning the throttle screw counter clockwise increases the rate and the Co2 value. allow the ap-

pliance to stabilize for approximately one minute after adjusting the throttle screw before you take a reading with your combustion analyzer.

IMPORTANT: Under all conditions CO levels

should not exceed 80 ppm.

Set appliance to low re mode as described in the “User

Interface Quick Reference” section of this manual and check CO2 level as stated in Step 5. Low re and high re values should be approximately the same.

After adjustments are made stop the appliance, disconnect the pressure gauge, tighten the inlet pressure

tap on the gas valve, remove the CO2 meter from the CPVC pipe, and seal the hole with a ¼” NPT black iron plug. Use thread sealing compound or teon tape to

ensure a proper seal.

Return the thermostat switch to its original position.

Installers: Complete and sign the “Installa-

tion and Checkout Certicate” on the last page

of this manual.

Operate boiler for 5 minutes.

Turn off all other gas appliances, extinguishing standing

pilots where applicable.

At the gas meter, measure the time in seconds required to use one cubic foot of gas.

NOTE: Boiler must be in high fire mode for this operation.

See the “User Interface Quick Reference” in this manual for

more information on putting the boiler in high fire mode.

Calculate the BTUH Input Rate as follows:

Btuh input rate = 3600 x heating value from Step 3

16 +/- 2 seconds

The measured input rate will vary with vent length, gas

caloric content, altitude and ambient temperature. The

boiler should be set up with the combustion specica-

tions in the “Boiler Adjustment” section.

DETERMINE LP GAS INPUT RATE

LP gas input rate is determined by measuring the C0 produced during combustion. This value should be set according to the guidelines table on the following

page.

MEASURE FLAME SENSE

Flame sense can be an indicator of issues with air intake venting, exhaust venting, burner and ignitor condition and supply gas piping pressure. Using a multim-

eter capable of reading 0-20 VDC, attach one lead to the “F” terminal on the low voltage terminal block on the boiler control, and the other to any ground surface on the boiler. See Figure #2. The ame sense voltage must be in accordance with the values listed in the Flame Signal Guidelines chart later in this manual.

Figure #2

MEASURE THE NATURAL GAS INPUT RATE

Correct input rate is essential for proper and efcient operation of the burner and boiler.

Determine the elevation at the installation site.

See Table 2 in Section IV of the separate “Installation

Manual” (P/N# 240006103) to determine the correct ap-

proximate input rate for the local elevation.

Obtain the yearly average heating value of the local gas

utility. At sea level elevation, it should be approximately 1000 BTU per standard cubic foot.

V - CHECKOUT PROCEDURES AND ADjUSTMENTS

Pressure Guidelines

Fan speed Minimum RPM Maximum RPM Fuel gas line inlet

Pressure differential Pres-

sure

natural gas lP natural gas lP

N/A N/A At least 4” WC

At least 10”

0.3” WC 2.0” WC

Note: Differential pressure values listed for comparison only. These values will change with vent length and altitude of installation.

Combustion Guidelines

outside Natural Gas LP Gas

Temperature %CO

70°F and up 21°C and up

30°F to 70°F

-1°C to 21°C 30°F and below

-1°C and below

9.6% to 10%

9.3% to

9.6%

9.0% to

9.3%

3.9% to

3.2%

4.4% to

3.9%

5.0% to

4.4%

CO %CO2 %O

less than

80 PPm

less than

80 PPm

less than

80 PPm

11.1% to

11.5%

10.8% to

11.1%

10.5% to

10.8%

4.1% to

3.4%

4.5% to

4.1%

4.9% to

4.5%

Flame Signal Guidelines

Fan speed Minimum RPM Maximum RPM

Flame Signal

greater than 3.0 VdC

N/A

less than

80 PPm

less than

80 PPm

less than

80 PPm

VI - DETAILED SEqUENCE OF OPERATION

VII- SERVICE HINTS

WARNING

Do not attempt to modify the characteristics of

this boiler in any way!! Fire, explosion, or risk of shock hazard may cause property damage,

severe injury, or death.

IMPORTANT

If any component does not function properly,

make sure it is correctly installed and wired be-

fore replacing it.

Static electricity discharge can damage the

integrated modulating boiler control (IMBC).

Touch metal surface to discharge static elec-

tricity before touching control.

The boiler control cannot be repaired.

3. If it mal-

functions it must be replaced.

Only trained, experienced service technicians

should service the boiler control systems. After

troubleshooting, follow the “Detailed Sequence of Operation” in this manual for a normal light

off procedure.

All controls are factory tested in the assem-

bly process and a defective control is gener-

ally the least likely cause. if you suspect you

have a defective boiler control, read through

the “Troubleshooting” section of this manual

before you replace it.

It is extremely unlikely that the two consecutive

6. controls are defective. If it seems to be happening, chances are that either there is noth-

ing wrong with the control or it is being dam-

aged by some other problem (for example, an electrical short burning out a transformer).

TROUBLESHOOTING TOOLS

Have the following tools available prior to troubleshooting your boiler:

•

Voltmeter that can check 120 VAC, 24 VAC, and 12

VdC Continuity tester•

Contact Thermometer•

Inclined Manometer or Pressure Gauge with 0-6.0” range •

(0.01” scale) for measuring suction pressures at pres-

sure switch

•

U-Tube Manometer or Differential Pressure Gauge with 0-14” range (0.1” scale) for measuring inlet and manifold

gas pressures

INITIAL SERVICE CHECKS

Prior to troubleshooting:

Make sure that circuit breaker is on or fuse is okay at

electrical panel. make sure that service switch is on.

Check for 120 VAC (minimum 102 VAC to maximum 132

VAC) to boiler.

Make sure thermostat is calling for heat and contacts (in-

cluding appropriate zone controls) are closed. Check for 24 VAC between thermostat wire nuts and ground.

Make sure all external limit controls are either installed (and closed) or temporarily jumpered for testing.

Make sure that gas is on at the gas meter, at all appropri-

ate manual shutoff valves, and at the gas control valve.

Gas pressures should be a maximum of 10” w.c. (natu-

ral gas) or 14” w.c. (for LP gas) with no ow (lockup) or with boiler on and a minimum of 5” w.c. with gas owing (verify during boiler startup with boiler at high re).

Check that wire connectors at the boiler control and at

the originating control are securely plugged in or connected.

Check that all hoses are securely connected and are not

plugged in or damaged.

VIII - TROUBLESHOOTING

1500010 - SW PRESS NORM

OPEN SET PT .04”/0.14”

YELLOW LABEL

1552004 - TUBE, ORANGE, 3/16” X 5/16” OD SILICONE

1230006 - CAP BLK VINYL 3/16” 2 REQ’D

1552014 - TUBE SILICONE, 3/16” ID

1500011 - SW PRESS NORM CLOSED SET PT 3.5” WHITE LABEL

GAS VALVE

PB-002.02 - ORIFICE PILOT 390686-1 HW-LP BBR10

1552004 - TUBE, ORANGE, 3/16” X 5/16” OD SILICONE

1552004 - TUBE, ORANGE,

3/16” X 5/16” OD SILICONE

1110001 - CLAMP ROTOR HC-5ST-R, 22 REQ’D

SIGHT GLASS

AIR INLET

CONNECTION

151009 - TEE PLASTIC

BARBED HOSE, 3/16” ID

5 REQ’D

WARNING

Electrical shock may cause serious injury or death. The following procedures may expose you to dangerous line voltage so use caution to avoid touching live electrical contacts. All service must be performed by a trained, experienced service technician.

WARNING

Should overheating occur or the gas supply fail to shut off, do not turn off or disconnect the electrical supply to the pump. Instead, shut off the gas at a location external to the appliance

Do not use the boiler if any part of the gas con-

trol system has been underwater. A qualied

service technician should inspect the boiler and replace any part of the control system and any gas control which has been underwater.

DIFFERENTIAL AIR PRESSURE

the differential air pressure switch is a safety device

which will prevent the boiler from ring if there is an air intake, boiler heat exchanger or vent blockage. To check the differential air pressure:

Turn off service switch or lower thermostat setting.

Remove vinyl caps from tee.

Install testing lines as shown to inclined manometer or

differential pressure gauge with the ability to read 0.01” increments to at least 6.0” w.c.

Turn on service switch and set thermostat to call for

heat.

Use only your hand to turn the gas control knob. Never use tools. If the knob will not turn by hand, don’t try to repair it. Force or attempt-

ed repair may result in a re or explosion.

CAUTION

WHAt tO DO IF YOu sMeLL GAs

do not try to light any appliance.• do not use any electrical appliance.• do not touch any electrical switches; do not use •

any phones in your building.

•

Immediately call your gas supplier from a neigh-

bor’s phone. Follow the gas supplier’s instruc-

tions. if you cannot reach your gas supplier, call

the re department.

Boiler Status Diff. Pressure Switch Contacts

not running 0”

running with

Blockage

Running w/out

Blockage (approx.)

If manometer readings do not correspond to the chart above, check for possible causes:

• Blockage or moisture in suction lines to switch.

• Blockage in air intake or vent pipes.

• Undersized air intake or vent pipes.

• Loose blower wheel on motor shaft.

• Incorrect pressure switch or pressure switch setpoint

When pressure reading is proper and the pressure switch is operating properly, remove testing lines and reinstall vinyl caps to

tee and 3-way connector.

greater than or

equal to setpoints

Min. Fire: 0.3” 3.5” Closed

Max. Fire: 2” 0.14” Closed

3.5” Closed

0.14”

open

3.5” open

0.14” Closed

WARNING

VIII - TROUBLESHOOTING

WARNING

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Always disconnect power to boiler before servicing. Failure to comply could result in severe personal injury, death or substantial property damage. Never jumper (bypass) any device except for momentary testing as outlined on the following pages of this manual. Severe personal injury, death or substantial property damage can result.

CONTROL MODULE FUSES

IMPORTANT: always check control module fus-

es before replacing control module or any major components (blower, etc.) If one of these fuses is

blown, it can prevent control module or other com-

ponents from operating.

Turn OFF power to boiler at external line switch.

Remove jacket front panel.

Remove control module cover.

Inspect fuses F1 and F3 (shown below).

The boiler is shipped with four spare fuses attached to

Do not jumper fuse or replace with any fuse ex-

cept as specied. Failure to comply could result

in severe personal injury, death or substantial

property damage.

Install control module cover and jacket top front cover

after fuse inspection.

Restore power to boiler at external line switch and verify

boiler operation after completing boiler service.

CHECKING TEMPERATURE SENSORS

The boiler temperature sensors (outdoor, return water, and

supply water) are all resistance-type devices.

The table below shows the correct resistance value for

the sensor at various temperatures.

Temp

°F

32 34,265 37,871 130 3,698 4,088 40 27,834 30,764 140 3,043 3,364 50 21,630 23,907 150 2,517 2,782 60 16,944 18,727 160 2,091 2,311 70 13,372 14,780 170 1,744 1,928 80 10,629 11,747 180 1,461 1,615

90 8,504 9,399 190 1,229 1,359 100 6,847 7,568 200 1,038 1,147 110 5,545 6,129 210 880 972 120 4,517 4,992 212 851 941

Sensor Ohms

Min Max Min Max

Temp

°F

Sensor Ohms

F1 and F3 Fuses

the control module cover.

If necessary, replace open fuse (F1 is 115V, 5-amp fastblow; F3 is 24V, 4-amp slow-blow).

Use the resistance values at 32°F, 60°F, 70°F and 212°F

to measure the sensor resistance at known tempera-

tures (ice point, room temperature and sea level boiling point). For ice point and boiling point, insert the sensor in water at that temperature. Use an ohm meter to read

resistance value.

To check whether the control module is correctly sens-

ing temperature, you can use a resistance decade box. Connect the decade box temporarily in place of a sensor and use the control module “Information” mode to read the temperature.

VIII - TROUBLESHOOTING

Boiler Not Firing And: Check For: Step Corrective Actions:

Control display blank 120 vac at terminals L1 and L2 of

line voltage strip?

120 vac on both sides of fuse F1? (Turn OFF external power to boiler before removing cover.

Wiring correct, in good condition,

and securely attached?

Display rst digit shows 0; last digits show 2 or 3-digit number (boiler outlet water temp.)

Display rst digit shows a number from 1 to 8; last digits show 2 or 3-digit number (boiler outlet water temp.)

Display ashes “9,” then “b.” Last two digits show code number. 1

Room thermostat and DHW aquastat satised?

Thermostat or aquastat calling for heat but boiler not ring.

1 NO - Check external line switch and fuse or breaker.

1 NO - Turn off power to boiler and replace fuse if necessary.

Inspect boiler interior wiring to determine cause of fuse

opening.

1 Correct if needed. Replace any damaged wiring or

components. Replace control module if problem persists.

1 YES - Boiler off, no call for heat. Turn up thermostat or

aquastat. Boiler should start.

1 Check voltage on both sides of low voltage fuse F3.

(Turn OFF external power before removing cover.) If necessary, replace fuse. Determine reason for fuse failure if possible.

2 Check/set boiler parameters 2 and 3. Make sure space

heat or DHW is turned on. Turn on if necessary.

3 Turn off power to boiler. Temporarily jumper low voltage

terminal strip terminals T1 and T2 or DHW T1 and DHW T2. Retry. If boiler operates, check CH and DHW thermostat and wiring. Replace if necessary. Remove temporary jumper(s).

4 Turn off power to boiler. Check wiring against wiring

diagram; verify all wiring in good condition and secure.

replace wire harnesses and retry. 6 Replace control module. 1 Boiler in normal operating mode.

see User Interface Quick Reference and Soft Lockout

Troubleshooting in this manual for for more information

on the soft lockout code.

SOFT LOCKOUT (Display ashes “9” and then “b” in rst position; last two digits on steady (code))

Code Reason For Soft Lockout Corrective Actions (pressing RESET should restart boiler immediately):

WARNING: Electrical shock hazard. Turn off power to boiler when working with wiring or replacing any boiler component.

08 0.14” Pressure switch contacts open 1 Check pressure switch for proper operation. Replace pressure switch if moisture

has entered switch. Check venting for blockage. Clear if present.

18 High Limit Operation: Burner off

until outlet water temp. drops below 180 °F

19 High Limit Operation: Burner off

until return water temp. drops below 190 °F

This should only happen when the heat demand is lower than the lowest ring rate of the boiler, such as operation of a single, small zone. Check system for:

Verify boiler and system are full of water.

• Make sure system does not have trapped air.• Inspect and verify system piping and components.• Verify piping agrees with boiler manual recommendations.•

Use contact thermometer to check outlet water temp. Compare to temp. shown with

display in “INFO” mode (“1” in rst digit). Replace return temp. sensor if results are

not close. Replace control module if sensor replacement doesn’t solve problem.

Check system for:

Verify boiler and system are full of water.

• Make sure system does not have trapped air.• Inspect and verify system piping and components.• Make sure water ow is not reversed or pipes crossed.•

2 Use contact thermometer to check return water temp. Compare to temp. shown with

display in “INFO” mode (“2” in rst digit). Replace return temp. sensor if results are

not close. Replace control module if sensor replacement doesn’t solve problem.

VIII - TROUBLESHOOTING

SOFT LOCKOUT (Display ashes “9” and then “b” in rst position; last two digits on steady (code))

Code Reason For Soft Lockout Corrective Actions (pressing RESET should restart boiler immediately):

WARNING: Electrical shock hazard. Turn off power to boiler when working with wiring or replacing any boiler component.

24 High Limit Operation: Return temp.

is higher than supply temp.

25 High limit operation: outlet water

temp. increased too quickly. Non-adjustable default setting

9.8°F/sec

aquastat contacts open

LWCO contacts open

3.5” Switch open

1 Verify proper setting of control.•

2 Check water level in boiler, ll if low.•

Verify boiler and system are full of water.

• Make sure system does not have trapped air.• Inspect and verify system piping and components.• Make sure water ow is not reversed or pipes crossed.•

Use contact thermometer to check return water temp. Compare to temp. shown with

display in “INFO” mode (“2” in rst digit). Replace return temp. sensor if results are

not close. Replace control module if sensor replacement doesn’t solve problem.

This usually indicates ow rate too low. Check system for:

•

Verify boiler and system are full of water. Make sure system does not have trapped air.• Inspect and verify system piping and components.• Verify piping agrees with boiler manual recommendations.•

Verify operation of boiler circulator:

•

Check voltage at circulator junction box to ensure 120 vac when boiler oper-

ates. if no voltage, check wiring and wiring connections.

High voltage terminal strip terminals 5 and 6 should show 120 vac for space • heating; terminals 3 and 4 should show 120 vac for DHW. Replace circulator if powered but not operating. Replace line voltage wire harness if necessary. Replace control module if wire • replacement doesn’t resolve.

Water temp too high, wait for temperature to drop below 180 degrees.•

Press LWCO reset switch on display panel• If problem still exists, check LWCO probe and board according to manufacturer’s •

instructions. replace if necessary.

Check pressure switch for proper operation. Replace if moisture has entered switch. Check venting for blockage. Clear if present.

29 Blower turning when it should be off. 1

30 High limit operation: Temp. rise

across boiler too high.

61 Pressure switch contacts closed. 1 Check pressure switches for proper operation. Replace pressure switch if moisture

65 Blower not operating when turned

on.

Check boiler wiring against wiring diagram. Replace line voltage and low voltage wiring harnesses if necessary. Replace control module if wire replacement doesn’t

resolve.

This usually indicates ow rate too low. Check system for:

Verify boiler and system are full of water.

• Inspect and verify system piping and components.• Verify piping agrees with boiler manual recommendations.• Make sure system pressure drop is not too high.•

Verify operation of boiler circulator.

•

Check voltage at circulator junction box to ensure 120 vac when boiler

operates. if no voltage, check wiring and wiring connections.

has entered switch.

Turn off power to boiler. Remove line voltage connector at blower. Restart boiler

and check voltage across blower plug terminals. If 120 vac is NOT present, inspect

wiring and tightness of connections. replace line voltage wire harness if necessary.

Replace control module if wire harness replacement doesn’t resolve.

If 120 vac is present on blower wire harness, replace harness and retry. If problem persists, replace blower motor.

VIII - TROUBLESHOOTING

HARD LOCKOUT (Display ashes rst digit “E” and last two digits (code))

Code Reason For Hard Lockout Corrective Actions (pressing RESET should restart boiler immediately):

WARNING: Electrical shock hazard. Turn off power to boiler when working with wiring or replacing any boiler component.

00 Flame detected on startup. 1

02 Ignition failed through 5 attempts. 1

03 gas Valve disconnected. 1 Verify gas valve connection.

Voltage lost after lockout occurred. 1 Control module will only restart with manual reset, even after power loss (but the

04 05

internal control failure. 1 Reset control and retry. If problem persists, replace control module.

06 07 08

Burner may be operating too hot due to incorrect combustion. Inspect ame during operation following the procedure in this manual. If ame is acceptable at both high and low re, go to step 2. If ame is not acceptable:

For propane boilers, verify propane orice is correct and properly installed. • Obtain and install propane orice if necessary. For correctly oriced propane or natural gas boilers, replace gas valve if • burner glows excessively.

2 Look into the burner inspection window after the boiler shuts down. If ame is still

present, gas valve may be leaking. Replace gas valve. BEFORE replacing valve, check gas line pressure coming to boiler. Pressure must not exceed 13” w.c. or valve damage could occur.

If no ignition spark occurs:

•

Check ignition electrode cable, electrode connector, and connections. Inspect ignition electrode cable and electrode for insulation damage.• Check ground lead from ground terminal strip to heat exchanger access cover.•

2 If spark occurs, but no ame:

Verify manual gas valve in boiler is open.• Verify plastic line from gas valve to air inlet elbow is connected to gas valve • and elbow, and line is unobstructed with no kinks. Check incoming gas pressure.• Verify gas lines are free of obstruction and purge gas lines of air if •

necessary.

Verify ue gas vent and air supply piping are correctly installed, in good • condition, and free of obstructions. Check voltage to gas valve (it should be approx. 19-21 vdc (24 vrac) during • ignition attempt). Check gas meter to verify gas ows when gas valve is activated.• Remove and inspect/clean ignition electrode. Clean white oxides if necessary • and replace ignition electrode if in poor condition or unable to be cleaned. Disconnect gas valve from Venturi. Inspect Venturi gas line to verify there are • no obstructions. Replace gas valve. Check for possible ue gas recirculation at vent/air terminations or inside • boiler housing. If gas valve is powered, gas ows when activated, and above steps have • been veried, replace gas valve and retry.

3 Flame occurs but ame signal too low (less than 3 vdc between X1-5 and ground):

•

Inspect ame at both low and high re rates. Inspect and clean burner if necessary. Replace burner if not in good condition. Check gas ow rate at gas meter with boiler at high re. If input is not within • about 10% of boiler rating, replace gas valve. (Length of the vent/air piping will affect boiler ring rate, with longer piping causing lower inputs.) Check ground wire and connections from ground terminal screw to X1-6 terminal • on wiring harness. Use ground continuity meter to verify good ground path.

Follow procedure to inspect and clean ignition electrode. replace ignition • electrode if necessary.

If above does not correct problem, replace control module.•

error code information is lost).

VIII - TROUBLESHOOTING

HARD LOCKOUT (Display ashes rst digit “E” and last two digits (code))

Code Reason For Hard Lockout Corrective Actions (pressing RESET should restart boiler immediately):

WARNING: Electrical shock hazard. Turn off power to boiler when working with wiring or replacing any boiler component.

internal control failure. 1 Reset control and retry. If problem persists, replace control module.

09 11 12 Casting temperature switch opened. 1

internal control failure. 1 Reset control and retry. If problem persists, replace control module.

thru

17 18 Thermal Overrun Condition:

water temp. above 200 °F

19 Thermal Overrun Condition:

Return water temp. above 190 °F

28 Blower not running. 1 Turn off power to boiler. Remove line voltage connector at blower. Restart boiler

29 Blower signal not 0 when it should

be.

Temp difference between supply & return, indicated by blocking code b30, was too large for 20 successive times. Non adjustable default Max Delta set to 100°F

31 Outlet water temp. short circuit. 1 Inspect outlet water temp. sensor and wiring. Replace sensor if wiring correct and

32 Return water temp. short circuit. 1 Inspect return water temp. sensor and wiring. Replace sensor if wiring correct and

36 Supply water temp. sensor open

circuit.

37 Return water temp. sensor open

circuit.

internal control failure. 1 Rest control and retry. If problem persists, replace control module.

60 61 65 Blower signal too low (not enough

driving force).

outlet

Determine reason for limit action and correct. Check for air trapped at top of casting.

2 If limits are closed, check wiring and connections. Apply a temporary jumper across

terminals 6 and 8 and check operation. If problem persists, check boiler internal wiring. Replace low voltage harness if necessary. Replace control module if harness replacement doesn’t resolve.

1 Check system for:

Verify boiler and system are full of water.• Make sure system does not have trapped air.• Inspect and verify system piping and components.• Make sure water ow is not reversed or pipes crossed.•

2 Use contact thermometer to check outlet water temp. Compare to temp. shown with

display in “INFO” mode (“1” in rst digit). Replace return temp. sensor if results are

not close. Replace control module if sensor replacement doesn’t solve problem.

1 See Code 18, Corrective Action#1 (above). 2 Use contact thermometer to check return water temp. Compare to temp. shown with

display in “INFO” mode (“2” in rst digit). Replace return temp. sensor if results are

not close. Replace control module if sensor replacement doesn’t solve problem.

and check voltage across blower plug terminals. If 120 vac is NOT present, inspect

wiring and tightness of connections. replace line voltage wire harness if necessary.

Replace control module if wire harness replacement doesn’t resolve.

2 If 120 vac is present on blower wire harness, replace harness and retry. If problem

persists, replace blower motor.

1 Inspect wiring and connections. If wiring is correct, replace blower assembly. If

blower assembly replacement is unsuccessful, replace control module.

1 Inspect supply & return water sensors for proper resistance. 2 Inspect piping for proper conguration. For example, when used in a radiant

heating application.

in good condition. Replace low voltage wiring harness if problem persists. Replace control module if harness replacement doesn’t resolve.

1 See Corrective Action# 1 under Code 31 (above)

1 See Corrective Action# 1 under Code 32 (above)

1 Inspect wiring and connections. If wiring is correct, replace blower assembly. If

blower assembly replacement is unsuccessful, replace control module.

Ix - USER INTERFACE qUICK REFERENCE

STANDBY MODE - KEY FUNCTIONS AND DISPLAY

When boiler is powered on, the display will always show a single character (which represents the boiler’s current operating sequence) followed by the measured outlet water temperature during self-test.

When entering Standby Mode, user

interface display briey shows Stby

Press and Hold Key(s) in BLACK

Stby

(1)

Duration Result Display

[MODE] [STEP] [STORE] [+] [-]

Hold

[MODE] [STEP] [STORE] [+] [-]

Hold Turn DHW OFF/ON. (Display shows “d” and DHW factory setting or OFF.)

[MODE] [STEP] [STORE] [+] [-]

Hold

[MODE] [STEP] [STORE] [+] [-]

(1)

Where two keys are shown pressed at the same time, you must press the keys together. A slight delay in pressing one of the keys may

cause a different result.

(2)

Outlet water “target temperature” means:

Outdoor sensor not connected - Target is xed setpoint temp. Control attempts to maintain boiler outlet water temperature to setpoint.

Outdoor sensor connected - Target is temperature calculated by control module based on outside air temperature.

then displays Sequence and Measured or Target Outlet Temperature.

Outlet water target temperature. (Display shows “c” and outlet water

tap

target temp.)

Turn space heating OFF/ON. (Display shows “c” and outlet water temp.

or OFF.)

Show factory setting for DHW. (Make sure to adjust desired water

tap

temperature for DHW on the DHW tank aquastat.)

Set burner to high re. (Display shows “H” and measured outlet water temp.)

Set burner to low re. (Display shows “L” and measured outlet water temp.)

Deactivate forced high/low ring. (Display shows sequence and measured outlet water temp.)

tap Change to next mode. (Para)

(2)

0 180

c 190

d 140

H 180

L 180

0 180

Para

STANDBY MODE - BOILER SEqUENCE DISPLAY

after display shows Stby for a brief period, the rst character shows boiler status, followed by boiler outlet water temp. If the burner is

being held off due to a soft lockout, the display alternates between showing “9” followed by boiler outlet water temp. and “b” followed by the two-digit codes below. Soft lockout means the boiler will start again automatically if the condition is corrected or timed out.

Press [RESET] button to restart boiler without waiting for timeouts below.

First

Other

Digit

Digits

0 1 2 ignition

3 Burner on for CH heating 4 Burner on for DHW heating

5 Checking airow before prepurge

Standby - no call for heat

Pre-purge (10 seconds) or Post-purge (15 seconds)

Burner off because temperature setting has been reached

Pump on after CH heating cycle for run-on

of 10 seconds

Pump on after DHW heating cycle for run-

on of 30 seconds

Burner on, running in high re mode (manually set for test)

Actual (measured) outlet water temperature

Burner on, running in low re mode (manually set for test)

Boiler Status

First

Code #Boiler is in soft lockout when “9” or “b” shown. Reason

Digit

“9” alternating with “b”

for boiler soft lockout is:

Outlet temp. too high (over 203°F). Burner off until outlet

_18

water temp. drops 9°F below target temp.

Return temp. too high (over 203°F). Burner off until both

_19

outlet and return water temp. drops 9°F below target temp.

Return temp. higher than supply temp. Burner off waiting for

_24

correction.

Outlet water temp. rose too quickly. Burner off 10 min. (burner

_25

recycles, increasing wait 1 min. each attempt to max. 15 min.)

External limit open, LWCO tripped or 3.5” press switch open on limit

_26

wired in soft lockout (auto reset) circuit. Burner off for 2½ minutes.

Blower signal not 0 when it should be. Burner off until signal

_29

condition terminates.

Temp. rise across boiler more than 100°F. Burner off for 2½

_30

minute wait (plus 1 minute for each failed attempt, up to max. of 22 minutes each time).

_61 air pressure switch does not open.

_65 Waiting for blower to start.

display shows Para until a key is pressed

Press and Hold Key(s) in BLACK

[MODE] [STEP] [STORE] [+] [-]

Ix - USER INTERFACE qUICK REFERENCE

PARAMETER MODE

Press [MODE] button 1 time from Standby Mode.

Para

(1)

Duration Result Display

Hold FAST increase setting

then displays Parameter and Current Status.

tap

step to next parameter (continue tapping

step to change to 1, 2, 3, or 4)

tap Increase setting

DHW Setting

DHW Setup

1 180

1 140

2 01

[MODE] [STEP] [STORE] [+] [-]

tap Decrease setting Space Heating Setup

Hold FAST Decrease setting

Outlet Temperature

(see details below)

[MODE] [STEP] [STORE] [+] [-] tap

Store current setting (tap this key after setting the parameter as desired)

[MODE] [STEP] [STORE] [+] [-] tap Next mode (info)

DHW Setting: left digit shows “1” and right digit shows “140.” DO NOT change this

setting. Performance could be unreliable. Set DHW tank temp. on DHW aquastat.

(1)

After the [stORe] button is pressed, the set value will ash twice to conrm the change. Change will take effect after you leave

DHW Setup: left digit shows “2” and right digit should show “01.”

DO NOT change this setting. DHW

performance could be unreliable or

unsafe.

Space Heating (SH) Setup: left digit shows “3” and right digit should show “01.” DO NOT change this setting as it

might affect performance of your boiler.

SH Temperature: left digit shows “4” and right three digits show

target outlet water temp. (at 32°F outside if outdoor sensor is used).

adjust to desired settings with + and - keys.

Parameter Mode.

INFORMATION MODE

Press [MODE] button 2 times from Standby Mode.

display shows Info until a key is pressed

Press and Hold Key(s) in BLACK

Info

(1)

Duration Result Display

[MODE] [STEP] [STORE] [+] [-]

(1)

Digits after ashing dot show measured outlet temperature.

(2)

Digits after ashing dot show -18.

(3)

Digits after ashing dot show outside temperature.

(4)

Digits after ashing dot show target outlet temperature.

(5)

Digits after ashing dot show rate of change in °F per second.

(6)

Digits after ashing dot show -32.

NOte: Display will show A-32 if [steP] is pressed after “9” appears.

then displays Parameter, Flashing Dot, and Current Status.

tap

step to next

parameter

Measured outlet water temperature (First digit shows 1 and dot ashes)

Return water temperature (First digit shows 2 and dot ashes)

This function not used (First digit shows 3 and dot ashes)

Outside temperature (First digit shows 4 and dot ashes)

This function not used (First digit shows 5 and dot ashes)

Target outlet water temperature (First digit shows 6 and dot ashes)

Outlet water temp. change over time (First digit shows 7 and dot ashes)

Return water temp. change over time (First digit shows 8 and dot ashes)

This function not used

(First digit shows 9 and dot ashes)

(1)

(2)

(3)

(2)

(4)

(5)

(6)

3 01

4 190

Info

1.190

1.180

2.150

3.-18

4. 42

5.-18

6.190

7. 1

8. 1

9.-32

Ix - USER INTERFACE qUICK REFERENCE

HARD LOCKOUT MODE

Boiler in hard lockout (requires manual RESET)

Display ashes rst digit E

Code Reason for hard lockout Code Reason for hard lockout

00 Flame detected on start-up 18 Supply water temperature higher than 200°F 02 Ignition failed after 5 retries 19 Return water temperature higher than 190°F 03 gas valve disconnected 25 Outlet temperature increased too fast 04 Power lost after lockout 28 No signal from blower; blower not running or defective blower motor 05 internal control failure 29 Blower signal not “0” when it should be

07 11 internal control error 32 Return temperature sensor short circuit 12 Casting temperature switch open 36 Outlet temperature sensor open circuit 13 internal control failure 37 Return temperature sensor open circuit 14 15 internal control failure 60 Internal error reading parameters 16 internal control failure 61 Air ow circuit failure 17 internal control failure 65 Not enough blower driving force

internal control failure 30

internal control failure 31 Outlet temperature sensor short circuit

internal control failure 44 internal control failure

and last two digits (lockout code) (see below)

Max difference (b30) was too large for 20 successive times. Non adjustable default max delta set to 100°F.

xI - INSTALLATION AND CHECKOUT CERTIFICATE

Boiler Model: Boiler Serial Number: Date of Installation:

Measured BTUH Input: Boiler Location: Altitude of Location:

Honeywell AM Kit Installed? (Yes/No): Service Dates:

System Type (Give Brief Description):

installation instructions Have Been Followed•

Checkout Procedure/Adjustments Performed• Maintenance/Service Issues Reviewed With Owner or Maintenance Person• Installation Manual Afxed Adjacent To or On Boiler•

Installer/Technician’s Company:

Installer’s Name:

Company Address:

Company Phone Number:

Installer’s Signature:

For technical assistance with this product, in the United States call toll free 1-800-325-5479,

and in Canada call toll free 1-888-270-8324.

eCr international

PO Box 4729

Utica, NY 13504-4729

www.ecrinternational.com

ECR International 95M-200 User's Manual And Troubleshooting Manual

Specifications and Main Features

Frequently Asked Questions

User Manual