Rinnai M-Series Condensing Boiler Level III Service & Troubleshooting Training ENHANCING LIVES BY CHANGING THE WAY WATER IS HEATED

Transcription

1 Rinnai M-Series Condensing Boiler Level III Service & Troubleshooting Training 1

2 Agenda Rinnai Resources Rinnai M-series Boiler Technical Specification Periodic Maintenance Component Review and Replacement Sequence of Operation Key Controller Parameters Troubleshooting Fundamentals 2

3 About Rinnai Founded in 1920 Based in Japan 20 Subsidiaries/86 Sales Offices Globally World s #1 selling brand of Tankless Water Heaters North America headquartered in Peachtree City, GA The highest standards of quality Over 600 R & D Engineers Rinnai is a leader in advanced automation and precision assembly Every product is tested under live conditions before shipping Rinnai America has its own state-ofthe-art CSA Certified Testing Lab & CSA Accredited Technicians 3

4 About Rinnai New North American Headquarters R&D Innovation and Training Center New building over 2X current sq. ft. US Tankless Manufacturing April 2018 Non-condensing Water Heaters Will reach >100,000 units by 2019 New 60+ Acre Production Facility in Griffin, GA 4

5 Service & Support Customer Service Applications Support Parts Department General calls, consumer questions, etc. General sizing questions, commercial applications. Order Service Repair Parts Available from 8 am to 8 pm EST, Monday - Friday Warranty Department Warranty claim issues. Available from 8 a.m. to 5 p.m. EST, Monday- Friday Tradesman: customerservice@rinnai.us Wholesaler: sales@rinnai.us 5

6 Service & Support CONTRACTORS ONLY DIRECT LINE RINNAIS ( ) Technical Support Department This Phone Number is only provided to Technicians FOR CALLS WHILE SERVICING PRODUCT Office Hours: Monday Friday 8 a.m. to 8 p.m. EST On Call hours: 24 / 7 / 365 Leave a message with on call agent You will get a call you back within 20 minutes 6

7 Training Website or trainingevents.rinnai.us 7

8 Rinnai Dealer Program 8

9 Specifications 9

10 M-Series Models Solo Models Model AFUE Max Input Min NG Input M060S M060C M090S M090C M120S M120C M160S M160C 95% 95% 95% 95% 60,000 BTU 17.6 kw 17,000 BTU 5.0 kw 90,000 BTU 26.4 kw Turndown Ratio (NG) 3.5 : : : 1 120,000 BTU 23,500 BTU 35.2 kw 5.1 : kw 160,000 BTU 46.9 kw 6.8 : 1 Combi Models Model M060C M090C M120C M160C DHW Performance F T (10L/min@39 C T) F T (16L/min@39 C T) 10

11 M-Service Features Built for Long Life & Easy Service Minimal Maintenance 2yr / 4yr Service Routines Easy Access from Front & Left side More access to DHW Flat Plate Easier Access for service maintenance Best in Class Reliable Components Honeywell, Grundfos, EBM Papst Brass 3 way valve cartridge DHW Flow Sensor Stainless Steel Heat Exchanger Quality Components Built for Easy Service No tools required to remove Condensate Trap Electrode Assembly Burner Assembly <3 minute Removal Plate Heat Exchanger <3 minute Removal 11

12 Rinnai Serial Nomenclature The M-Series serial # is found on the boiler rating plate label on the lower left side and on all major components Example Serial # KF012345JB: Manufactured in June 2018 Each serial # begins with a 2 letter date code First Letter - Year Second Letter - Month A 2009 A January B 2010 B February C 2011 C March D 2012 D April E 2013 E May F 2014 F June G 2015 G July H 2016 H August J 2017 J September K 2018 K October L 2019 L November M 2020 M December 12

13 M-Series Warranty Product Warranty Description Residential Commercial Primary Heat Exchanger 12 YRS 5 YRS Boiler Parts 2 YRS Labor 1 YR Warranty covers: Defects in materials/workmanship Indoor installations installed per the manual and all applicable code Warranty DOES NOT cover failure due to: Accident, abuse/misuse, alteration/misapplication Improper Installation/Maintenance Poor water quality, scale issues, freezing Please refer to the Documentation Set for full warranty details and guidelines 13

14 M-Controller User Menu: Controller main screen icons Freeze protection active Service routine needed Outdoor reset (outside) temp DHW (with box) DHW demand Heat panel (with box) CH demand Burner Active (w/power bar) ECO DHW Comfort Mode OFF (COMFORT will show if ON) AUTO Outdoor reset Active Bottom line descriptor (operating mode) Heat generation lock External safety circuit open (LWCO, etc) CH or DHW Pump Overrun minute pump operation after demand 14

15 M-Controller 007 Service Mode 007 is a service menu that grants access to technical level adjustments Altitude Outdoor Reset Parameters Frequency of Maintenance Component Testing Fault Code Information Diagnostic Features Other Setup Features 1.From the controller Home screen, press BACK and OK buttons simultaneously for 7 seconds 2.Turn the wheel to 007, press OK 3.Navigate the menu 15

16 Maintenance 16

17 M-Service Recommended Service Tools For service of the boiler these items are recommended: Large adjustable wrench 4mm & 5mm hex bit 8mm socket or nut driver 5 in 1 screwdriver Flue gas analyzer and manometer Installation manual Other Helpful Tools Smart phone / tablet Thermostat screwdriver Multi-meter (volt/ohm/micoamp) 4 Year Service Kit (Part # model specific) Rinnai Boiler Tool Kit. (Part # ) 17

18 M-Maintenance Setting the Service Warning Frequency After completing the installation and commissioning, set the service frequency to notify the end user when the boiler is due for (recommended) service A warning code 3P9 will display when the counter expires The boiler will continue to operate (a wrench icon appear on home screen) 007 Menu Description Detail Sets period of time for service notification Default is 12 months Rinnai s 1 st recommended service frequency is 24 months Activates notification feature Default is OFF (0), must change to ON (1) for the frequency warning to post Resets notification counter After maintenance is complete, this resets the counter and clears the warning 18

19 M-Maintenance Service Warning Contact Info M-Series Boilers also allow the contractor to enter his/her company name and phone number This will display with the periodic service warning This will also display with fault codes Enter the 007 menu Configuration Wizard Service Options Service Center Data Enter company name and phone number 19

20 M-2 Year Service Inspect and clean the condensate trap Inspect the boiler, vent system, and surroundings. Check system pressure, gas pressure and flue gas O₂%. Discuss boiler performance with end user View error code history (parameter 8.6.0) Visually inspect flame, Verify proper O2 20

21 M-2 Year Service Verify Incoming Gas Pressure Fuel Type Minimum Load Gas Pressure In. w.c. Optimal In. w.c Maximum In. w.c NG (Natural Gas) LPG (Liquid Propane) Inlet gas pressure testing: Close manual gas shut-off valve Connect manometer to inlet test port Operate all appliances on the gas service at full power to test load gas pressure at the boiler gas valve test port (see figure at right) Gas Valve Inlet Test Port 21

22 M-2 Year Service Verify Venting Installation Reference I/O manual for full details of approved vent materials 22

23 M-2 Year Service Pressure requirements psi Warning 1P4 / ΔT reduced (until 19 psi is reestablished) <10 psi Fault 108 Boiler inoperable until 19 PSI is reestablished (air purge begins) PSI psi Minimum requirement for normal operation 20 psi Recommendation for fill valve setting TIP: Boiler display pressure should not vary more than 5 psi from the system pressure gauge. If so, drain boiler, remove and clean the pressure sensor and gauge. Replace as needed. 23

24 M-2 Year Service Review Fault Code History Enter 007 Menu Select Complete Menu View Parameter Take note of time/date Recent errors may indicate a problem with a boiler part or the installation (gas pressure, water pressure, venting) 24

25 M-2 Year Service Verify O₂ Levels (Flue gas testing) Service mode (Chimney Active) allows boiler to be forced into a specific fire-rate This is primarily used when verifying O₂ levels, load and max gas pressures IMPORTANT: Boiler must have a very high load (CH or DHW) during this setting 1.From the Home screen, press and hold the Chimney Active button for 7 second 2.The following screen appears indicating the Chimney Active mode is active Chimney Active 100% 3.Chimney Active Use the selector to adjust. Press OK 100% (max fire) 0% (low fire) 4.To exit Chimney Active mode, press the Back button until the Home screen appears 25

26 M-2 Year Service Flue Gas Testing Maximum Input Minimum Input Model NG O₂% LP O₂% NG O₂% LP O₂% M M090S Min values should be M090C higher than the M120 M measured max value Tip: clockwise adjustment of screw increases O₂, counterclockwise decreases Throttle Screw for O₂ adjustment 26

27 M-2 Year Service Condensate Trap Inspection No tools required to remove Twist & pull sealing ring down (white) Flip lever up (grey) Rotate and pull down siphon cup and pipe to remove Clean Check O-ring, replace if necessary, Apply silicon lubricant to O-ring to ease re-installation 27

28 M-4 Year Service Overview Purchase 4-year Maintenance Kit (model dependent) Includes all required gaskets! Remove condensate trap Remove air supply silencer Remove internal gas pipe Remove burner top clamp rods Remove burner, fan & hood Vacuum burner / replace gaskets Vacuum top of heat exchanger Remove electrode assembly 28

29 M-4 Year Service Burner / Fan Removal Remove air supply silencer by unlocking Velcro fastener and pulling up Remove internal gas pipe with adjustable wrench Unplug two (2) fan connectors 29

30 M-4 Year Service Burner / Fan Removal Rotate the lock tabs ¼ turn inward with 4mm hex bit Push down on burner and slide rods forward to remove DO NOT BREAK RED TABS! 30

31 M-4 Year Service Burner / Fan Removal Gently pull burner/fan assembly forward DO NOT DRAG ceramic burner against hex After removal, use vacuum brush to clean top tubes of the heat exchanger as needed IMPORTANT: Do not allow dirt and debris to fall into the heat exchanger DO NOT use compressed air and gas to clean the top of the heat exchanger 31

32 M-4 Year Service Burner Cartridge Service To separate cartridge from housing, release T-clip (with flat head screwdriver) Vacuum ceramic cartridge (NEVER BLOW AIR INTO CARTRIDGE!) IMPORTANT: Both orange gaskets must be replaced if burner is removed. DO NOT REUSE EXISTING GASKETS! 32

33 M-Service Features Burner / Fan Separation Loosen left screw (8mm) Remove right screw (8mm) Inspect fan impeller, blow air into venturi if needed to clean If fan is separated from burner, gasket MUST be replaced! 33

34 M-4 Year Service Electrode Assembly Remove three (3) connectors from electrode assembly Lift tab to remove electrode assembly Gasket MUST be replaced if the assembly is removed! Electrode gap is 3-4mm Confirm new assembly gap before install NOTE: This assembly must be replaced during 4 year service frequency 34

35 Component Review/Removal 35

36 Component Review/Removal Heat Exchanger Sensors T1 Supply temperature (wet well) T2 Return temperature (dry well) Pressure sensor (unscrew to remove) 36

37 Component Review/Removal Pump Removal Boiler must be drained and isolated Unplug pump power connector & PWM connector (next to white insert) Loosen pump nuts Ensure new gaskets are installed Upon reinstall rotate top pipe out, then back after starting bottom nut Note pump direction arrow 37

38 Component Review/Removal Heat Exchanger Removal Boiler must be drained and isolated Remove air supply silencer, internal gas pipe, condensate trap, burner/fan assembly, electrode ignition Remove condensate tray (2 ea 5mm hex bit screws) Note gasket in rear of tray ensure it remains intact 38

39 Component Review/Removal Heat Exchanger Removal Remove pins on supply & return lines Gently pull supply and return lines away from hex Pump nut must be loosened Swing return pipe away from hex Rotate pump to front of unit 39

40 Component Review/Removal Heat Exchanger Removal Remove two (2) 5mm bottom screws Loosen two (2) 5mm top screws Lift heat exchanger up, then away from body Replace all gaskets / O- rings exposed during process (included with new heat exchanger) NOTE: T1 temp sensor and deaerator (can vent) must be moved to new heat exchanger 40

41 Component Review/Removal Gas Valve Removal Disconnect gas valve electrical connection Remove caps covering screws on top of cabinet Remove two (Philips head) screws Gently pull gas valve away from supply pipe Replace any gaskets/orings that are exposed (included with new gas valve) Leak check connections as needed After replacement, verify pressure and O₂ 41

42 Component Review/Removal DHW Combi Assembly T3 DHW temperature sensor is located to the left of side of the plate heat exchanger (isolate DHW before removal) The flow sensor is a rotating wheel that actuates DHW priority at 0.4 gpm. Flow is maintained as low as 0.26 gpm. It is NOT recommended to remove (only in instances where flow is not detected & if replacement sensor is on hand) The 3-way valve actuator can be removed with a single clip 42

43 Component Review/Removal Plate Heat Exchanger Removal (Combi Models) Boiler must be drained and isolated In order to have clearance to remove, the 3-way valve actuator must be removed Remove two (2) 4mm hex bit screws Replace O-rings that have been exposed (4 each) Ensure new plate is installed in proper orientation (markings-up) 43

44 Sequence of Operation 44

45 Sequence of Operation Ignition sequence Boiler in Standby DHW or Heat Demand Setpoint (Tset) calculated (CH/DHW) Prestart checks: -Fan rpm -Heat Exchanger temp T1 Tset - 6 F -Dynamic water pressure check -Flame current check Gas valve opens / Ignition (initial power 70%) 4 second flame current check (>0.8 µa) If no flame detected, 4 second reset then re-ignition (up to 5 total attempts) Code 5P1, 5P2 Once flame is detected, boiler modulates to min power/max pump (for CH) and max power/max pump (for DHW) 45

46 Sequence of Operation CH (with outdoor reset) Boiler in Standby Heat Demand (TT closed) Setpoint (Tset) calculated using outdoor reset Ignition Sequence ΔT Control monitoring maintains 36 F by modulating pump speed Supply temperature determined by outdoor reset curve Burner OFF if T1 T-set by 9 F OR demand ends (TT open) Burner modulates to minimum power / pump runs at high power Burner ON if demand still present and T1 T- set by 5 F Gradient control will slowly increase T1 supply temperature to T1 target When heat demand ends, CH pump runs for 1 minute. A new heat demand will not restart the burner for 5 minutes after the last heat demand ends 46

47 Sequence of Operation Combi DHW (w/demand) Boiler in Standby DHW demand (flow sensor 0.4 gpm) Ignition Sequence Burner modulates to match T3 DHW temperature to the DHW Tset Burner OFF if T3 T-set by 9 F OR flow sensor 0.26 gpm Burner restarts if demand still present and T1 T-set by 5 F DHW pump overrun begins (30 seconds if T1<167 F, 3 minutes if T1>167 F) 47

48 Sequence of Operation Combi DHW (comfort mode) Boiler in Standby T2 DHW Comfort Mode setpoint Setpoint (T-set) calculated Ignition Sequence Modulation (DHW Comfort Mode=low load) T1=Setpoint (T-set), boiler modulates based on T2 Burner OFF if T2 Comfort Mode setpoint (model dependent) DHW pump overrun begins (30 seconds if T1 < 167 F, 3 minutes if T1>167 F) 48

49 Sequence of Operation Solo Indirect Tank DHW (w/10kω sensor) Boiler in Standby DHW demand (T3 < Setpoint - 2 F ) Setpoint (T-set) calculated Ignition Modulation (DHW=max load) T1=Setpoint (T-set), boiler modulates based on T3 Burner OFF if T3 > 5 F + Setpoint OR T2 > 14 F + Setpoint DHW pump overrun begins (30 seconds if T1<167 F, 3 minutes if T1>167 F) 49

50 Sequence of Operation Freeze Protection Boiler Freeze Protection System Freeze Protection If T1<47 F, boiler pump runs for 2 minutes If outdoor sensor between 35 and 25 F, boiler pump will operate 10 minutes every 6 hours Combi models: 3-way valve alternates per 1 minute If outdoor sensor 24 F, boiler pump operates continuously If T1<39 F, burner will fire for 30 seconds in low fire (or when T1>47 F) This feature can be disabled in parameter Solo models: If tank sensor T3<47 F, burner fires until T3>57 F This feature cannot be disabled 50

51 Sequence of Operation Other considerations Every 24 hours, if there is no heat demand (CH or DHW), the pump will be started for 10 seconds and the 3-way valve will be exercised This verifies pump operation 1P9 fault code will post if the PCB does not see an increase in pressure when the pump is energized (this is a blocking code) 140 fault code will occur this happens twice consecutively (this requires a RESET This also prevents the diverter valve from sticking Anti-legionella Logic Every 7 days, M-Series Solo boilers will automatically bring an indirect tank to 149 F This counter begins at install This feature can be disabled at Parameter

52 Parameters 52

53 Parameters Boiler parameters (Chapter 2) PARA Default Range Description F F F F DHW setpoint temp (also achieved by pressing BACK and turning dial on home screen) Max Water Temp (absolute max) Will limit outdoor reset curve settings ,200 Will allow you to set higher than 10.2K but no effect F/min 0-27 F/min ON ON/OFF Combi 2 Solo to +5 F How quickly boiler reaches setpoint from cold start Early models have C to F conversion error (-32) Disables outdoor reset sensor (also available from AUTO function in main menu (CH) or 4.2.1) 0=all Combi models 1=Solo boiler with 10KΩ NTC thermistor in DHW indirect tank 2=Solo boiler with aquastat in DHW indirect tank 0=Eco (off) 1=Schedule 2=Comfort Outdoor reset temp sensor correction May need if outdoor reset is in direct sunlight, etc. DHW Comfort Mode Also available from home screen (DHW) 53

54 Parameters Boiler parameters (Chapter 2) PARA Default Range Description =OFF 1=ON Anti-legionella Cycle (Solo models only) OFF ON/OFF Activates manual mode for component testing OFF ON/OFF Manual control of pump with burner off OFF ON/OFF Manual control of fan with burner off OFF ON/OFF Manual control of 3-way valve with burner off OFF ON/OFF Forces chimney mode (same as button) OFF ON/OFF NA OK=YES ESC=NO 0=NO 1=NC 0=OFF 1=ON Forces Air purge (or turn off same as holding BACK for 7 seconds) Resets all parameters to factory defaults (green button) External Safety contact (LWCO, etc) (NOTE: DO NOT USE OPTION 2) System (plant) frost protection, pump operation based on outdoor temp sensor value 54

55 Parameters Heating (Z1) parameters (Chapter 4) PARA Default Range Description LT=1.0 HT= LT=122 F HT=185 F F 0=Low Temp 1= High Temp 0=OFF 3=ON LT= HT=1.0=3.5 Depends on curve settings LT= F HT= F LT= F HT= F Outdoor reset curve presets (see separate slides) Thermoregulation: outdoor temperature reset Also available from AUTO function in main menu (CH) or DO NOT USE 1,2, or 4 Slope of outdoor reset curve (see separate slides), depends on setting Heating curve offset (parallel shift) Maximum supply temp ( F) Minimum supply temp ( F) 55

56 Parameters Service parameters (Chapter 8) PARA Unit Description Hours Total pump hours Hours Total hours boiler on power (electricity) Hours Total fan hours Cycles Total fan cycles Cycles Total CH flame ignitions Cycles Total DHW flame ignitions Hours Total CH burner hours Hours Total DHW burner hours (add w/ch for absolute total) Occurrence Total number of flame faults Cycles Total ignition cycles OFF/ON PCB signal if fan is ON or OFF RPM Fan speed % Pump speed way valve position 0=DHW, 1=CH 56

57 Parameters Service parameters (Chapter 8) PARA Unit Description l/min DHW rate (note this is in liters multiply by.264 for GPM) % Pump modulation (will never read above 90%) kw Boiler power during operation (multiply by 3412 for BTU) PSI Actual PSI (also on home screen) F CH Flow Setpoint, also called T-set F T1 (Supply temp) F T2 (Return temp) F T3 combi (DHW temp) F Outdoor temp sensor (also on home screen) F Indirect tank temp 57

58 Parameters Service parameters (Chapter 8) PARA Unit Description Months Maintenance frequency ON/OFF Maintenance frequency activation /1 Maintenance frequency reset SW Version (display board) SW version (main PCB) Flame Rod Current 58

59 Fault Codes & Troubleshooting 59

60 Troubleshooting WHEN TROUBLESHOOTING IT IS IMPORTANT TO REMEMBER. REMEMBER ALL RESOURCES AVAILABLE TO YOU Rinnai documentation (Installation Manuals, Technical Bulletins, Application manuals, etc) Rinnai Technical Support Rinnai Website and Partner Portal: Rinnai LMS Training Portal: REMEMBER THE QUALITY OF THE PRODUCT Rinnai s quality control is second to none. Every Rinnai Product is fired and tested at the factory. If it is a new install, look to the installation. It is probably not a manufacturing issue REMEMBER THE BASICS Use parameters info to validate operation and error code history to see recent problems Jump terminals TT to confirm boiler will respond to a heat call 60

61 Troubleshooting No Heat, No DHW (With no fault code) Is the boiler in air purge (De-aeration)? This 7 minute program initiates when: Anytime boiler is powered on Boiler water pressure drops < 10 psi Is Heat generation lock displayed on home screen? Check external safety contact circuit LWCO Overheat slab sensor 61

62 Troubleshooting No Heat (With no fault code and DHW functioning) No box around rad symbol with heat demand User menu in Summer Mode? (No target temp and bar shown on right side of home screen) User menu OFF (screen will be blank) OK Summer/Winter/Off Recommended to keep in Winter at all times Is the TT circuit (blue screw terminal) closed? Is Tstat calling or relay end switch is closed. TT terminal can be jumped to test Is Warm Weather Shut Down Active? Ensure outdoor temp sensor reading is <71 F If sensor reading is unreasonably high Test sensor resistance and wiring Examine sensor location for heat source Sunlight, exhaust, uninsulated wall mount 62

63 Troubleshooting No Heat (With no fault code) Box around rad symbol with heat demand If CH Pump Over Run shown on home screen, boiler is off on temperature. Check CH target temp Check CH Flow (supply) temp Verify all outdoor reset parameters If boiler supply temperature is above target temperature, 3 way valve may be stuck in DHW position This could be an actuator failure Activate manual mode (2.6.0) Set 3-way valve to CH on the manual menu off the home screen Remove actuator from 3-way valve If heating operation is restored, check actuator and replace if needed 63

64 Troubleshooting Slow Heating (With no fault code) Check the Hydronic System Are system pumps working? Are zone valves open? Are boiler supply and system supply temperatures similar? If system supply is much lower, system flow is very high What is the system ΔT? If <12 F, check for emitter problems or over-pumping If >40 F, system flow may be too low. Check for restriction or external pump issue Verify All outdoor reset parameters 64

65 Troubleshooting Verifying Outdoor Reset Parameters Heating Curve Offset (or turning dial on controller Home screen) This setting shifts the outdoor reset target temperature up or down When the offset is negative the boiler supply temperature will be relatively low Increase to zero or a positive number to raise current supply temperature Temperature Gradient (ramp up) Increase if <9 F This will allow the boiler to heat the system faster 65

66 Troubleshooting Verifying Outdoor Reset Parameters Low or High outdoor reset curve. Only total slab radiant applications should use the low temperature curve Slope If curve slope is too low, the boiler may not heat effectively in colder weather The 1.5 default setting works well with a newer tight building Increase setting to 2.0 for an average house and 2.5 for an older drafty house Max supply temperature If set too low, boiler may not heat effectively in colder weather Min supply temp When set too low, the boiler may not heat effectively in mild weather The minimum recommended setting for baseboard is 100 F 66

67 Troubleshooting Verifying Outdoor Reset Parameters Outdoor Reset Curve Min/Max Temp Guidelines Type of Heat Emitter Typical Minimum Supply Temperature Typical Maximum Supply Temperature Hydronic Air Handler F F Unit Heater F F Base Board convectors F F Cast Iron / Panel Radiator F F Undermount Radiant F F Poured concrete radiant F F *NOTE: These are basic guidelines. Please check with manufacturer of emitter or consult your heating design engineer. 67

68 Troubleshooting Other flow or pressure-related issues (with no fault code) Closely Spaced Tees Poor hydraulic separation design will cause boiler to: Struggle to maintain proper ΔT Struggle to maintain proper temp Short cycle If Tees are too far apart: Primary loop will have pressure drop The system pump will influence the boiler (not good) System piping should be (at least) one pipe size larger than primary (boiler) loop If not, boiler flow will reduce System pump will influence the boiler flow 68

69 Troubleshooting Other flow or pressure-related issues (with no fault code) System issues M120/160 models cannot be direct coupled External pumps can interfere with boiler flow and temperature control When multiple zones have different head loss, lower flow zones will get less heat from the boiler. Solution: primary/secondary boiler piping 69

70 Troubleshooting No Domestic Hot Water (With no fault code and CH functioning) DHW temp and bar should display on left side of home screen If temp and vertical bar are missing, ensure Heating Only mode is not selected If so change to Winter 70

71 Troubleshooting No Domestic Hot Water (With no fault code and CH functioning) If needed, isolate boiler and confirm DHW flow Check for crossover Verify mixing valve setting Reverse flow (backward piping) Ensure check valves are functioning If DHW temp is present on controller, look for box around faucet icon If missing, the boiler has not recognized a DHW demand Confirm DHW at parameter Activation flow is 0.4 gpm If flow is >0.4 gpm, check T3 DHW temperature sensor at parameter If flow is <0.4 gpm, check for blocked flow restrictor or flat plate If faucet box is present Check 3-way valve actuator position at parameter If 0, remove actuator and check action Ensure cartridge is not stuck in heating 71

72 Troubleshooting Pressure Fault Codes: 1P4 & psi Warning 1P4 / ΔT reduced (until 19 psi is reestablished) LWCO not required per NFPA 54 due to this pressure control technology <10 psi Fault 108 Boiler inoperable until 19 PSI is reestablished (air purge begins) PSI psi Minimum requirement for normal operation 20 psi Recommendation for fill valve setting 72

73 Troubleshooting Pump Verification Fault Codes: 1P9 & 140 During a call for heat (CH or DHW), boiler PCB fails to see an increase in pressure (at sensor) when pump is energized 1P9 is blocking code 140 is fault (2 successive 1P9 codes) and will require RESET Verify the Boiler Pump is operational, and spins freely Remove flat screw on front of pump and insert a 4mm Allen wrench into front of pump and verify it spins freely. Temporarily remove condensate hose and trap if needed for access Verify boiler pressure gauge and controller PSI are reading accurately When boiler pump is off, these should be within 1-2 psi When boiler pump is on, controller psi will be higher 73

74 Troubleshooting Other Pressure-related Fault Codes: 102 & Pressure sensor values are out of range Verify pressure sensor is connected and seated properly Replace if needed 109 (reset required) Pressure sensor value exceeds 43 PSI If proper 30 PSI PRV is connected and functioning, this should NEVER occur Verify operation of PRV and autofill valve Replace pressure sensor 74

75 Troubleshooting Ignition and Flame Fault Codes:5XX 5P1 (warning code) Flame not detected on 1 st ignition attempt (will try again) 5P2 (warning code) Flame not detected on 2 nd ignition attempt (will try again) 501 (reset required) Flame not detected after 5 ignition attempts 5P3 (warning code) Flame rod current lost after successful ignition (boiler will ignite again) 504 (reset required) Flame rod current lost after success ignition (boiler will require RESET) Verify: Flame / spark ignition through site glass Gas Pressure Vent issues (blockage, clearances, equivalencies) Proper gas conversion/altitude settings NOTE: If boiler successfully starts, check flue gas O₂% and flame current (Parameter 8.7.5) Minimum flame current is 0.8 µamps REMINDER: If ignition assembly is removed (for inspection), gasket must be replaced! 75

76 Troubleshooting Gas Valve-related Fault Codes:309 & (reset required) Flame rod current detected for 3 seconds AFTER gas valve signal (120V) OFF Verify: Flame present after CH/DHW call ends If there is no flame, check flame rod, wiring, etc. If there is flame, verify 120V signal to gas valve OFF If signal OFF, replace gas valve as needed If signal still ON, replace PCB as needed Replace valve if needed Flame rod wiring, proper grounding, etc. 502 (reset required) Flame rod current detected BEFORE gas valve powered ON (120V) Verify: Flame present before gas valve clicks open Replace valve if needed Flame not present before gas valve clicks open Verify flame rod wiring, proper grounding, etc. 76

77 Troubleshooting Temp Sensor-related Fault Codes: 11X & 20X 110 T1 (Supply) temp sensor values out of range (wet well) 112 T2 (Return) temp sensor values out of range (dry well) 201 T3 (Combi models, DHW) temp sensor values out of range (wet well) Verify: Temp values available at parameters (T1), (T2), (T3) Sensor resistance wiring, resistance values (see table) Replace sensor if needed, etc. 114 Outdoor reset temp sensor not detected or values out of range Verify: Outdoor reset is required for system. If not, disable at parameter or Temp values available at parameter Sensor resistance wiring, resistance values (see table) Replace sensor if needed, etc. 203 Tank temp sensor (Solo models) values out of range Verify: Parameter setting Temp values available at parameter Sensor resistance wiring, resistance values (see table) Replace sensor if needed, etc. 77

78 Troubleshooting Temp Sensor-related Fault Codes Refer to the Owner s/installation manual for temperature sensor resistance tables 78

79 Troubleshooting Over-temp Fault Code: (reset required) T1 (supply) or T2 (return) sensor detects water temperature is >212 F for 3 seconds. Verify: No air in boiler Run air purge (parameter 2.7.1) Boiler pump operation T1 or T2 sensor resistance wiring, resistance values (see table) Replace sensor if needed, etc. 79

80 Troubleshooting Fan Fault Code: (reset required) Fan speed out of range (rpm too high or low) Verify: Fan installed and connected correctly Replace as needed If fan is running continuously, control connection may be off If fan does not run when control connection is off, check voltage on line connection 80

81 Troubleshooting PCB Fault Codes: 303 & or 306 (reset required) PCB error Verify: PCB wiring, supply voltage, proper ground Replace as needed (contact technical support) 81

82 Troubleshooting Reset Fault Code: (reset required) RESET button pressed (to clear code) more than 5 times in less than 15 minutes Wait 15 minutes for next reset 82

83 Troubleshooting Voltage Measurements Due to the intuitive controller, parameter menu, and fault code detail, very few electrical measurements are required for troubleshooting Temperature sensors see manual for resistance tables All internal temp resistors are 10KΩ The outdoor reset temp sensor is 1KΩ Flame rod current parameter will display PCB reading of flame rod current. Meter not required. Fan voltage 120 vac ( vac) Gas valve 120 vac ( vac) Pump 120 vac ( vac) 3-way valve 120 vac ( vac) Contact technical support if you feel additional troubleshooting guidance 83

84 Troubleshooting Wiring Block 84

85 END of Training 85