RITZ America Corporation GAS-FIRED DIRECT VENT OILER NH-00- DV NH-0- DV Rev: January, 00 Service Manual Refer to this manual whenever performing service or maintenance on this appliance. This manual will be used for service technician training seminars. The specifications and descriptions in this manual may be changed without prior notice. For further assistance, contact Noritz Technical Support at -866-66-89. Do not short circuit any safety device on this appliance Contents Important Safety Information.... Product Features.... Specifications/Performance Table.... Dimensions... 6. Components.... Operating Principle... 9 6. Operation Flow Chart.... iring Diagram... 8. Troubleshooting... Error Codes and Checkpoints... Checkpoints... 6 Error Descriptions and How to Reset... Operation Panel (Remote Controller)... 0 Displaying Maintenance Monitors on the Operation Panel (Remote Controller)... 0 Maintenance Monitor List... Circuit oard Replacement... hen Changing the Fan Motor... Gas Line Requirements... Gas Line Sizing Charts... Manifold Gas Pressure Adjustment... 6 Periodic Inspection... Changing oiler Settings... 9 Installations at Elevations Above,000 ft....0 Emergency operation procedure... 0 9. Installation Check... S-06-908
Important Safety Information To prevent damage to property and injury to the user, the icons below warn of varying levels of risk. ARNING Ignoring this indication will cause an immediate danger of death or serious injury. CAUTION Ignoring this indication may result in death or serious injury. Prohibited.. Safety Tips for Service ear the appropriate clothing and protective gear: CAUTION In order to prevent injury or accident, wear a protective helmet, safety boots and a lifting belt whenever necessary. Use only the appropriate tools and parts: Only use replacement parts manufactured by Noritz for this model as listed in the ARNING Parts List for service on this unit. Use appropriate tools. Modification of the unit is prohibited: Do not attempt to modify or alter the unit. This will cause a fire hazard and a risk of electrical shock. hen servicing: ARNING Disconnect the power supply during maintenance and repairs to reduce the risk of electric shock. If it is necessary to have the electricity connected during repairs, use extreme caution not to touch parts that may cause a shock. Do not short circuit any safety device on this appliance: If a safety device is not functioning properly, replace the part. Do not under any circumstances short circuit the part. Exhaust and gas leakage caution: Always check for leaks when installing or modifying the exhaust vent or gas piping. ARNING. Post-Service Checks Check parts for leaks: Confirm that there are no gas, water, or exhaust leaks regardless of whether the CAUTION service performed could have caused them. Check that the flue collar and vent pipe are installed correctly and that they are in good condition. Confirm that there are no gas, water or exhaust leaks regardless of whether the service performed could have caused them. Check for combustibles: CAUTION Check insulation resistance: ARNING After service or maintenance is completed, check that there are no combustibles in the vicinity of the unit. After service or maintenance is completed, measure the resistance between the electrical wires and ground. If it is less than 0M, there is a risk of electrical shock. Properly reconnect the power supply: Confirm that the power supply has been reconnected properly after service or maintenance is completed. Also confirm that there is no dust or other obstacles that might ARNING cause an electric shock or a fire hazard.
. Product Features. An external controller is unnecessary in a basic system. An external zone controller is unnecessary for the indirect tank (PRIORITY) and heating systems (PRIORITY ) which do not use multiple zones. The boiler has two T-T connections and two circulator output terminals.. Dual temperature control The hot water supply temperature can be set between 0 F-80 F. It can be customized for PRIORITY and PRIORITY.. Flow switch activation The boiler is equipped with a water flow switch which prevents the boiler from firing when little or no flow is circulating through the heat exchanger. Should the circulator, zone valve, etc. fail, the flow switch will also prevent damage to the heat exchanger.. Freeze prevention Freezing within the boiler caused by a drop in temperature at the installation site or a backflow of cold air from the outdoors is prevented with the on-board freeze prevention control. *Refer to the "Installation and Instruction Manual" for limitations on this control.
. Specifications/Performance Table Item Model Name Type Installation Air Supply/Exhaust Heating method Ignition Operating Pressure Safety valve setting pressure Amount of boiler water used Dimensions eight ater Holding Capacity Connection Sizes Supply Return Gas Inlet Power Supply Supply Consumption ( * ) Materials Casing Flue Collar Heat Exchanger Safety Devices Accessories Specification NH-00-DV NH-0-DV Indoor all Hanging Direct Vent / Sealed Combustion Closed type hot-water circulation method Direct Ignition -0 psi 0 psi - GPM (bypass minimum-flow rate:.gpm)."(height) x 8."(idth) x 9."(Depth) 6. lbs. 0. Gallon " " /" 0 VAC (60Hz) NG : 9 LP : NG : 9 LP : 9 Zincified Steel Plate/Polyester Coating Stainless Steel Copper Sheeting, Copper Tubing Flame Rod, Thermal Fuse, Lightning Protection Device (ZNR), Overheat Prevention Device, Freezing Prevention Device, Fan Rotation Detector, oil-dry Safety Device, oil-dry Protection Device, Overcurrent Protection Device Pressure & Temperature Gauge, Safety Relief Valve (valve, fitting, and gasket), Anchoring Screws, s * The values listed are for the boiler only. The maximum current draw by the unit with pumps connected will be 6 amperes or less. Performance Item Gas Consumption NG LP AFUE NG LP Standard output Temperature Settings Maximum Performance Minimum Performance Maximum Performance Minimum Performance Fahrenheit Centigrade NH-00-DV 99,900 btuh NH-0-DV 0,000 btuh,00 btuh,00 btuh 99,900 btuh 0,000 btuh,00 btuh,00 btuh 8.% 8.0% 8.0% 8.8%,00-6,00 btuh,00-,00 btuh 0-0 F (In F intervals), 6, 80 F (9 Options) 60-80 C (In C intervals), 8 C (6 Options)
Heating load - Temperature Specification Note) Maximum temperature is 88 F (8 C) Setting Temp. + F (approximately) Setting Temp. + C Temperature Setting Temp. Proportional control Setting Temp. Setting Temp. -8 F (approximately) Setting Temp. -0 C NH-0-DV NH-00-DV,00 btu/h,00 btu/h,00 btu/h 6,00 btu/h Heating load Pressure Loss Characteristics The total flow rate of the heating circuit should be no less than gpm ( L/min.) and no greater than gpm (6 L/min.). Flow rate (L/min) 0.8.6.. 9.0.8 6.6 0.. 8.0.8.6 9...0 60.8 6.6 Flow rate (GPM)
. Dimensions." (VIE FROM TOP)." 0.6" 8.9" IRING THROUGHAYS 6.8".6".".8" 6."." ATER SUPPLY(")." " 6.8" ATER RETURN(") GAS INLET(/") 6.".".9".8".".6" 0." 9."."."." AIR INLET 8.".9" " " 9." FLUE COLLAR " 6."." OPERATION PANEL OTTOM OF CASE OTTOM OF CASE.".8".9"." 6." 0.".6" IRING THROUGHAYS ATER SUPPLY."." GAS INLET ATER DRAIN VALVE (ATER FILTER) PRESSURE RELIEF VALVE (ATER DRAIN VALVE) ATER RETURN 6
. Components Air Inlet Exhaust Flue Air Inlet Thermistor High Limit Switch Safety Relief Valve Heat Exchanger Circuit oard SC Thermal Fuse ater Return Thermistor Heat Exchanger Thermistor Igniter Fan Motor Transformer Junction ox ater Supply Thermistor Flame Rod Ignition Electrode Manifold Circuit oard Gas Valve Mechanism ater Flow Switch ater Supply Drain Plug Gas Inlet ater Drain Plug (Inlet Filter) ater Return
Operation Panel (RC-68M) urner On Indicator hen burning, the indicator is lit. PRIORITY Indicator The indicator will flash when the temperature of PRIORITY (Indirect tank use) is displayed. The indicator is lit during PRIORITY (Indirect tank use) operation. Temperature Setting (Ex.: 80 F) Error Code A number will flash if a failure occurs. PRIORITY utton For setting the temperature of PRIORITY. PRIORITY Indicator The indicator will flash when the temperature of PRIORITY (Heating use) is displayed. The indicator is lit during PRIORITY (Heating use) operation. Setting uttons For changing the set temperature and performing various settings. Power On/Off utton For turning the boiler on and off. Maximum Temperature Setting utton For changing the maximum temperature setting of PRIORITY. PRIORITY utton For setting the temperature of PRIORITY. * efore use, remove the protective sheet from the remote controller surface. 8
. Operating Principle High limit switch Safety relief valve Exhaust ater return thermistor Heat exchanger thermistor Over heat prevention device (Thermal fuse) Controller SC Igniter Circulator outputs, Contact for Lamp T-T connection Controller Ignition plug Flame rod urner Gas proportioning valve Primary gas valve Air inlet thermistor AC 0V Transformer Gas solenoid valve- Air supply ater flow switch Gas solenoid valve- Gas solenoid valve- Rotational frequency sensor Fan motor ater supply thermistor ater drain plug Inlet filter Supply Gas Return Drain plug 9
< How to Use, NH-00-DV / NH-0-DV >. Normal Operation (Priority or Priority). Turn on the power by pressing the "POER" button on the operation panel (remote controller). (Power indicator lit.). hen the Operation switch of the "Indirect tank" or "Room thermostat" is turned ON (Priority or Priority calls for heat), the boiler supplies power to the Priority or Priority circulator.. hen the water flow switch is ON and water supply thermistor detection temperature is lower than combustion start temperature, the fan will initiate and pre-purge any residual combustible gas in the combustion chamber, and then the igniter begins to spark. Finally, the gas valves open, and burner is ignited by the spark.. hen the flame rod detects a flame, the igniter stops sparking.. The computer will then control the gas and fan to maintain the supply temperature set on the operation panel (According to "Priority temperature setting" or "Priority temperature setting"). The temperature can be adjusted using the "Priority" button or "Priority" button on the operation panel. * hen "Priority" and "Priority" both call for heat, the boiler gives priority to the "Priority" circuit. * hen the heating load is too small, the burner is controlled ON/OFF. 6. hen the Operation switch of the "Indirect tank" or "Room thermostat" is turned OFF (Priority or Priority no longer calls for heat), the gas valve will close and the burner flame will go out. After the post purge removes residual gas from the combustion chamber and post circulation removes the residual heat from the heat exchanger, the appliance stops.. hen the boiler is not being used for an extended period of time, turn off the power by pressing the "POER" button on the operation panel. (Power indicator OFF). Error Codes If the flame rod does not detect a flame, or if the high limit switch has been triggered, the gas valve will close, the flame will go out, and an error code will flash on the operation panel. In order to reset the boiler and remove the error code, turn the power off by pressing the "POER" button on the operation panel, and then press it again to turn the boiler back on. If the problem requires service ( the thermal fuse is triggered, etc.) the gas valves will stay closed and resetting the appliance will not eliminate the error code. If this is the case, the boiler must be serviced (repaired) before it will work again.. Miscellaneous If the boiler will not be used for a long period of time, turn off the power, and close the manual gas valves on the supply line. 0
6. Operation Flow Chart Connect power Fix problem Priority operation Power button ON Power indicator (green) lit Self-diagnosis Normal combustion possible arning indication Use for less than 0 years Self-diagnosis Normal combustion possible 90 arning indication Maximum output limited 0 Self-diagnosis Normal combustion possible arning indication The boiler will continue to operate with the error code blinking on the operation panel (remote controller). 99 90 Disconnect power Error code stops flashing Priority & do not call for heat Power button OFF F 9 Priority calls for heat Priority does not call for heat Change to the priority temperature setting Priority indicator (green) lit Priority circulator ON Priority operation A E Priority operation A Overheat Prevention Device (Thermal Fuse) normal (Less than 6 F) Priority calls for heat A Priority, circulator OFF Initial check ater flow switch ON (. GPM or more) C (after sec.) (after 60 sec.) 9 Priority circulator abnormality ater flow switch OFF failure 6 C Priority indicator (orange) lit Priority circulator ON Initial check normal 6 Overheat Prevention Device (Thermal Fuse) triggered (6 F or more) ater return thermistor Open or Shorted ater supply thermistor Open or Shorted Heat exchanger thermistor Open or Shorted Flame rod circuit abnormality (µa or more) Circuit board abnormality 0 a Combustion control D Priority does not call for heat Priority indicator (orange) OFF E G Shutdown procedure Priority operation A F G Fan motor OFF urner ON indicator (red) OFF Primary gas valve closes Gas solenoid valve- closes Gas solenoid valve- closes Gas solenoid valve- closes Gas proportioning valve closes D 9 Primary gas valve opens Gas solenoid valve- opens Gas solenoid valve- opens Gas proportioning valve opens ater flow switch ON (. GPM or more) 0 Igniter sparks (after sec.) ater supply thermistor combustion start temperature 8 Fan motor ON Fan speed (target 00rpm) Flame rod detects ( µa or more) (after 60 sec.) (after 60 sec.) Gas valve drive circuit abnormality Priority circulator abnormality ater flow switch OFF failure Re-ignition (8 times or less) Extinction ( times or less) High limit switch is normal (rd) 6 6 Ignition failure Flame rod 0 High limit switch Fan motor OFF H I Priority does not call for heat Primary gas valve closes Gas solenoid valve- closes Gas solenoid valve- closes Gas solenoid valve- closes Gas proportioning valve closes urner ON indicator (red) OFF Priority circulator OFF (Passage of 0 seconds from a.) Fan motor OFF (Passage of seconds from a b.) Circulator lock prevention control Priority circulator OFF (Passage of 0 seconds from a.) Priority does not call for heat b Priority indicator (green) OFF Combustion stop H Priority circulator OFF (Passage of 0 seconds from b.) I 6 urner ON indicator (red) lit Igniter stops sparking Gas solenoid valve- opens Gas solenoid valve- closes st,th,th:after sec. others:after sec. Igniter stops sparking Primary gas valve closes Gas solenoid valve- closes Gas solenoid valve- closes Gas proportioning valve closes * Connect power or Passage of 60 hours from the last circulation Priority circulator ON 9 Priority circulator ON * * Proportional control (gas,fan) Gas solenoid valve- closes urner ON indicator (red) OFF urner ON indicator (red) OFF Heating load,000btu/h or more Gas solenoid valve- opens Heating load less than,000btu/h Flame rod detects no flame (0. µa or less) Primary gas valve closes Gas solenoid valve- closes Gas solenoid valve- closes Gas solenoid valve- closes Gas proportioning valve closes Passage of 0 seconds from the circulator ON Priority circulator OFF Priority circulator OFF * * Gas solenoid valve- closes * Time is managed respectively "Priority and ". Only the circulator where timer is up operate. ater flow switch ON (. GPM or more) 6 6 90 0 ater supply thermistor < combustion stop temperature ater supply temperature does not stabilize 8 9 8 ater return thermistor Open or shorted Heat exchanger thermistor Open or shorted Combustion abnormality E Safety device triggered * Fan speed abnormality ater flow switch ON failure ater supply thermistor Open or shorted Overheat Prevention Device (Thermal Fuse) triggered (6 F or more) High limit switch triggered * hen the present fan speed is 00 rpm more or less than the target speed.
Freeze prevention control 0 arning indication 0 Air inlet thermistor normal Air inlet thermistor F ( C) or less ater supply thermistor F ( C) or less ater supply thermistor F ( C) or less ater return thermistor F ( C) or less ater return thermistor F ( C) or less Heat exchanger thermistor F ( C) or less Heat exchanger thermistor F ( C) or less Priority Freeze prevention control permission 9 Priority circulator ON Priority Freeze prevention control permission Less than minutes from Priority circulator ON Priority circulator ON Priority Freeze prevention control disabled Priority circulator OFF (after 60 sec.) Combustion control D Priority Freeze prevention control disabled ater flow switch ON (. GPM or more) (after 0 sec.) E Priority Freeze prevention control completion Priority Freeze prevention control completion C Priority Freeze prevention control disabled Priority circulator OFF (after 60 sec.) Less than minutes from Priority circulator ON Priority Freeze prevention control disabled ater flow switch ON (. GPM or more) (after 0 sec.) Priority Freeze prevention control completion Priority Freeze prevention control completion D Less than minutes from Priority circulator ON Combustion control D E Priority Freeze prevention control disabled Less than minutes from Priority circulator ON ater supply thermistor 86 F (0 C) or more Priority Freeze prevention control completion Combustion stop H I Priority Freeze prevention control disabled Priority Freeze prevention control completion Manual circulator operation procedure Priority circulator ON * Priority button ON Priority indicator (orange) flashing Display P flashing Display of lit ater flow switch ON (. GPM or more) (after sec.) Display of lit (after sec.) Display on lit Passage of hours from this procedure start Priority circulator OFF Priority indicator (orange) OFF Display OFF * Combustion stop H I Priority Freeze prevention control completion Priority Freeze prevention control disabled Priority circulator OFF Priority & Freeze prevention control data clear Passage of minutes from water flow switch OFF * This flow chart has described priority circulator manual operation. Please press the "Priority button", when you want to operate Priority circulator. * Press and hold the Priority or button for at least seconds. * The circulator will be turned off when either the Power button is turned "ON" or the Priority or button is held in for at least seconds. * ater return thermistor 0 F (0 C) or more Fahrenheit select Centigrade select C C Priority Freeze prevention control incomplete Priority circulator OFF Control temperature Temperature setting (Control temperature) 80 6 0 6 60 0 0 Combustion start temperature 6 8 6 0 6 60 0 Combustion stop temperature 88 88 8 6 6 8 8 8 80 0 6 60 8 8 6 ater supply thermistor 86 F (0 C) or more Combustion stop H I Priority Freeze prevention control completion Priority Freeze prevention control disabled Priority circulator OFF Priority & Freeze prevention control data clear ater return thermistor 0 F (0 C) or more D Priority of control Combustion stop D Priority Freeze prevention control incomplete H Priority circulator OFF hen "Priority" and "Priority" both call for heat, this appliance gives priority to the "Priority" circuit. I
. iring Diagram IRING DIAGRAM RO OKL COLOR CODING : hite R : Red K : lack V : Violet O : Orange L : lue GY : Gray G : Green R : rown Y : Yellow SYSTEM CONTROL CIRCUIT OARD 0 8 6 <CN> 9 R K L <CN89C> L 6 L <CN> <CN> 6 8 9 G V R V R RESISTANCE EARTH K K K K ATER FLO SITCH ATER RETURN THERMISTOR ATER SUPPLY THERMISTOR HEAT EXCHANGER THERMISTOR AIR INLET THERMISTOR THERMAL FUSE FAN SPEED CORRECTOR FLAME ROD V V L L K K L L <CN89> L L <CN8> R L 6 8 0 9 6 8 09 6 8 09 V L V L L <CN8> K G <CN0> 6 <CN> 6 Y RO L 6 8 9 <CN6> MAIN CIRCUIT OARD <CN0> K O 6 8 K L GY O Y 0 9 8 K 6 K <CN> <CN0> 6 <CN8> O Y Minimum Manifold Pressure Set utton Maximum Manifold Pressure Set utton L R O L O Manifold Gas Pressure Increase utton Manifold Gas Pressure Decrease utton GY K 8 6 L R O L GY K Y AIR FLO SITCH EMERGENCY OPERATION SITCH L R DU 0 SV 0 GAS VALVE UNIT K K GY GY SV H SV H O O SV H FAN MOTOR Factory Use Only FM REMOTE CONTROLLER RC-68M L L R(Vdc) Y(FG) L(GND) R(Vcc) L L L L L L R R Y Y L L R R <CN> RY LR O Y L R L L <CN0> <CN89A> <CN0> G L L POER CIRCUIT OARD <CN9> L ELECTRODE EARTH IGNITER IG K <CN0> K HIGH-LIMIT SITCH K TRANSFORMER EARTH K L K K L L K K O L L R O R K EARTH G TERMINAL A V R TERMINAL C V R V R V R Factory Use Only 6 8 K K O L L R O R K K R R O O TERMINAL JUNKTION OX
TERMINAL A TERMINAL C K G V R Hot Neutral GND Power Input AC0Volts TERMINAL Aquastat Thermostat Priority Priority (Indirect tank) (Heating) T-T Connection (DCV 0.Amp.) K K R R O O Hot Neutral Priority (Indirect tank) Hot Neutral Priority (Heating) Power supply for circulator AC0Volts Max..Amp. urner Power For External Lamp No Power supply(only Contact) RELAY RESISTANCE TERMINAL C RELAY RELAY 6 RELAY RELAY DRIVING CIRCUIT CPU CENTRAL PROCESSING UNIT SITCH DCV DETECT RESISTANCE CIRCUIT DCV PRIORITY THERMOSTAT PRIORITY AQUASTAT V POER CIRCUIT GND GND HOT NEUTRAL ARRESTER VARISTOR VARISTOR EARTH TERMINAL RELAY RELAY 6 POER FOR EXTERNAL LAMP POER SUPPLY(ONLY CONTACT) URNER FOR EXTERNAL LAMP POER SUPPLY(ONLY CONTACT) RELAY 6A FUSE PRIORITY POER SUPPLY FOR CIRCULATOR RELAY 6A FUSE PRIORITY POER SUPPLY FOR CIRCULATOR AC0V PRIMARY AC00V SECONDARY 0A(FUSE) RELAY GAS FURNACE RELAY 9 IG IGNITER DC90V RELAY 0 RELAY SV0 SOLEID VALVE 0 DC90V RELAY SV SOLEID VALVE H HIGH LIMIT SITCH RELAY SV SOLEID VALVE H RELAY SV SOLEID VALVE H DC0V DC0V DCV POER CONTROLLER FAN FAN MOTOR A DCV PRIMARY SECONDARY C FAN CONTROL OUTPUT FAN ROTATION SPEED INPUT FAN PULSE CONTROL CIRCUIT A V POER CIRCUIT C FAN CURRENT VALUE INPUT GND ATER FLO SITCH THERMAL FUSE RELAY Sub-CPU SU CONTROL UNIT RELAY CPU D RELAY RELAY RELAY RELAY DRIVING CIRCUIT CENTRAL PROCESSING UNIT ATER SUPPLY THERMISTOR ATER RETURN THERMISTOR RELAY 9 RELAY 0 HEAT EXCHANGER THERMISTOR DU GAS PROPORTION VALVE POER CONTROL CIRCUIT AIR INLET THERMISTOR FLAME DETECTING CIRCUIT FR FLAME ROD EARTH D V POER CIRCUIT GND
8. Troubleshooting Display 0 6 0 0 6 Error Codes and Checkpoints Description Combustion abnormality (TU drop) (arning indication) Ignition failure (Initial flame fault detection) Flame rod does not detect flame (Flame fault detection) Overheat Prevention Device (Thermal Fuse) triggered ater supply temperature does not stabilize (Supply temperature is too low) (Heating load is too much) High limit switch triggered ater flow switch ON failure Air inlet thermistor abnormality ater return thermistor abnormality ater supply thermistor abnormality Heat exchanger thermistor abnormality 6 Fan motor abnormality Priority circulator abnormality ater flow switch OFF failure Diagnosis Point (Trouble Point) Check for abnormal combustion. Check flue for blockage or obstruction. Check the gas supply piping and pressure. Check for igniter spark ( 0 ). Check gas solenoid valves ( ). Check flame rod ( ). Check ground, paying special attention to the ground connection to the circuit board. Check for accidental extinction of the flame. Check for abnormal combustion. Check gas solenoid valves. Check flame rod ( ). Check ground, especially on circuit board. Check for melting or damage to the thermal fuse ( ). Check for improper connection of thermal fuse. Check the heating load. Check the supply temperature. If the supply temperature is lower than F ( C), adjust the flow in the heating circuit and/or check the temperature setting on the operation panel. Check if high limit switch is triggered ( ). Check for improper connection of high limit switch. Check for blocking of the water flow switch ( 8 ). Check for short circuit of the water flow switch. Measure the resistance through the air inlet thermistor ( 0 ). Check for an open or short circuit. Check for improper connection of air inlet thermistor. Measure the resistance through the water return thermistor ( ). Check for an open or short circuit. Check for improper connection of water return thermistor. Measure the resistance through the water supply thermistor ( ). Check for an open or short circuit. Check for improper connection of water supply thermistor. Measure the resistance through the heat exchanger thermistor ( ). Check for an open or short circuit. Check for improper connection of heat exchanger thermistor. Check that the fan is rotating and check the pulse frequency from the fan rotational frequency sensor ( 8 9 ). Check for improper connection of the fan. Check voltage from circuit board. Check that the circulator is running. Check for improper connection of the circulator ( ). Check voltage from circuit board. Check for improper connection of the water flow switch ( ). 6 Priority circulator abnormality ater flow switch OFF failure Check that the circulator is running. Check for improper connection of the circulator ( 9 ). Check voltage from circuit board. Check for improper connection of the water flow switch ( ). 0 60 6 90 90 99 P on P of Circuit board abnormality Gas valve drive circuit abnormality Flame rod circuit abnormality (Detection of flame when no flame is present) Circuit board setting abnormality (High elevation connector, Dip switch, etc) Operation panel (Remote controller) transmission abnormality Circuit board SC transmission abnormality Combustion abnormality Combustion abnormality (arning indication) (The appliance is stopped) Combustion abnormality (The appliance is stopped) Manual circulator operation mode Circuit board failure Check for damage to the gas valve drive circuit on the circuit board. Measure the current from the flame rod when there is no flame ( 6 ). Check for a ground fault. Check for proper setting of maintenance writers on circuit board. Check the circuit board (microcomputer) for damage. Check the Dip switch. Check the "Control switch connector" (ex.high elevation connector etc.). Note ), ) Check connection from operation panel (remote controller) to circuit board. Check operation panel (remote controller) and circuit board for damage. Note ) Check connection from circuit board SC to circuit board. Check circuit board SC and circuit board for damage. Note ) Check for abnormal combustion. Check flue for blockage or obstruction. Check for abnormal combustion. Check flue for blockage or obstruction. Check for abnormal combustion. Check flue for blockage or obstruction. P on : ater flow switch ON (Flow rate is. GPM or more) P of : ater flow switch OFF (Flow rate is less than. GPM) The error codes in bold cannot be reset by turning the boiler OFF on the operation panel. Disconnect, then reconnect electrical power to the boiler to reset the system. Note ) This error code is not mentioned in the flowchart. Note ) This error code is displayed when a "Control switch connector" is disconnected or connected while the boiler has power. Disconnect power to the boiler before making this adjustment. Control switch connectors : "High Elevation Disconnect (Fan Speed Corrector)" "Air Flow Connector (Air Flow Switch)" "Emergency operations only (Emergency Operations Switch)"
Checkpoints Ref. No. 6 8 9 0 6 8 9 0 - - - - - - - - - Part Overheat Prevention Device (Thermal Fuse) Priority Circulator ater Return Thermistor ater Supply Thermistor Heat Exchanger Thermistor Flame Rod ater Flow Switch Fan Motor Fan Motor Igniter Primary Gas Solenoid Valve Gas Solenoid Valve - Gas Solenoid Valve - Gas Proportioning Valve Flame Rod Gas Solenoid Valve - High Limit Switch ater Flow Switch Priority Circulator Power Supply (Main Circuit oard) Power Supply (SC Circuit oard) Contact for "URNER" lamp Contact for "POER" lamp Circuit board Check points CN & Pin No. ire color CN & Pin No. CN8 CN6 CN6 CN8 CN CN CN CN0 CN0 CN0 6 CN0 CN8 CN0 CN CN CN CN9 CN89 A CN89 C 8 Air Inlet Thermistor CN6 Power Supply (Power Circuit oard) Power Supply (Power Circuit oard) Operation Panel (Remote Controller) Priority T-T Connection Priority T-T Connection CN8 L - L K - - - L - urnercase L - Electrode K - K K - K R - L R - L Y - L K - - L K - L CN8 CN6 CN6 R - R O - O - CN CN CN CN CN0 - - CN0 CN CN9 CN89 A CN89 C Normal value Ω or less AC 08 - V DC -. V DC -. V CN6 - CN6 DC -. V CN89 C C 0 khz - 00 khz DC 0.µA or less DC 8 - V DC V or less DC - V DC 0 - V 00 Hz - 00 Hz AC 90-0 V DC 80-00 V 0. - kω DC 80-00 V 0. - kω GY - L R - L CN0 CN8 DC 80-00 V 0. - kω DC 0. - V 0-90 Ω L - urnercase - 0 khz - 00 khz L - - Electrode - DC µa or more O - L CN0 DC 80-00 V 0. - kω K - CN 6 Ω or less K - K CN DC 8 - V K - AC 08 - V - CN6 DC 0. -. V K - L - L - L L - L L - L V - R - CN89 C C AC 90-0 V AC 90-0 V DC - 6 V DC - 6 V DC - 6 V DC - 6 V DC - 6 V 6 Ω or less 8 Ω or less Remarks - F 0-00 C - F 0-00 C - F 0-00 C hen igniter is sparking hen valve is open Coil resistance hen valve is open Coil resistance hen valve is open Coil resistance Coil resistance hen valve is open Coil resistance Contact resistance hen switch is OFF Note ), ) Priority No calls for heat Priority No calls for heat hen flame is detected. Contact resistance hen "POER" is ON. Contact resistance Note ) Note ) Note ) hen switch is OFF Note ) hen switch is ON Note ) Note ) Note ) ater Return / ater Supply / Heat Exchanger Thermistor Temperature Characteristics Temperature ( F) 0 68 86 0 0 8 6 Temperature ( C) 0 0 0 0 0 0 60 0 80 Resistance (kω).. 0..0.9...9. Note ) "ater flow switch ON / OFF" can be confirmed by "Maintenance Monitor". Refer to "Maintenance Monitor List". Note ) There is a possibility that "ater Flow Switch" has been ON though "PRIORITY & T-T connection" both do not call for heat (No circulation). Note ) Air Inlet Thermistor Temperature Characteristics Temperature ( F) - 0 68 86 Temperature ( C) -0-0 0 0 0 0 Resistance (kω) 06. 9.6. 0.6.6 8.0 6
Error Descriptions and How to Reset Error Code 0 Content of Error Method of detecting Error No. Diagnosis point (Trouble Point) Combustion abnormality (TU drop) (arning indication) Use for 0 years or more and combustion is abnormal. Check for abnormal combustion. Check flue for blockage or obstruction. Check the gas supply piping. Ex.) "Presence of LPG gas" "The gas was shut off with gas meter" "Is the gas supply valve open?" Check the gas supply pressure. How to Fix Problem and Reset appliance A blinking "0" indicates there has been a TU drop, but combustion will continue. Please keep the gas supply pressure within the proper pressure range. Flow chart No. Part CN & Pin No. wire color CN & Pin No. Normal value See pg. Remarks Check for igniter spark. Check for improper connection of Igniter. Check ground, paying special attention to the ground connection to the circuit board. Measurement of igniter. Check for improper connection of igniter. Replace igniter when the voltage is normal value but it does not spark. 0 Igniter CN0 K - CN AC 90-0 V hen igniter is sparking. Ignition failure (Initial flame fault detection) Flame rod does not detect flame (Flame fault detection) Detection of ignition failure. Detection of extinction of flame. Check the flame rod. Check for improper connection of Flame rod. Check ground, paying special attention to the ground connection to the circuit board. Measurement of flame rod. Check for improper connection of flame rod. Measurement of primary gas solenoid valve. Check for improper connection of primary gas solenoid valve. Flame rod Primary gas solenoid valve CN8 CN0 6 L - urnercase L - Electrode - L CN0 0 khz - 00 khz DC µa or more DC 80-00 V 0. - kω hen valve is open. Coil resistance Check the gas solenoid valve. Check the gas proportioning valve. Check the manifold gas pressure. Measurement of gas solenoid valve-. Check for improper connection of gas solenoid valve-. Measurement of gas solenoid valve-. Check for improper connection of gas solenoid valve-. Measurement of gas proportioning valve. Check for improper connection of gas proportioning valve. Gas solenoid valve- Gas solenoid valve- Gas proportioning valve CN0 CN0 CN8 8 K - L GY - L R - L CN0 CN0 CN8 DC 80-00 V 0. - kω DC 80-00 V 0. - kω DC 0. - V 0-90 Ω hen valve is open. Coil resistance hen valve is open. Coil resistance Coil resistance Check the manifold gas pressure. See pg. 6 Check flue for blockage or obstruction. Overheat prevention device (Thermal fuse) triggered Overheat prevention device (Thermal fuse) triggered. Check for melting or damage to the overheat prevention device (thermal fuse). Check for improper connection of overheat prevention device (thermal fuse). Measurement of overheat prevention device (thermal fuse). Check for improper connection of overheat prevention device (thermal fuse). If the overheat prevention device (thermal fuse) has fused, it has been exposed to temperature in excess 6 F. First fix the cause of the high temperature exposure (hole in the heat exchanger, etc) and then replace the overheat prevention device (thermal fuse). Overheat prevention device (Thermal fuse) CN8 L - L CN8 Ω or less Measurement of gas solenoid valve-. Check for improper connection of gas solenoid valve-. Gas solenoid valve- CN0 8 GY - L CN0 DC 80-00 V 0. - kω hen valve is open. Coil resistance 6 ater supply temperature does not stabilize. (Supply temperature is too low) (Heating load is too much) The supply temperature is not over F ( C) or more after one hour. It becomes an error if it repeats three times. Check the gas solenoid valve. Check the gas proportioning valve. Check the gas supply pressure. Check the manifold gas pressure. Measurement of gas solenoid valve-. Check for improper connection of gas solenoid valve-. Measurement of gas proportioning valve. Check for improper connection of gas proportioning valve. Check the gas supply pressure. 6 Gas solenoid valve- Gas proportioning valve CN0 CN8 O - L R - L CN0 CN8 DC 80-00 V 0. - kω DC 0. - V 0-90 Ω See pg. hen valve is open. Coil resistance Coil resistance Check the manifold gas pressure. See pg. 6 Check the heating load (calculate total heating load). Add a boiler if necessary. ( Total heating load is more than this boiler's maximum output) * If you can drop the heat radiation, the following methods are possible: adjust the by-pass circuit flow rate (increase) in the heating circuit and/or check the temperature setting on the operation panel. 0 High limit switch triggered High limit switch triggered. Check if high limit switch is triggered. Check for improper connection of high limit switch. The possibility of "ater flow switch ON failure" Measurement of high limit switch. Check for improper connection of high limit switch. High limit switch CN K - CN 6 Ω or less Contact resistance ater flow switch ON failure Check for blocking of the water flow switch. Check for short circuit of the water flow switch. Confirm "ater flow switch ON / OFF" by Maintenance Monitor (No.6). Measurement of water flow switch. Check for improper connection of water flow switch. Remove it if the water flow switch is blocking, 8 ater flow switch CN K - K CN DC 8 - V hen switch is OFF.
Error Code 0 6 6 6 0 60 6 Content of Error Method of detecting Error No. Diagnosis point (Trouble Point) Air inlet thermistor abnormality ater return thermistor abnormality ater supply thermistor abnormality Heat exchanger thermistor abnormality Fan motor abnormality Priority circulator abnormality Priority circulator abnormality Circuit board abnormality Gas valve drive circuit abnormality Flame rod circuit abnormality (Detection of flame when no flame is present) Circuit board setting abnormality (High elevation connector, Dip switch, etc.) Operation panel (remote controller) transmission abnormality. Detection of open/short abnormality of air inlet thermistor. Detection of open/short abnormality of water return thermistor. Detection of open/short abnormality of water supply thermistor. Detection of open/short abnormality of heat exchanger thermistor. Detection of fan speed abnormality. hen the "water flow switch" did not turn ON even if the Priority circulator was turned on. hen the "water flow switch" did not turn ON even if the Priority circulator was turned on. Detection of circuit board abnormality. Detection of circuit board abnormality. Detection of flame when no flame is present. Detection of circuit board setting abnormality. Detection of operation panel (remote controller) transmission abnormality. Circuit board SC transmission Detection of circuit board SC abnormality transmission abnormality. Measure the resistance through the air inlet thermistor. Check for improper connection of the air inlet thermistor. Measure the resistance through the water supply thermistor. Check for improper connection of the water supply thermistor. Measure the resistance through the water supply thermistor. Check for improper connection of the water supply thermistor. Measure the resistance through the heat exchanger thermistor. Check for improper connection of the heat exchanger thermistor. Check that the fan is rotating and check the pulse frequency from the fan rotational frequency sensor. Check for improper connection of the fan. Check voltage from circuit board. Check the Priority circulator is running. Check for improper connection of the circulator. Check connection from circuit board SC to Junction box. Check whether the Priority circulator fuse on the Junction ox is open. Check for improper connection of the water flow switch. Check for blocking of the water flow switch. Check the Priority circulator is running. Check for improper connection of the circulator. Check connection from circuit board SC to Junction box. Check whether the Priority circulator fuse on the Junction ox is open. Check for improper connection of the water flow switch. Check for blocking of the water flow switch. Circuit board abnormality. Gas valve drive circuit abnormality. Measure the current from the flame when there is no flame. Check for proper setting (Dip switch). Check for "Control switch connector" is disconnected or connected while the boiler has power. Check connection from operation panel (remote controller) to circuit board. Check the operation panel (remote controller) and circuit board for damage. Check connection from circuit board SC to circuit board. Check the circuit board SC and circuit board for damage. How to Fix Problem and Reset appliance Confirm the air inlet thermistor detection temperature by Maintenance Monitor (No.8). Compare to temperature characteristic list on pg.6. Check for open or short circuit or for an improper connection. Confirm the water return thermistor detection temperature by Maintenance Monitor (No.). Compare to temperature characteristic list on pg.6. Check for open or short circuit or for an improper connection. Confirm the water supply thermistor detection temperature by Maintenance Monitor (No.). Compare to temperature characteristic list on pg. 6. Check for open or short circuit or for an improper connection. Confirm the heat exchanger thermistor detection temperature by Maintenance Monitor (No.). Compare to temperature characteristic list on pg.6. Check for open or short circuit or for an improper connection. Confirm the measured fan speed by Maintenance Monitor (No.). If the fan motor does not rotate, but voltage is normal, then the fan motor should be replaced. If the voltage is abnormal, replace the circuit board. If the fan motor is rotating and if the voltage is normal, but there is a "6" error code, then the fan motor should be replaced. If the voltage is normal, but circulator is not running, replace the circulator. If the voltage is abnormal, replace the circuit board SC. If Priority circulator fuse has blown, remove the cause of excess current, and then replace the 6A fuse. Confirm "ater flow switch ON / OFF" by Maintenance Monitor (No.6). If the circulator is running, but water flow switch is OFF, check the flow rate and adjust if necessary. Remove it if the water flow switch is blocked. If the voltage is normal, but circulator is not running, replace the circulator. If the voltage is abnormal, replace the circuit board SC. If Priority circulator fuse has blown, remove the cause of excess current, and then replace the 6A fuse. Confirm "ater flow switch ON / OFF" by Maintenance Monitor (No.6). If the circulator is running, but water flow switch is OFF, check the flow rate and adjust if necessary. Remove it if the water flow switch is blocked. Disconnect the electrical power, then reconnect electrical power to the boiler to reset the system. If the circuit board abnormality is continuous, replace the circuit board. Disconnect the electrical power, then reconnect electrical power to the boiler to reset the system. If the error code "" is continuous, replace the circuit board. If the "" error code is displayed, check the signal from the flame rod (also make sure that there is not a problem with the grounding of the appliance). If the signal is normal, replace the circuit board. If it is abnormal, replace the flame rod. Check the Dip switch setting. If a setting is incorrect, correct the Dip switch setting. This error code is displayed when the "Control switch connector" is disconnected or connected while the boiler has power. Disconnect power to the boiler before making this adjustment. If there is a voltage abnormality, replace the circuit board. If a voltage is normal, replace the operation panel (remote controller). If there is a voltage abnormality, replace the circuit board. If a voltage is normal, replace the circuit board SC. Flow chart No. 0 Part CN & Pin No. CN6 ater return CN6 thermistor 8 9 9 6 Air inlet thermistor Flame rod CN CN8 CN89A CN89 wire color - ater supply thermistor CN6 - Heat exchanger thermistor Fan motor Priority circulator fuse Priority circulator fuse ater flow switch Priority circulator Priority circulator fuse ater flow switch CN6 CN CN CN89C CN89 - - R - L R - L Y - L K - Junction box K - K K - Junction box K - K L - urnercase L - urnercase L - L L - L L - L L - L CN & Pin No. CN6 CN6 CN6 CN6 CN CN CN CN89A CN89 CN89C CN89 Normal value DC 0.-. V DC -. V DC -. V DC -. V DC - V DC 0 - V 00 Hz - 00 Hz AC 08 - V Closed circuit DC 8 - V DC V or less AC 08 - V Closed circuit DC 8 - V DC V or less 0 khz - 00 khz DC 0.µA or less DC - 6 V DC - 6 V DC - 6 V DC - 6 V Remarks - F 0-00 C - F 0-00 C - F 0-00 C hen Priority calls for heat. hen switch is OFF. hen switch is ON. hen Priority calls for heat. hen switch is OFF. hen switch is ON. Control switch connectors: *High Elevation Disconnect (Fan Speed Corrector) *Air Flow Connector (Air Flow Switch) *Emergency operations only (Emergency Operations Switch) 8
Error Code 90 99 No Error Code Content of Error Method of detecting Error No. Diagnosis point (Trouble Point) Combustion abnormality Combustion abnormality (arning indication) (The appliance is stopped) Combustion abnormality (The appliance is stopped) The operation panel (remote controller) is not turned ON (No indication) though "Power button" was pushed. urner ON Indcator is lit even when the Power button is set to OFF. urner ON Indcator is lit even when the Priority or is not being used. The room does not get warm. The heating does not operate. The heating turns off by itself during heating and there is no warm air. Operation sounds are heard from the boiler even though it is not being used. The appliance does not operate even if there is a call for heat. Detection of combustion abnormality. Detection of combustion abnormality. Check for abnormal combustion. Check flue for blockage or obstruction. Check for abnormal combustion. Check flue for blockage or obstruction. The electrical power does not connect. Check the electrical power input. The electrical power is not supplied to the circuit board. Check the electrical power input. A fuse is blown. Check whether the 0A fuse on the power circuit board is open. Check connection from operation panel (remote controller) to circuit board. Check the operation panel (remote controller) and circuit board for damage. The circulator automatically operates for combustion to prevent freezing. Has Priority been running for an extensive period? Priority (Heating use) will stop even during operation when Priority (Indirekt tank use) operation starts. These noises indicate the proper operation of devices which are designed to let the appliance reignite more quickly, and ensure temperature of the boiler water is stable. The sound is from the circulator operating to prevent freezing. This appliance automatically operates the circulator for several seconds when the appliance has not been used for approximately days to prevent the circulator from malfunctioning due to build-up of deposits. Check for improper connection of Priority T-T connection ("From circuit board SC to terminal C" or "From terminal C to Aquastat"). Check for improper connection of Priority T-T connection ("From circuit board SC to terminal C" or "From terminal C to Room thermostat"). How to Fix Problem and Reset appliance If abnormal combustion is detected, the error code will flash and combustion stops. This error code can be reset by turning the boiler OFF on the operation panel. Remove the cause of the abnormal combustion. Check maintenance monitor No.66. If the fan has increased its speed by 08-09 %, the error code will flash but combustion continues. If the fan has increased its speed by 0 %, the error code will flash and combustion stops. If this error code is displayed and the boiler has been in use for 0 years, the boiler has reached the end of its life cycle and should be replaced. Check for improper connection of "Junction ox" or "Transformer". Remove the cause of excess current, and then replace the 0A fuse. If there is a voltage abnormality, replace the circuit board. If a voltage is normal, replace the operation panel (remote controller). It is not abnormal. In this case, the set temperature of the aquastat controlling the indirect tank may be higher than the set temperature of this appliance. Change to a correct temperature setting. Refer to "User's information manual" P.. It is not abnormal. It is not abnormal. It is not abnormal. It is not abnormal. If there is a voltage abnormality, replace the circuit board SC. If a voltage is normal, replace the Aquastat. If there is a voltage abnormality, replace the circuit board SC. If a voltage is normal, replace the Room thermostat. Flow chart No. Part Priority T-T connection Priority T-T connection CN & Pin No. A CN 9 CN89A CN89 C C wire color K - L - L - L L - L V - CN & Pin No. A CN 9 CN89A CN89 C R - C Normal value AC 08 - V AC 90-0 V Closed circuit DC - 6 V DC - 6 V DC - 6 V DC - 6 V Remarks Priority does not call for heat Priority does not call for heat 9
Operation panel (Remote controller) Priority indicator (orange) urner ON indicator (red) Priority indicator (green) Temperature adjustment buttons Power indicator (green) Power button Display User setting button Priority button Priority button Displaying Maintenance Monitors on the Operation Panel (Remote Controller) < Display Procedure >. Press and hold both the up [ ] and down [ ] Temperature adjustment buttons simultaneously for more than seconds. This can be done regardless of whether the power has been turned on or the boiler is operating. Note ) Please turn on the "Power button" once after connecting the electrical power. Note ) Maintenance monitors cannot be displayed while in "Manual circulator operation mode". < Indications >. The maintenance monitor data No. will appear on the display for seconds, and then the data will appear.. In order to switch to other maintenance monitor data, press either the up [ ] or down [ ] button once. The data No. will then reappear, then different data No. can be selected using the up [ ] or down [ ] buttons. hen the maintenance monitor data No. is changed, the data No. will be displayed for seconds, after which the data will appear.. ith the operation panel (remote controller) in maintenance monitor mode, "Supply temperature" cannot be adjusted. < Returning to Normal mode >. For releasing the indication, press and hold both the up [ ] and down [ ] Temperature adjustment buttons simultaneously for more than seconds, or leave it alone for more than 0 minutes. < Clearing Error Codes from Memory > hen the Power button is OFF, press and hold the down [ ] button for more than seconds. hen a "beep" sound is heard, the error codes have been cleared. 0
Data No. Maintenance Monitor List 0 0 06 08 09 8 6 6 66 6 8 88 89 9 9 9 9 9 96 9 98 Item Total Plug-in Time Total Combustion Time Total Combustion Time Number of Ignition Times Number of Ignition Times Fan Rotational Frequency Calculated Fan Speed ater Return Thermistor Detection Temperature ater Supply Thermistor Detection Temperature Heat Exchanger Thermistor Detection Temperature Air Inlet Thermistor Detection Temperature Fan Motor Current Value ater Flow Switch Initial Fan Speed Correction Final Fan Speed Correction Circuit oard ID: Product Circuit oard ID: Product Circuit oard ID: Version Error Code History Error Code History Error Code History Error Code History Error Code History Error Code History 6 Error Code History Error Code History 8 Data (Display Reading x Multiplier) Multiplier X 00 X 0 X 0000 X 00 X 00000 X 0 X 0 X X 0. X X 0. X X 0. X X X 0 [x:xx] X X [:xy] [:xy] [:xy] Unit hour hour hour time time rpm rpm F C F C C F C ma Minimum Value for Indicatiuon 00 hours 0 hours Disp. Range [000] - [999] 0000 hours Disp. Range [000] - [06] 00 times Disp. Range [000] - [999] 00000 times Disp. Range [000] - [06] rpm rpm F 0. C F 0. C F F % % Most Recent Error Code Next Most Recent Error Code Next Most Recent Error Code Next Most Recent Error Code Next Most Recent Error Code Next Most Recent Error Code Next Most Recent Error Code Next Most Recent Error Code 0. C F C 0 ma % % [00] - [0] [00] - [0] Remarks Disp. Range [000] - [0] Disp. Range [0] - [00] Disp. Range [-0] - [00] OFF : [000], ON : [] A=0,=0,C=0... Z=6 A=0,=0,C=0... Z=6 A=0,=0,C=0... Z=6 * * * * * * * * * If the same error code is repeated, it will appear in the history list twice. If it is repeated more than twice, it will only appear twice. * A difference in the calculated (#) and the measured (#) fan speeds of 00 or less is normal. * hen Fahrenheit is selected. * hen Centigrade is selected.