ECR International 95M-200 User manual

Control manual and troubleshooting guide
95M-200
GAS-FIRED DIRECT VENT
MODULATING HOT WATER BOILER
P/N 240006104, Rev. B [06/08]
DO NOT DESTROY THESE INSTRUCTIONS!!
Please read carefully and keep in a safe place
for future reference.
IMPORTANT: Installation must comply
with local requirements and with the Na-
tional Fuel Gas Code, ANSI Z223.1 for U.S.
installations or CSA B149.1 or B149.2 for
Canadian installations.
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 Oper-
ating Instructions before attempting to program
the control, and be sure to perform all steps in
the order specied. Failure to comply could re-
sult in severe personal injury, death, or substan-
tial property damage.
Revise boiler control parameters only if you fully un-
derstand the purpose and result of the changes. Tam-
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
!
WARNING
!

2

3
CONTROL MANUALAND OPERATING INSTRUCTIONS
Printed in USA • Made In USA
95-200M GAS FIRED DIRECT VENT MODULATING HOT WATER BOILER
Keep this manual near boiler
and retain for future reference.
TABLE OF CONTENTS
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.
Indicates an imminently hazardous situation
which, if not avoided, will result in death, seri-
ous injury or substantial property damage.
DANGER
!
Indicatesapotentiallyhazardoussituationwhich,
if not avoided, could result in death, serious in-
jury or substantial property damage.
WARNING
!
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.
CAUTION
!
IMPORTANT: Read the following instructions
completely before installing!!
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

4
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 tar-
get 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 1.
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
2.
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.
This boiler is controlled by a microprocessor electronic con-
trol 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 po-
larity 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 han-
dling 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 cal-
culated as described under “Outdoor Reset Operation”
when outdoor sensor is connected.
EXCEPTION:• See explanation of “Supply Temperature
Boost.”
II - OPERATING INFORMATION

5
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.
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.
CAUTION
!
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.
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: All boilers are
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.
Target Outlet Temperature, °F
Outside Temperature, °F
Outdoor Reset Target Temperature
210
50
70 60 50 40 30 20 10 0 -10 -20
70
90
110
130
150
170
160
190
120
Parameter 4 = 190°F
Parameter 4 = 150°F
Parameter 4 = 170°F
Reset Curve Calculations
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.
Target Outlet Temperature, °F
Outside Temperature, °F
Default Reset Curve
Outdoor Reset Target Temperature
210
50
70 60 50 40 30 20 10 0 -10 -20
70
90
110
130
150
170
160
190
180
120
Parameter 7 = 60°F
Parameter 4 = 180°F
Parameter 6 = 0°F
II - OPERATING INFORMATION

6
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): The control uses sensors on the supply
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
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
overshoots and less short cycling than a conventional on/off
boiler.
Domestic Hot Water (DHW): When used in conjunction
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: This control has the ability to sense outside
air temperature using a factory supplied, eld installed sen-
sor. The controller detects the presence of the sensor and
acts according to the parameters programmed into the con-
troller.
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.
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.
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. “OperatingInstructions”
in this manual.
Once the boiler has started and is operating,
3. 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 1.
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-
B.
play shows “3.”
The last digit must show a “1.” If any other number
C.
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 2.
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
B.
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.

7
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.
C. 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 1. [PARA]
(parameter mode).
Press the “Step” button until the rst digit of the display
2.
shows a “2.”
The last digit must show a “1.” If any other number dis-
3.
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
4.
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
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 1.
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.
2.
Wait a few seconds, then turn on power to boiler. 3.
[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.
[1180]
• Prepurge. Blower speed will increase to igni-
tion speed. The blower will run in prepurge for 10 sec-
onds.
[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.
[3180]
• Burner on, space heating. Once ame is prov-
en and stable, the burner turns down to low re for
approximately 2 minutes.
After this low re period, the burner is allowed to mod-
•
ulate. Firing rate depends on actual outlet water tem-
perature versus target temperature.
Allow boiler to bring water temperature to target tem-
5.
perature.
[6180]
• Target temperature reached. The burner will
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.
Lower room thermostat to stop call for heat.
6.
[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.
7.
Return the room thermostat to normal setting. 8.
VERIFY OPERATION – DHW
If necessary, reconnect DHW aquastat wiring to boiler. 1.
Turn off power to boiler at service switch. 2.
Wait a few seconds, then turn on power to boiler. 3.
[A150] Self-check on power-up for a few
seconds.
[0150] No call for heat.
IV - BOILER STARTUP

8
IV - BOILER STARTUP
Raise DHW aquastat above tank temperature to call for heat. 4.
[5150]• Blower/DHW circulator on. Blower and DHW cir-
culator energize and control checks for air ow.
[1150]
• Prepurge. Blower speed will increase to ignition
speed. The blower will run in prepurge for 10 seconds.
[2150]
• 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 5 attempts or control will lockout (dis-
play will show [E 02]).
Verify ame failure operation by closing boiler manual
•
gas valve to prevent gas ow. Open gas valve after
testing.
[4150]
• Burner on, DHW. Once ame is proven and
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 tem-
5.
perature.
[6150]
• Target temperature reached. The burner will
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. 6.
[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.
[8150]
• DHW circulator run-on. The DHW circulator
continues to run for 30 seconds.
[0150]
• No call for heat. Boiler is now in standby mode
(waiting for heat call).
Repeat steps 1-6 several times to verify operation.
7.
Return the DHW aquastat to normal setting. 8.
OPERATING INFORMATION
To check operating conditions (Ex.- actual or target tem- 1.
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
2.
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.
Replace boiler front jacket panel after
performing any service to the boiler.
WARNING
!

9
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 connec-
tions 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. 1.
Turn off manual gas ball valve. 2.
Set thermostat for a call for heat. 3.
Boiler begins normal sequence of operation. 4.
After approximately 30 seconds of pre-purge the appli- 5.
ance will attempt to light.
After 4 seconds the gas valve closes and the control 6.
retries 5 time, before entering lockout mode.
To reset the control, follow the instructions in Section IV 7.
of this manual, “Putting The Boiler In Operation.”
Return thermostat to previous setting.
8.
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. 1.
Set thermostat for call for heat. 2.
Boiler should not begin normal sequence of operation. 3.
Attach wire to the sensor probe. 4.
Return thermostat to previous setting. 5.
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.
Check incoming gas pressure to the appliance using a pressure 1.
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
sideof 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.
Gas Valve
Figure #1

10
V - CHECKOUT PROCEDURES AND ADJUSTMENTS
Drill a ½” hole in the plastic CPVC vent pipe or exhaust 2.
tee, just large enough to allow access for the sample
probe of your combustion analyzer.
Turn the thermostat to the closed position so the appli-
3.
ance is activated.
Set appliance to high re mode as described in the
4.
“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
5.
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 6.
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, dis-
7.
connect 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.
8.
Installers: Complete and sign the “Installa-
tion and Checkout Certicate” on the last page
of this manual.
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. 1.
See Table 2 in Section IV of the separate “Installation 2.
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
3.
utility. At sea level elevation, it should be approximately
1000 BTU per standard cubic foot.
Operate boiler for 5 minutes. 4.
Turn off all other gas appliances, extinguishing standing 5.
pilots where applicable.
At the gas meter, measure the time in seconds required
6.
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: 7.
Btuh input rate = 3600 x heating value from Step 3
16 +/- 2 seconds
The measured input rate will vary with vent length, gas 8.
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 C02
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 in-
take venting, exhaust venting, burner and ignitor con-
dition 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

11
V - CHECKOUT PROCEDURES AND ADJUSTMENTS
Pressure Guidelines
Fan Speed Minimum RPM Maximum RPM
Fuel Natural Gas LP Natural Gas LP
Gas Line Inlet
Pressure N/A N/A At least 4” WC At least 10” WC
Differential Pres-
sure 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 %CO2%O2CO %CO2 %O2CO
70°F and up 9.6% to
10%
3.9% to
3.2%
Less than
80 PPM 11.1% to 11.5%
4.1% to
3.4%
Less than
80 PPM
21°C and up
30°F to 70°F 9.3% to
9.6%
4.4% to
3.9%
Less than
80 PPM 10.8% to 11.1%
4.5% to
4.1%
Less than
80 PPM
-1°C to 21°C
30°F and below 9.0% to
9.3%
5.0% to
4.4%
Less than
80 PPM 10.5% to 10.8%
4.9% to
4.5%
Less than
80 PPM
-1°C and below
Flame Signal Guidelines
Fan Speed Minimum RPM Maximum RPM
Flame Signal Greater than 3.0 VDC
N/A

12
VI - DETAILED SEQUENCE OF OPERATION

13
IMPORTANT
If any component does not function properly,
1. make sure it is correctly installed and wired be-
fore replacing it.
Static electricity discharge can damage the
2. 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
4. 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-
5.
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 hap-
pening, 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).
VII- SERVICE HINTS
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
1.
electrical panel.
Make sure that service switch is on. 2.
Check for 120 VAC (minimum 102 VAC to maximum 132 3.
VAC) to boiler.
Make sure thermostat is calling for heat and contacts (in-
4.
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
5.
(and closed) or temporarily jumpered for testing.
Make sure that gas is on at the gas meter, at all appropri-
6.
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
7.
the originating control are securely plugged in or con-
nected.
Check that all hoses are securely connected and are not
8.
plugged in or damaged.
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.
WARNING
!

14
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.
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.
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.
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, experi-
enced service technician.
VIII - TROUBLESHOOTING
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. 1.
Remove vinyl caps from tee. 2.
Install testing lines as shown to inclined manometer or 3.
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
4.
heat.
Boiler Status Diff. Pressure Switch Contacts
Not Running 0” 3.5” Closed
0.14” Open
Running with
Blockage Greater Than or Equal To Setpoints 3.5” Open
0.14” Closed
Running w/out
Blockage (approx.)
Min. Fire: 0.3” 3.5” Closed
Max. Fire: 2” 0.14” Closed
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.
1500010 - SW PRESS NORM
OPEN SET PT .04”/0.14”
YELLOW LABEL
1552004 - TUBE, ORANGE,
3/16” X 5/16” OD SILICONE
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
!
WARNING
!
CAUTION
!

15
VIII - TROUBLESHOOTING
Label all wires prior to disconnection when ser-
vicing controls. Wiring errors can cause improp-
er and dangerous operation. Always disconnect
power to boiler before servicing. Failure to com-
ply could result in severe personal injury, death
or substantial property damage. Never jumper
(bypass) any device except for momentary test-
ing as outlined on the following pages of this
manual. Severe personal injury, death or sub-
stantial 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. 1.
Remove jacket front panel. 2.
Remove control module cover. 3.
Inspect fuses F1 and F3 (shown below). 4.
The boiler is shipped with four spare fuses attached to 5.
the control module cover.
If necessary, replace open fuse (F1 is 115V, 5-amp fast-
6.
blow; F3 is 24V, 4-amp slow-blow).
F1 and F3 Fuses
WARNING
!
Install control module cover and jacket top front cover 7.
after fuse inspection.
Restore power to boiler at external line switch and verify
8.
boiler operation after completing boiler service.
CHECKING TEMPERATURE SENSORS
The boiler temperature sensors (outdoor, return water, and 1.
supply water) are all resistance-type devices.
The table below shows the correct resistance value for
2.
the sensor at various temperatures.
Temp
°F Sensor Ohms Temp °F Sensor Ohms
Min Max Min Max
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
Use the resistance values at 32°F, 60°F, 70°F and 212°F 3.
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-
4.
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.
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.
WARNING
!

16
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? 1NO - Check external line switch and fuse or breaker.
120 vac on both sides of fuse F1?
(Turn OFF external power to boiler
before removing cover.
1NO - Turn off power to boiler and replace fuse if necessary.
Inspect boiler interior wiring to determine cause of fuse
opening.
Wiring correct, in good condition,
and securely attached? 1Correct if needed. Replace any damaged wiring or components. Replace control module if problem persists.
Display rst digit shows 0; last
digits show 2 or 3-digit number
(boiler outlet water temp.)
Room thermostat and DHW
aquastat satised?
1YES - Boiler off, no call for heat. Turn up thermostat or
aquastat. Boiler should start.
Thermostat or aquastat calling for
heat but boiler not ring.
1Check 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.
2Check/set boiler parameters 2 and 3. Make sure space
heat or DHW is turned on. Turn on if necessary.
3Turn 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).
4Turn off power to boiler. Check wiring against wiring
diagram; verify all wiring in good condition and secure.
5Replace wire harnesses and retry.
6Replace control module.
Display rst digit shows a number from 1 to 8; last digits show 2 or
3-digit number (boiler outlet water temp.)
1Boiler in normal operating mode.
Display ashes “9,” then “b.” Last two digits show code number. 1See 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 1Check 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
1This 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.•
2Use 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.
19 High Limit Operation: Burner off
until return water temp. drops below
190 °F
1Check 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.•
2Use 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.

17
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 HighLimit Operation: Return temp.
is higher than supply temp.
1Verify 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.•
2Use 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.
25 High limit operation: Outlet water
temp. increased too quickly.
Non-adjustable default setting
9.8°F/sec
1This 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.•
2Verify 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.
26 Aquastat contacts open
or
LWCO contacts open
or
3.5” Switch open
1 Verify proper setting of control.•
Water temp too high, wait for temperature to drop below 180 degrees.•
2Check water level in boiler, ll if low.•
Press LWCO reset switch on display panel•
If problem still exists, check LWCO probe and board according to manufacturer’s • instructions. Replace if necessary.
3Check 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. 1Check boiler wiring against wiring diagram. Replace line voltage and low voltage
wiring harnesses if necessary. Replace control module if wire replacement doesn’t
resolve.
30 High limit operation: Temp. rise
across boiler too high.
1This 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.•
2Verify 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.
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.
61 Pressure switch contacts closed. 1 Check pressure switches for proper operation. Replace pressure switch if moisture
has entered switch.
65 Blower not operating when turned
on. 1Turn 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.
2If 120 vac is present on blower wire harness, replace harness and retry. If problem
persists, replace blower motor.

18
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. 1Burner 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.
2Look 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.
02 Ignition failed through 5 attempts. 1If 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.•
2If 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.
3Flame 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.•
03 Gas Valve Disconnected. 1 Verify gas valve connection.
04 Voltage lost after lockout occurred. 1 Control module will only restart with manual reset, even after power loss (but the
error code information is lost).
05 Internal control failure. 1 Reset control and retry. If problem persists, replace control module.
06
07
08

19
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.
09 Internal control failure. 1 Reset control and retry. If problem persists, replace control module.
11
12 Casting temperature switch opened. 1
Determine reason for limit action and correct. Check for air trapped at top of casting.
2If 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.
13
thru
17
Internal control failure. 1 Reset control and retry. If problem persists, replace control module.
18 ThermalOverrunCondition:Outlet
water temp. above 200 °F
1Check 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.•
2Use 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.
19 Thermal Overrun Condition:
Return water temp. above 190 °F
1See Code 18, Corrective Action#1 (above).
2Use 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.
28 Blower not running. 1 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.
2If 120 vac is present on blower wire harness, replace harness and retry. If problem
persists, replace blower motor.
29 Blower signal not 0 when it should
be.
1Inspect wiring and connections. If wiring is correct, replace blower assembly. If
blower assembly replacement is unsuccessful, replace control module.
30
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
1Inspect supply & return water sensors for proper resistance.
2Inspect piping for proper conguration. For example, when used in a radiant
heating application.
31 Outlet water temp. short circuit. 1Inspect outlet water temp. sensor and wiring. Replace sensor if wiring correct and
in good condition. Replace low voltage wiring harness if problem persists. Replace
control module if harness replacement doesn’t resolve.
32 Return water temp. short circuit. 1Inspect return water temp. sensor and wiring. Replace sensor if wiring correct and
in good condition. Replace low voltage wiring harness if problem persists. Replace
control module if harness replacement doesn’t resolve.
36 Supply water temp. sensor open
circuit. 1See Corrective Action# 1 under Code 31 (above)
37 Return water temp. sensor open
circuit. 1See Corrective Action# 1 under Code 32 (above)
44 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).
1Inspect wiring and connections. If wiring is correct, replace blower assembly. If
blower assembly replacement is unsuccessful, replace control module.

20
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 Stby then displays Sequence and Measured or Target Outlet Temperature.0 180
Press and Hold Key(s) in BLACK(1) Duration Result Display
[MODE] [STEP] [STORE] [+] [-]
Tap Outlet water target temperature. (Display shows “c” and outlet water
target temp.) (2) c 190
Hold Turn space heating OFF/ON. (Display shows “c” and outlet water temp.
or OFF.)
[MODE] [STEP] [STORE] [+] [-] Tap Show factory setting for DHW. (Make sure to adjust desired water
temperature for DHW on the DHW tank aquastat.) d 140
Hold Turn DHW OFF/ON. (Display shows “d” and DHW factory setting or OFF.)
[MODE] [STEP] [STORE] [+] [-] Hold Set burner to high re. (Display shows “H” and measured outlet water
temp.) H 180
[MODE] [STEP] [STORE] [+] [-] Hold Set burner to low re. (Display shows “L” and measured outlet water
temp.) L 180
[MODE] [STEP] [STORE] [+] [-] Hold Deactivate forced high/low ring. (Display shows sequence and
measured outlet water temp.) 0 180
[MODE] [STEP] [STORE] [+] [-] Tap Change to next mode. (Para) Para
(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.
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
Digit Other Digits Boiler Status
0
Actual (measured) outlet water temperature
Standby - no call for heat
1Pre-purge (10 seconds) or Post-purge (15
seconds)
2 Ignition
3 Burner on for CH heating
4Burner on for DHW heating
5 Checking airow before prepurge
6Burner off because temperature setting
has been reached
7Pump on after CH heating cycle for run-on
of 10 seconds
8Pump on after DHW heating cycle for run-
on of 30 seconds
HBurner on, running in high re mode
(manually set for test)
LBurner on, running in low re mode
(manually set for test)
First
Digit Code #Boiler is in soft lockout when “9” or “b” shown. Reason for boiler soft lockout is:
“9” alternating with “b”
_18 Outlet temp. too high (over 203°F). Burner off until outlet
water temp. drops 9°F below target temp.
_19 Return temp. too high (over 203°F). Burner off until both
outlet and return water temp. drops 9°F below target temp.
_24 Return temp. higher than supply temp. Burner off waiting for
correction.
_25 Outlet water temp. rose too quickly. Burner off 10 min. (burner
recycles, increasing wait 1 min. each attempt to max. 15 min.)
_26
External limit open, LWCO tripped or 3.5” press switch open on limit
wired in soft lockout (auto reset) circuit. Burner off for 2½ minutes.
_29 Blower signal not 0 when it should be. Burner off until signal
condition terminates.
_30 Temp. rise across boiler more than 100°F. Burner off for 2½ 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.