HTP EFTC-140F User manual

Service Manual
EFTC-140F Hot Water Combination Boiler
Advanced Heating
& Hot Water Systems
120 Braley Road, East Freetown, MA 02717 •1-800-323-9651 •www.htproducts.com
LP-528 REV. 8.01.14

EFTC-140F Hot water combination boiler
Service Manual
EFTC-140F
(Hot Water Combination Boiler)
•NaturalGas(NG)– Factory Default
•LiquidPropaneGas(LP)–Field-Convertible
(Refertothegasconversionmanual.)
Model
WARNING
–Donotstoreorusegasolineorother󰘱ammablevaporsandliquidsinthevicinityofthisoranyotherappliance.
–WHATTODOIFYOUSMELLGAS
 ·Donottrytolightanyappliance.
 ·Donottouchanyelectricalswitch;donotuseanyphoneinyourbuilding.
 ·Immediatelycallyourgassupplierfromaneighbor’sphone.Followthegassupplier’sinstructions.
 ·Ifyoucannotreachyourgassupplier,callthe󰘰redepartment.
–Installationandservicemustbeperformedbyaquali󰘰edinstaller,serviceagencyorthegassupplier.
Iftheinformationintheseinstructionsisnotfollowedexactly,a󰘰reorexplosionmayresult,
causingpropertydamage,personalinjury,ordeath.
Heat Exchanger bears the ASME “H” Stamp
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Chapter1ProductCharacteristics Speci󰘰cations 6
Dimensions 7
ComponentsDescription 8
Flow chart 9
Time chart 10
Operation󰘱owchart 11
Wiringdiagram 13
Connector function 15
Chapter2Componentsdescription MainControlBoard 17
Temperaturesensors 18
Burner Overheat Switch 19
Waterleveldetectionsensor 20
Detectionsensor 21
Jumpedwireconnection 22
AirPressureswitch 23
CondensateBlockageAPS 24
Flowsensor 25
Ignitiontransformer 26
FlameDetectionSensor 27
Gasvalve 28
BLDCFan 29
Burnerassembly 30
FireTubeHeatexchanger 31
Condensatetrap 32
InternalDHWstoragetank 33
InternalCH/DHWcirculationpumps 34
DHWMixingValve 35
Chapter3Howtousecontrolpanel Functionexplanation 36
Contolpanel 37
LCDSpeci󰘰cation 38
ControlPanelMode 38
DHWTemperatureControl 41
DHWTemperatureControl 41
CHSupplywatertemperaturecontrol 42
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Outdoortemperaturedisplay 42
Water󰘱owrate(GPMorLPM) 43
CHReturnwatertemperature 43
FanSpeed(RPM) 44
ProgramLockmode 44
CHSupplywatertemperature 45
DHWOutletWaterTemperature 45
ExhaustGasTemperature 46
Internalstoragetankwatertemperature 46
Overheattemperaturesensor 47
Viewsupplypowertime 47
ViewBurnerOperatingTime(Unit:1hr) 48
ViewBurnerOperatingTime(X1000hr) 48
ViewIgnitioncycles(X10times) 49
ViewIgnitioncycles(X10,000times) 49
PumpConditionDisplay 50
FaultCodeHistory 51
ClearErrorCodeHistory 51
SystemReset 52
ChangeDHWFlowRateMeasurementUnit 52
InternalStoragetankPreheatingMode 53
Changemaximumoutdoortemperature 53
Changeminimumoutdoortemperature 54
Fan,MaxRPMAdjustment 54
Fan,MinRPMAdjustment 55
ResetBurnerOperatingTime 55
DeleteIgnitingCycles 56
BoostFunction 56
CH anti-cycling time 57
BurnerONtemperature 57
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Warmweathershutdown 58
MaximumCHsupplytemperature 58
MinimumCHsupplytemperature 59
MaximumDHWSetTemperature 59
CHCapacity 60
DHWHeatingCapacity 60
InternalCHprimarypumppostruntime 61
InternalCHpumpoverruntimer(ON) 61
InternalCHpumpoverruntimer(OFF) 62
InternalDHWStorageTankSetPoint 62
InternalDHWStorageTankDi󰘯erential 63
DelayTime(fromDHWtoCHMode) 63
InternalCHPumpPostPurgeTimer 64
InternalCH&DHWPumpsTestMode 64
Chapter4Troubleshooting Flame Detection 65
GasDetection 66
APS/BurnerOverheatSwitch 66
StorageDHW/ExhaustOverheat 67
Errorcode 68
ErrorCode10 71
ErrorCode11 72
ErrorCode16 73
ErrorCode20 74
ErrorCode28 75
ErrorCode29 76
ErrorCode30 77
ErrorCode32 78
ErrorCode33 79
ErrorCode35 80
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ErrorCode36 81
ErrorCode37 82
ErrorCode38 83
ErrorCode40 84
ErrorCode41 85
ErrorCode42 86
ErrorCode43 87
ErrorCode61 88
ErrorCode66 89
ErrorCode68 90
ErrorCode72 91
ErrorCode76 92
ErrorCode80 93
ErrorCode81 94
ErrorCode85 96
ErrorCode94 96
Chapter5 Replacementinstructions BlowAssembly 97
GasValve 98
FlowSensor 99
ElectronicMixingValve 99
APS(AirPressureSwitch) 100
InterPrimaryCHCirculationPump 100
InternalDHWStorageTank 101
FlameDetectionSensor 101
Main Controller 102
IgnitionTransformer 103
Chapter6 Componentsdiagram RepairPartsDiagram 104
Memo 108
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ModelName EFTC-140F
GasInputRate MAX 140,000Btu/h
MIN 28,000Btu/h
AFUE 93.2%
HotWaterCapacity
35°FRise 7.1Gal
45°FRise 5.5Gal
77°FRise 3.2Gal
Installation Indoor/Floorstandtype
FlueSystem SealedCombustionDirectVent
VentRun 2″(50ft),3″(100ft)Schedule40PVC,CPVC,PP,SS
Ori󰘰ceSize NG(Ori󰘰ce/Needle) 0.232″(5.9mm)
LP(Ori󰘰ce/Needle) 0.185″(4.7mm)
GasSupplyPressure NG 3.5″WCto14″WC
LP 3.5″WCto14″WC
ManifoldPressure LowFire 2″/3"VENT NG:-0.0039″WC/-0.002″WC
High Fire 2"/3″VENT NG:-0.374″WC/-0.216″WC
PowerSupply
MainSupply 120V60Hz/6A
Maximum
PowerConsumption 160W
IgnitionSystem DirectElectronicIgnition/AutomaticFlameSensing
BurnerSystem SingleOri󰘰cePremixedFuelModulationMetalFiberInfrared
GasValveSystem Air ratio valve
Minimum Flow Rate 0.5GPM
InternalPipeMaterial Copper
Dimensions W15.7″-H53.0″–D26.8″
ShippingWeight 250lbs.
InternalStorageTankWaterCapacity 11Gallon
BoilerHeatExchangerCapacity 4Gallons
TotalWaterCapacity 15Gallons
MainController/ControlPanel GTX-920C/P-920C_CB-HTP
CHPressure Min15~Max30PSI
DHWPressure Max150PSI
ConnectionSizes
DHWInlet/
Hot Water Outlet 3/4″NPT
CHSupply/Return 1″NPT
GasInlet 1/2″NPT(1/2x3/4BellCouplingProvidedtoUpsizeGasLine)
Materials
Cabinet ColdRolledCarbonSteel
HeatExchanger PrimaryHeatExchanger:StainlessSteel
SubHeatExchanger:StainlessSteel
SafetyDevices
FlameRod,OverheatCutO󰘯Device,GasValveOperationDetector,
ExhaustTemperatureHighLimitSensor,WaterTemperatureHighLimit
Sensor
Chapter1ProductCharacteristics
■Speci󰘰cation
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Description Diameter
AGasConnectionAdapter 1/2″NPT(1/2x3/4BellCouplingProvidedtoUpsizeGasLine)
B‘CHsupply’Adapter 1″
C‘CHreturn’Adapter 1″
D‘DHWoutlet’Adapter 3/4″
E‘DHWinlet’Adapter 3/4″
FCondensateAdapter 1/2″
G DrainAdapter 1/2″
H ExhaustVentConnection 3″
I IntakePipeConnection 3″
■Dimensions
Chapter1ProductCharacteristics
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NO NameofComponent
1 ExhaustOutletCollar
2 MainPCBBracket
3 BLDCFAN
4 AutomaticAirVent
5 FlameDetectionSensor
6 MainPCB
7 ExhaustGasPipe
8 Manual Switch
9 PowerPort
10 CHCirculationPump
11 AirPressureSensor
12 Tilt Switch
13 SubHeatExchangerAssembly
14 InternalCirculationPump
15 WaterDischargePipe&Connector
16 CondensateOutletConnector
17 CondensateCollector
18 DHWInletConnector
NO NameofComponent
19 WaterMixingvalve
20 WaterFillValve
21 DHW Outlet Connector
22 CH Return Connector
23 CHSupplyConnector
24 MainHeatingExchangerAssembly
25 Con󰘰rmationWindowFlame
26 GasInletConnector
27 IgnitionTrans
28 Igniter
29 GasValve
30 AirPressureSensor
31 AirIntakePipe
32 AirIntakeCollar
■ComponentsDescription
K1-14CCB K1-19CCB
Chapter1ProductCharacteristics
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[ Domestic Hot Water Mode ]
[ Space Heating Mode ]
■Flowchart
Chapter1ProductCharacteristics
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FAN
FAN
FAN
3s1.5s3s
120s(1st:60s+2nd60s)
3s1.5s3s 1.0s10s1.0s3s
■Ifnormalignition
■If󰘱ameextinguishes
■Ifabnormalignition(Alarmafterthe10trial)
IGNITION
IGNITION
IGNITION
GASVALVE
GASVALVE
GASVALVE
FLAMEDETECTION
FLAMEDETECTION
FLAMEDETECTION
Chapter1ProductCharacteristics
■Timechart
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■Operation󰘱owchart
Chapter1ProductCharacteristics
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■Operation󰘱owchart
Chapter1ProductCharacteristics
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■WiringDiagram
Chapter1ProductCharacteristics
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■WiringDiagram
Chapter1ProductCharacteristics
Mixing Valve
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Connector
Descriptions HT
SELV
no.oflocationand
type Pinnr. BoardSilk
CN9
65001WS-12
1 - GROUND -
2 L PowerSupplyLine HT(120VAC)
3CP1 Pump1:DHWPump HT(120V~)
4IT Ignitor HT(120V~)
5L(HT) Pump2:CentralHeatingPump HT(120V~)
6GV GasValve HT(120V~)
7- - -
8N PowerSupplyNeutral HT(120V~)
9-12 ACPowerCOMLine HT(120V~)
CN1
SMW250-05
1
RS-485
RS485+ SELV(5VDC)
2RS485 - SELV(5VDC)
3GND -
4RS485+ SELV(5VDC)
5 RS485 - SELV(5VDC)
CN4
LWD1140-06
1
FAN
Unuse -
2 GND SELV(26VDC)
3VDD SELV(14VDC)
4Fanpower(startcoil) SELV(26VDC)
5Fanpower(endcoil) SELV(26VDC)
6Fanspeedfeedbacksignal SELV(14VDC)
CN8
SMW250-04
1
MCUISP
GND SELV(5VDC)
2 ISP/Resetport SELV(5VDC)
3ISPTOOL0Dataport SELV(5VDC)
4VCC SELV(5VDC)
CN11
LWD1140-16
1HWL Unuse SELV(12V~)
8
2LWL LowWaterLevelLeakageSensor SELV(12V~)
10
3HD CentralHeatingDemand SELV(5V)
11
4TH ConnecttotheDisplay
Control(Thermostat) SELV(14V)
12
5APS AirPressureSwitch SELV(14V)
13
6-NotUsed -
14
7BL BurnerLimit SELV(14V)
15
8HL CondensateBlock SELV(14V)
16
■Connectorfunction
Chapter1ProductCharacteristics
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Connector
Description HT
SELV
no.oflocationand
type
Pin
nr.
Board
Silk
CN7
LWD1140-14
1F.S FlameDetectSensor SELV(5VDC)
8
2OP.S Operationwatertemperaturesensor SELV(5VDC)
9
3DH.S DHWtemperaturesensor SELV(5VDC)
10
4I.S Returenwatertemperaturesensor SELV(5VDC)
11
5BG.S Exhausttemperaturesensor SELV(5VDC)
12
6ST.S Storagewatertemperaturesensor SELV(5VDC)
13
7SP.S CHOverheattemperaturesensor SELV(5VDC)
14
CN14
SMW250-09
1
IWM
GND SELV(14VDC)
2 IWMSteppermotorposition SELV(14VDC)
3VDD SELV(14VDC)
4IWMSteppermotorcoilXphase SELV(14VDC)
5IWMSteppermotorcoilYphase SELV(14VDC)
6VDD SELV(14VDC)
7IWMSteppermotorcoil/Xphase SELV(14VDC)
8IWMpowerIWMSteppermotorcoil/Yphase SELV(14VDC)
9NotUsed -
CN3
SMW250-06
1
WPS
NotUsed SELV(5VDC)
2 NotUsed SELV(5VDC)
3NotUsed SELV(5VDC)
4
FLUX1
VCC SELV(5VDC)
5WaterFlowSensor SELV(5VDC)
6GND SELV(5VDC)
CN5
SMW250-10
1RPM FANRPMCheck SELV(5VDC)
2 GND SELV(5VDC)
■Connectorfunction
Chapter1ProductCharacteristics
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Description/Part# MainControlBoard/7855P-008 CheckPoint N/A
Function Thispartcontrolsallcomponentscontainedinthecombinationboiler.
Failure Event Abnormalmaincontrolleroperation.
E󰘯ects Whenthemaincontrollerhasabnormalcondition,componentsmaynotoperate
properly.
ErrorCode Er38,Er70
Diagonostic Checkeachconnectionand/orwiresdamageonthePCB.
Color/WireNumber N/A
Chapter2Componentsdescription
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Description/Part#
CH Supply Temperature Sensor: 7855P-031
Storage Temperature Sensor: 7855P-057
DHW Temperature Sensor: 7855P-094
Exhaust Temperature Sensor: 7855P-092
Check Point CN7
Function The controller compares each sensor with setting temperature then goes to
safety shut down when measured temperature is over the setting temperature.
Failure Event Sensor malfunction or overheating condition detected.
E󰘯ects Improper temperature measurement.
ErrorCode Er 16, Er 28, Er 30, Er 32, Er 33, Er 35
Diagonostic ①Visibly check for breakage of wires and/or each connections
②Check each sensor’s resistance range with a multi-meter.
Color/WireNumber
①CH Water High Limit Sensor (black/purple): Connector ⑭,⑦
②Storage Temperature Sensor (black/orange): Connector ⑬,⑥
③Exhaust Temperature Sensor (black/white): Connector ⑫,⑤
④DHW Temperature Sensor (black/yellow): Connector ⑩,③
⑤CH Supply Temperature Sensor (black/white): Connector ⑨,②
NO Item Standard
1
Temperature –
Resistance Type
Idling Condition
Temperature(℃) Resistance(kΩ)
0 ± 0.1 ℃-10.99
25 ± 0.1 ℃-3.906
85 ± 0.1 ℃0.552 ± 3%
( )Blank is for reference measurement
2 Fixed Number (25/85) 3482.4K ± 2%
3Fixed Number of Heat
Dissipation 2.5mW/℃(Min.) (While not boiling)
4 Fixed Number of Heating 8(15)Sec (Max)(63.2% reaching time
while boiling)
5Range of Workable
Temperature - 4 ~ 230 º
F
①②③④⑤⑥⑦
⑧⑨⑩⑪⑫⑬⑭
CHWaterHighLimitTemperatureSensor
ExhaustTemperatureSensor
StorageTemperatureSensor
DHWTemperatureSensor CHSupplyTemperatureSensor
CN7
Chapter2Componentsdescription
LP-528 REV. 8.01.14