Super Hot MG-50-E Owner's manual

PN9362763
MG & SG SERIES BOILERS
S9361A CONTROL SUPPLEMENT MANUAL
FOR MODELS MG-50-E TO MG-150-E AND
SG-135-E TO SG-270-E
This supplement manual must be used in conjunction with the
Installation and Service Manual provided with your boiler. It
provides important instructions relevant to controller
programming, operation, troubleshooting, and wiring.
NEW CONTROLLER
Allied Engineering Company
Division of E-Z-Rect Manufacturing Ltd.
Manufacturers of Gas and Electric Boilers, Stainless Steel Tanks, Heat Exchangers and Electric Boosters.
94 Riverside Drive, North Vancouver, B.C. V7H 2M6 •Telephone [phone] •www.alliedboilers.com
Branches: Calgary •Edmonton •Toronto •Denver
Improper installation, adjustment, alteration, service or maintenance can cause propert
y
damage, injury, or loss of life.Please carefully read this manual along with the
Installation and Service Manual. For assistance or additional information, consult a
qualified installer, service agency or the gas supplier.
WARNING

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CONTROLLER PROGRAMMING AND SERVICE CODES Section 1
1.1 CONTROLLER PROGRAMMING AND SERVICE CODES
2012 NRCan and DOE Compliance and Operation
Operation of this control may delay the burner operation while the residual heat is circulated
out of the boiler.
Text Description
The integrated boiler control module provides ignition
sequence, flame monitoring and safety shutoff for
intermittent pilot spark ignition. It also provides limit rated
water temperature control for with two separate sensors in
one casing (3-wire).
The control is located on the front panel inside the boiler.
The control display, along with Up ▲, Down ▼, and “I” keys
may be used to view boiler operating status and program
parameters (Figure 1).
1.1.1 RUN MODE
Fi
g
ure 1 Control Dis
p
la
y
In the RUN mode, status items and parameters are viewable.
To read settings, press and release the “I” key to find the parameter of interest. Each setting will
alternately flash between the relevant display code listed in the Table 1 and its corresponding value. For
example, press and release “I” key until “HL_” setpoint is displayed, it will then flash a three-digit number,
i.e., 220, followed by ˚F (or ˚C). This indicates that the boiler water temperature of 220 ˚F is set. Other
operating parameters display the settings in a similar fashion.
Display
STA Status (see status numbers) StA
BT Boiler temperature bt
SP Operating setpoint SP
HL High limit setpoint HL
HDF Differential set-point HdF
FLA Flame current FLA
RUN Run time hours run
CYC Boiler cycles CYC
ERR Error (see error numbers) Err
Table 1 Run Mode Parameters

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1.1.2 INSTALLER MODE
To enter the adjustment mode:
1. Press with Up ▲, Down ▼, and “I” keys (see Figure 1) simultaneously for three seconds.
2. Press and release the “I” key until the parameter (listed in the Table 2) requiring adjustment is
displayed.
3. Press with Up ▲or Down ▼key until the parameter has reached the desired value.
4. After 60 seconds without any key inputs, the control will automatically return to the RUN Mode.
Table 2 Installer Mode O
p
tions
3-Digit 7-Segment Display
1st Screen 2nd Screen (setting value) 3rd Screen
Default Range Description
HL_ <high limit> ˚F or ˚C 180 ˚F 130 to 220 ˚F Adjust high limit setting
HdF <high limit differential> ˚F or ˚C 15 ˚F 10 to 30 ˚F Adjust high limit
differential
Or_ <pump overrun time> Sec 60 sec 0 to 120
seconds Pump post-purge time
otH <ODR maximal temp.> ˚F or ˚C 55 ˚F 40 to 70 ˚F Maximal outdoor
temperature
otL <ODR minimal temp.> ˚F or ˚C 0 ˚F -40 to 40 ˚F Minimal outdoor
temperature
btL <minimal water temp.> ˚F or ˚C 140 ˚F 130 to 150 ˚F Minimal boiler
temperature
tPL <minimal boiler temp.> ˚F or ˚C 140 ˚F OFF,
120 to 160 ˚F
Thermal purging
minimal temperature
(parameter is available
only if outdoor
temperature is invalid)
tPt <maximal delay> Min 2 1 to 10 minutes
Maximal thermal purge
time (parameter is
available only if outdoor
temperature is invalid)
rSt On or OFF N/A N/A Reset lockout
F-C ˚F or ˚C ˚F ˚F or ˚C Select degrees ˚F or ˚C
mode

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1.1.3 OPERATING CHECKOUT
After adjusting parameters, put the boiler into operation and observe operation through at least one
complete cycle to make sure that the controller operates properly. See controller troubleshooting section
to assist in determining boiler operation.
The sensor should fit snugly and should touch the bottom of the well for best temperature response. The
sensor is held inside the well using the well clip.
1.1.4 THERMAL PURGE
The intent of thermal purge is to ensure usable residual heat in the boiler is circulated until it is sufficiently
depleted from the system before the burner is allowed to fire. To that end, on a call for heat, the burner
remains off while the circulator runs until the boiler temperature drops to the thermal purge temperature
limit or the time delay is exceeded. Both of these parameters are adjustable. When the boiler temperature
falls below the thermal purge temperature limit or the time delay expires, the burner is allowed to fire.
In addition to the thermal purge temperature and thermal purge time delay parameters, two other
conditions release the integrated boiler controller from thermal purge and allow the burner to run in order
to maintain comfort in the space:
•The boiler temperature has dropped 10 °F from the boiler water temperature measured at the
beginning of the call for heat.
•Boiler temperature is cooling at a rate greater than 5 °F/minute while the circulator is running.
1.1.5 OPERATING STATE CODES AND TROUBLESHOOTING
When there is a problem during a call for heat or boiler operation, the controller provides specific
information to help resolve the issue quickly. If the controller is displaying “StA” by a number, use the
state code definitions in Table 3 to determine the problem and possible causes.
1.1.6 CONTROLLER MOUNTING
The controller has four tabs which align with four slots in the control panel. To remove the controller,
press and hold in the bottom two tabs while simultaneously rotating the controller about 45 degrees to
unhook the top two tabs.
Rotate 45°
PRESS and HOLD
both tabs while
rotating controller
Figure 2 Controller Replacement

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Table 3 State Code Definitions
Display
Code
State Specific Description
Operation Sequence
Idle/Standby The boiler is in standby - no call for heat
StA ↔1 Run circulator Heat request present but boiler water temperature sufficiently high to
run circulator pump only (no ignition sequence)
Thermostat Calls For Heat
Self Test Hardware self check, check of connected periphery, it is performed
at start up, in the beginning of the heat cycle and in the “Wait For
recovery” state
StA ↔17
Wait for recovery There is an external error and the control is waiting to recover, no
lockout
Circulator output energizes
StA ↔ 2
Wait for end switch
to open
The control is waiting for the end switch of the vent damper to open
at the beginning of a heat cycle. If the end switch doesn’t open in 60
seconds, the control goes to error code Err 2
StA ↔ 3
Wait for end switch
to close
The control is waiting for the end switch of venting damper to close at
the beginning of a cycle. If the end switch doesn’t close within 60
seconds, the control goes to error code Err 29
StA ↔ 4 Pump pre-purge/
thermal purge
System is purging before ignition trial-safety relay diagnostics
followed safety relay switch-on during last 2 seconds this sate
StA ↔ 6 Spark, ignition
activation
System is sparking permanently 13 seconds whilst pilot gas valve
relay is turned on
StA ↔7Prove flame System is proving flame signal, typically 2 seconds
StA ↔8Running System is in running mode, flame signal must be present
Call For Heat Ends
StA ↔9Pump post-purge System is purging at the end of a call for heat
Troubleshooting/Diagnostics
StA ↔10 Inter-purge
(retry/recycle delay)
If the control loses flame signal during state code 7 or 8, or flame is
not detected during stat code 6 to 8, it will recycle through the 30
seconds purge time and last 2 seconds part of pre-purge time
Err ↔ 2 Wait for end switch to
open – failed closed
The end switch of venting damper has not opened at the beginning
of the heat cycle. The control is not in lockout
Err ↔ 29 Wait for end switch to
close – failed open
Waiting time for pressure switch to close expired. The control is not
in lockout
Err ↔ 62 Soft lockout System is shutdown and will re-start following an enforced delay
StA ↔15 Wait for limit to close There may be a call for heat from the thermostat, but the limit switch
is open
Flame out of
sequence – before
trial
Flame signal sensed before trial for ignition.
Flame out of
sequence – after trial Flame out of sequence during post-purge.
StA ↔16
Wait for flame loss Flame signal still present when not expected.

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If the controller is displaying “Err” followed by a number, use the error code definitions in the Table 4 to
determine the problem and possible causes.
Table 4 Error Codes
Display State Solution
Err ↔ 2 End switch of venting
damper failed to open
The end switch contacts stuck closed. Check the venting
damper and replace it if necessary.
Err ↔ 4 Low flame current Check pilot assembly and replace it if necessary.
Err ↔ 6 Flame sensed out of
normal sequence
Flame sensed out of normal sequence (before opening gas
valve or after closing gas valve).
Err ↔18 Gas valve relays
welded 5 consecutive
soft lockouts
A manual reset is required.
Err ↔ 23 Flame sensed during
pre-purge
Flame sensed during pre-purge (before gas valve signaled
opened)
Err ↔ 24 Flame sensed during
post-purge
Flame sensed during post-purge (before gas valve signaled
closed)
Err ↔ 29 End switch of venting
damper failed to close
The end switch contacts stuck open. Check the venting
damper and replace it if necessary.
Err ↔ 32 Sensor error
Temperature sensor or interface failure (open or short
connection, increased connection resistance, dual sensor
mismatch) or failure of A/D conversion (invalid offset or gain,
too many failures during A/D conversion).
Err ↔ 57 Flame rod shorted to
burner ground Check and adjust or replace if necessary.
Err ↔ 58 AC line frequency error AC signal is too noisy or frequency is incorrect.
Err ↔ 59 Line voltage error AC voltage out of specification high or low.
Err ↔ 60 Thermostat input
higher than threshold Check thermostat wiring and replace it if necessary.
Err ↔ 61 Line voltage unstable Possibly too many heavy loads switching on and off cause
erratic supply voltage.
Err ↔ 62 Soft lockout Maximum number of retries exceeded.
Err ↔ 63 Soft lockout Maximum number of recycles exceeded.
Err ↔ 64 Soft lockout
Internal failure (Electronics failure). Caused by general
electronics failure such as relay open or shorted contacts,
flame sensing circuit error, or A to D error.
Err ↔ 65 Over temperature error Sensor measured temperature in excess of ECO limit.

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1.2 Replacement Parts

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