TriangleTube Delta Elite Series User manual

SERVICE TECHNICIAN’S
TROUBLE SHOOTING GUIDE
2006-15 EliteTSG-PG-4/06
F-25/30/35/40 & 45

Indicates a potentially hazardous situation, if ignored, can result in death, serious injury or sub-
stantial property damage.
Indicates special instructions on installation, operation or maintenance, which are important to the equip-
ment/product, but not related to personal injury hazards.
This guide is to be used in conjunction with the ELITE Installation and Maintenance manual.
Procedures and servicing listed in this manual must be performed by a qualified service technician,
installer,service agency or gas supplier. Any procedures or service performed by an unqualified
individual or service agency can result in severe personal injury, death or substantial property
damage.
WARNING
NOTICE
WARNING

This guide is to be used in conjunction with the Triangle Tube ELITE Combination Water Heater Installation
and Maintenance Guide.
Good Troubleshooting Practices
Before leaving for the job site:
-Check your parts and tools.
•Test equipment and tools that you will need:
Electrical meter that can measure voltage and continuity.
Pressure gauge, Watts #276H300 Test Gauge or similar.
Temperature Gauge or metering device.
Manometer.
Combustion analyzer.
Bucket, 1 gallon or larger with volume markings.
Stopwatch.
Standards tools of the trade (wrenches, screwdrivers...).
•Parts to solve most problems:
120V to 24V, 40 VA Transformer.
DPDT Relay, 24V coil with 120V rated contacts.
Thermostat Kit PGRKIT21.
-Know the ELITE model number.
-Review all appropriate manuals before leaving for the job site.
At the job site:
-Clarify the problem
-Have the ELITE manual and any other wiring, zone control or piping diagrams or installation guides read-
ily available.
-Turn to page 2 - read carefully and follow instructions step by step.
REMEMBER
Follow the Troubleshooting Guide step be step, always double checking your results. Skipping steps or not
completing steps can lead to wrong conclusions, repeated visits to the job site, unhappy customers and unnec-
essary warranty claims.
Introduction
1

Service Check List
2
- Check Manual Reset Limit
- Check the LED Code on Burner Control
-Check the Incoming Power Supply
- Check the Transformer / 24V Circuit
- Check the Safety Limits
- Check “Relay 1”
- Possible System Problems
- Unit Circulator Running?
- Check “Relay 2”
- Application Properly sized?
- Oversized Fixture Flow Rates
- Thermostatic Mixing Valve
- Recirculation System
- Thermostatic Mixing Valve
- Undersized Expansion Tank
- Faulty Expansion Tank
- Faulty Pressure Relief Valve
- Faulty Primary Fill Valve
- Inner Tank Leak
- Undersized or Missing Domestic Side
Expansion Tank
- High Domestic Supply Pressure
- Possible Water Hammering or Pressure Spikes
- Faulty T&P Relief Valve
- From Sources Other than the PERFORMANCE
- Lifting or Weeping Relief Valves
- Loose Piping Connections
- Water Smells Like “Rotten Eggs”
- Milky Water
- Rusty or Discolored Water
No Heat Call
Unit is Cold & Burner Not Firing
No Heat Call
Unit is Hot & Burner Fires
Insufficient Domestic Hot Water
Excessive Domestic Hot Water Temperature
Pressure Relief Valve Lifting or Weeping
Temperature / Pressure Relief Valve
Weeping or Lifting
Water Found on the Floor Near the Unit
Water Quality Problems
Yes
No Heat Call - Unit Cold & Burner Not Firing - Page 5-7
No Heat Call - Unit is Hot & Burner Fires - Page 8
Insufficient Domestic Hot Water - Page 9-10
Excessive Domestic Water Temperature - Page 11
Pressure Relief Valve Lifting - Page 12
Temperature / T&P Relief Valve Lifting - Page 13
Water on Floor - Page 14
Water Quality Problems - Page 15-16
- Combustion Test
- General Trouble Shooting Guidelines for Burners
Start Up Problems
Start Up Items - Page 17-21
No
No
No
No
No
No
No
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes

Service Instruction 1 - Accessing the Electrical Control Panel
1. Disconnect power supply to the ELITE prior to proceeding with the instructions.
Failure to disconnect the power supply prior to proceeding with the instructions could lead to pos-
sible electrical shock hazard and cause severe personal injury or death.
2. Remove the top jacket panel by disengaging the lock pins by applying an upward force along the front
edge of the panel.
3. Remove the front jacket panel by disengaging the lock pins using a flat head screwdriver.
a. Insert the screwdriver between the front jacket panel and the side jacket panel along the upper corner.
b. Use a twist motion to disengage the front panel from the side panel.
c. Repeat this process along the other side of the front jacket panel.
d. Once the upper corners are disengaged, lean the front panel forward and lift the panel up to disengage
the lower tabs.
Use extreme carenot to damage the jacket panels when using a screwdriver to disengage the front
jacket panel.
4. Remove the (4) locking pins located on the top and lower corners of the black control panel. Once the
locking pins are removed, the front control panel will lay forward exposing the control / electrical panel
components
5. If needed the power supply may be reconnected to allow further troubleshooting procedures.
Exercise extreme care when working with the electrical panel components exposed and the unit’s
electrical power reconnected. A potential electrical hazard exists when working in this condition.
Failure to exercise extreme caution could lead to severe personal injury or death.
6. Disconnect the electrical supply prior to any replacement of electrical components or prior to reassem-
bling the control panel to the unit.
7. To reassemble the front control panel, align the panel corners to the proper position on the side panel and
tighten the lock down pins.
WARNING
NOTICE
WARNING
Servicing Tips and Instructions
3

8. To reassemble the front jacket panel, insert the lower tabs into the side panels. Lift the panel up to align
the locking pins with the retaining clips and snap the panel into place.
9. Align the top jacket panel with the locking pins and snap downward into place.
Service Instruction 2 - Removing Front or Top Jacket Panel and Burner Panel
1. Insert the screwdriver between the jacket panel or burner panel and the side jacket panel near the panel
corner.
2. Use a twist motion to disengage the panel from the side panel.
3. Repeat this process along the corners of the jacket panel.
4. To remove the Front jacket once the upper corners are disengaged, lean the panel forward and lift the
panel up to disengage the lower tabs.
Use extreme carenot to damage the jacket panels when using a screwdriver to disengage the jack-
et panel.
Service Tip 1
All 120V wiring on the ELITE control panel is separate from the 24V wiring. The 120V wiring is located on
the terminal strip in front of the transformer. The 24V wiring is located on the terminal strip to the left of the
transformer. Both terminal strips are numbered from right to left; the 120V strip begins with #1 and the 24V
begins with #5. For control panel, see pages 22 through 23.
Service Tip 2
The control panel consists of (2) DPDT relays. The relays are designated as Relay 1, which controls the burn-
er function and is located near the transformer. The second relay, Relay 2, controls the circulator function and
is located on the left side of the control panel.
Service Tip 3
During initial startup the ELITE may emit an odor. This odor is due to the initial burning of ceramic fibers
in the combustion insulation and the oils on the interior tank surfaces. These odors will dissipate as the unit
continues to operate.
NOTICE
Servicing Tips and Instructions
4

Check the Manual Reset Safety Limit.
-The Manual Reset Safety Limit reset button is located on the center of the front control panel.
-If the Manual Reset Limit had tripped then check the following items:
• The function of the Manual Reset Limit.
• The setting of the Manual Reset Limit should be 205ºF.
• The function of the Primary Thermostat.
• Check the Primary return system temperature. The recommended supply/return temperature dif-
ferential is 20ºF to 30ºF.
Check the Burner Control.
Some oil burner controls are equipped with a LED indicator to aid the service technician in diagnosing poten-
tial problems. If a LED is part of the burner control. consult with the control manufacturer and/or the burn-
er manufacturer for a detail list of flash codes and troubleshooting guidelines.
If the burner control contains a reset button, depress the button for approximately 60 seconds and release. If
the burner resets and attempts to ignite, consult the burner manufacturer’stroubleshooting guidelines or the
general troubleshooting guidelines listed on page 17.
Note: If the burner control has no reset button, turn the power supplied to the unit OFF for approximately 60
seconds and then ON.
Check the Incoming Power Supply.
-Access the control panel components per Service Instruction 1.
- Check for voltage across terminals 1 and 2 for 120V.See Service Tip 1.
• If voltage is not present check incoming electrical supply.
- Check for 120V,polarity, across terminals 1 and G. See Service Tip 1.
• If voltage is present across terminals 1 and G, then polarity is correct.
•If voltage is not present check incoming electrical supply wire connections and electrical supply
source.
-Proceed to Check the Transformer and 24V Circuit.
Check the Transformer and 24V Circuit.
-Complete the procedure for checking Incoming Power Supply.
- Check for voltage across terminals 5 and 6 for 24 volts. See Service Tip 1.
No Heat Call - Unit is Cold & Burner Not Firing
5

• If voltage is not present, and 120V is supplied to the unit replace the Transformer.
- Proceed to Check the Safety Limits.
Check the Safety Limits.
- Complete the procedures for checking Incoming Power Supply and for checking the Transformer and
24V Circuit.
-Check for voltage across terminals 6 and 7 for 24 volts. See Service Tip 1.
•If voltage is not present, check the following items related to the LWCO device:
- Is the system pressure above 10 psig? The system pressure must be above 10 psig for the LWCO
device to activate.
- If the system pressure is above 10 psig, check for continuity across the LWCO device terminals.
Replace the LWCO device if switch is proven open.
- Check for voltage across terminals 6 and 8 for 24 volts. See Service Tip 1
•If voltage is not present, check the following items related to the Manual Reset Limit:
- Push the reset button located on the Control Panel. Does it reset?
- If the manual reset limit does reset check to ensure limit is set to 205ºF and ensure primary sup-
ply/return differential is 20º to 30ºF.
- Is the Manual Reset Limit functioning properly? Is the manual reset limit tripping at a tempera-
ture setting of 205ºF? Replace the Manual Reset Limit as needed.
- Check the function of the Automatic Reset Limit by:
1. Turn the Secondary thermostat to the highest possible setting. The installer may need to run domes-
tic hot water with the unit shut down in order to cool the inner tank and to initiate a “call for heat” on
the Secondary thermostat.
2. Check for voltage across terminals 6 and 11 for 24 volts. See Service Tip 1. If voltage is not present
check the following:
-Check for voltage across terminals 12 and 6 for 24 volts. If voltage is present continue to run
domestic hot water to cool the unit down.
-Turn the Secondary thermostat to the lowest possible setting and check for voltage across termi-
nals 12 and 6 for 24 volts. If voltage is not present, replace the Secondary thermostat.
3. If 24 volts is present at terminals 11 and 6, check for 24 volt across terminals 14 and 6. If voltage is
not present check the following:
- Is the system temperature below 160ºF?
- If the temperature is below 160ºF, then replace the Automatic Reset Limit.
No Heat Call - Unit is Cold & Burner Not Firing
6

- If the system temperature is above 160ºF, initiate a “call for heat” within the system and attempt
to cool the unit down. If the unit cools down and the Automatic Reset limit does not reset, replace
the limit.
The reason for either the Manual Reset or the Automatic Reset Limit to activate in a lockout mode may
be due to a low return temperature from the system. It is recommended to maintain a 20ºF to 30ºF dif-
ferential between the primary supply temperature and the primary return temperature. In radiant systems
using a mixing valve or other means of providing tempered water to the system it is recommend to use a
bypass loop between the primary supply and return piping. This by-pass loop should contain a valve that
can be used to divert primary water from the supply to the return. The valve should be adjusted to increase
the return temperature and a supply /return differential of 20º to 30ºF. Once the differential is achieved,
no further adjustments are required on the valve.
Check the Function of “Relay 1”. See Service Tip 2.
• If 24 volts is present at terminals 14 and 6, then check for 120 volts at terminals 4 and 2. See Service
Tip 1.
- If 120 volts is not present at terminals 4 and 2, replace the “Relay 1”.
NOTICE
No Heat Call - Unit is Cold & Burner Not Firing
7