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Operation Manual 08/2011

1. 18 SAFE INSTALLATION USE AND 3 Quick Setup S799 9B OI 18 FP Oy tH EP EMEN 3 Starting up S7999B OI 19 GENERAL SAFETY EE k ka st ik 4 Page Navigation vv twvtasridiiesbizoue val vii atak 19 INTRODUC FONG ta il at a n t epa e e e e 9 TROUBLESHOOTING 29 Model 5 MAINTENANCE 1 44 loo gii aS 5 Maintenance Schedules 24 CPI E EOM 5 Inspect Boiler Area eeu rire kana di vans tin Fo skies tem dades Pas t ses ine mis 44 6 General Maintenance 44 BOILER START UP AND OPERATIONS 8 44 LIGHTING AND OPERATING INSTRUCTIONS 10 Bumer 45 CONTROL SYSTEM otter 13 Pressure Relief Valve eerte tete 45 Burner Control System 13 Blower 45 Nu 13 Air Filter 45 Communications and Displays
2. FLAMMABLE THIS APPLIANCE DOES NOT HAVE A PILOT IT 1 USE ONLY YOUR HAND TO TURN THE MAIN MANUAL GAS VALVE NEVER USE TOOLS IF THE KNOB WILL NOT PUSH IN OR TURN BY HAND DON T TRY TO REPAIR IT CALL A QUALIFIED SERVICE TECHNICIAN FORCE OR ATTEMPTED REPAIR MAY RESULT IN A FIRE OR EXPLOSION DO NOT USE THIS APPLIANCE IF ANY PART HAS BEEN UNDER WATER IMMEDIATELY CALL A QUALIFIED SERVICE TECHNICIAN TO INSPECT THE APPLIANCE AND TO REPLACE ANY PART OF THE CONTROL SYSTEM AND ANY GAS CONTROL WHICH HAS BEEN UNDER WATER DONOT OPERATE APPLIANCE UNLESS UNIT IS FILLED WITH WATER AND WATER LINES ARE FULLY OPEN 6 OPEN MAIN VALVE TURN MAIN GAS VALVE TO ON OR OPEN POSITION THE VALVE IS IN THE ON POSITION WHEN THE HANDLE IS PARALLEL TO THE GAS FLOW DIRECTION THIS APPLIANCE IS EQUIPPED WITH AN IGNITION DEVICE WHICH AUTOMATICALLY LIGHTS THE BURNER DO NOT TRY TO LIGHT THE BURNER BY HAND TURN ON POWER TO THE APPLIANCE SET SYSTEM TEMPERATURE CONTROLLER TO DESIRED OPERATING TEMPERATURE IF THE APPLIANCE WILL NOT OPERATE FOLLOW THE INSTRUCTIONS TO TURN OFF GAS TO APPLIANCE CALL YOUR SERVICE TECHNICIAN OR GAS SUPPLIER CLOSE MAIN VALVE TURN MAIN MANUAL GAS VALVE TO OFF OR CLOSED POSITION THE VALVE IS IN THE OFF POSITION WHEN THE HANDLE IS PERPENDICULAR TO THE GAS FLOW DIRECTION ADJUSTMENT A WARNING Failure to make accurate adjustments could cause improper combustion r
3. 2 14 Condensate Removal 46 14 Venting Maintenance ccccecssesesesesecececececevececececscececececevererevevereees 46 Burner Control Operation r si sisi owa a UR PRU pk a UAR lp 14 Heat Exchanger Maintenance ee 46 General Operational Sequence eerte ertet iners 15 Handling Ceramic Fiber Materials ce 47 L a E RC T 16 Replacement Parnis EN IE ee ae eee 47 Local Operator Interface Display MEM eum 48 WE AUON tk sis kt e tik isi kem ket a p 15 LIMITED WARRANTY bi dpa b 49 SAFE INSTALLATION USE AND SERVICE The proper installation use and servicing of this boiler is extremely important to your safety and the safety of others Many safety related messages and instructions have been provided in this manual and on your boiler to warn you and others of a potential injury hazard Read and obey all safety messages and instructions throughout this manual It is very important that the meaning of each safety message is understood by you and others who install use or service this boiler This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death DANGER indicates an imminently W
4. If fault repeats verify electrical grounding If fault repeats replace module 35 CODE DESCRIPTION RECOMMENDED TROUBLESHOOTING OF NOTE LOCKOUT CODES Return to Configuration mode and recheck selected parameters reverify and reset module If fault repeats verify electrical grounding If fault repeats replace module 212 213 214 Invalid Prepurge time setting 215 216 217 218 219 220 22 222 Unconfigured Outlet high limit setpoint setting Invalid Preignition time setting Invalid Prepurge rate setting Invalid Purge rate proving setting Invalid Run flame failure response setting Invalid Run stabilization time setting Invalid Stack limit enable setting Invalid Stack limit response setting Unconfigured Delta T limit setpoint setting Unconfigured DHW high limit setpoint setting 223 Unconfigured Stack limit setpoint setting 224 225 226 Invalid Outlet high limit setpoint setting 227 Invalid DHW high limit setpoint setting 228 229 230 231 Invalid Delta T limit delay setting Invalid DHW demand source setting Invalid Flame threshold setting Invalid Stack limit setpoint setting Invalid Modulation output setting Invalid CH demand source setting 232 Invalid Pressure sensor type setting 233 234 235 Invalid IAS closed response setting Invalid Outlet high limit enable setting Invalid Outlet connector type setting 236 Invalid Inlet connector type setting 237 Invalid DHW connect
5. f its add stage action has been triggered it will remain in this condition until either a stage has been added Or The criteria for its being in an add stage condition is no longer met only then will it take another look around to see what state it should go to next DEFINITIONS Modulating stage The modulating stage is the Control System that is receiving varying firing rate requests to track the load First stage This is the Control System that was turned on first when no slave Control Systems were firing Previous stage The Control System that was added to those stages that are firing Just prior to the adding of the Control System that is under discussion Next stage The Control System that will or might be added as the next Control System to fire Last stage The Control System that is firing and that was added the most recently to the group of slaves that are firing Typically this is also the modulating stage however as the load decreases then the last added stage will be at its minimum rate and the previous stage will be modulating Lead boiler The Lead boiler is the Control System that is the first stage to fire among those stages which are in the equalize runtime Lead Lag group If a boiler is in the Use first group it may fire before the Lead boiler fires First boiler A Control System may be assigned to any of three groups Use First Equalize Runtime or Use Last If one or more Cont
6. BURNER 2 155F LOU 137F LOU VIEW 2 _ LEAD LAG 2 4 serue FIGURE 19 79998 HOME PAGE BOILER 1 IN NORMAL OPERATION Servic s EX Deno Available Available 1 Disabled VIEW INDIVIDUAL FIGURE 20 79998 LEAD LAG HOME PAGE On System applications each Burner Control System is represented on the Home page by an icon and name Pressing the icon allows the user to zoom in on that boiler and see its specific details These details are provided on a new page which can include additional buttons that display additional detail and operation information which itself leads to other pages The pages are traversed in a tree structure method as shown in Figure 21 The Control System icons will appear in one of four colors indicating the boiler status Blue Normal operation Red Lockout condition e Gray Standby mode burner switch off e Gray and crossed out communication error disconnected or powered off Yellow Preparing for Start up Up to 8 Systems can be displayed on the Home page The name of each boiler is displayed next to the Control System icon button When Lead Lag is enabled the system header temperature and firing rate are displayed for each System When the burner is in standby or not firing the firing rate is not displayed NOTE The boiler name may be cut off on the Home page when all icons are present The Home page also includes a System Analysis butt
7. It is recommended that the intake and exhaust piping of the boiler be checked every 6 months for dust condensate leakage deterioration and carbon deposits A WARNING Do not use a nylon brush or other static creating material to clean dust and carbon deposits from heating surfaces and vent Such deposits are flammable and may be ignited by static electricity Use a metal brush to minimize the danger of explosion Qualified Service Agent should follow this procedure when the boiler s intake and exhaust piping need cleaning 46 Turn off the electrical power and manual gas shut off e Allow boiler parts to cool before disassembly Remove the vent pipe e Check parts and chimney for obstructions and clean as necessary Remove burner from boiler and other metal parts as required to clean as necessary e Refer to parts list for disassembly aid Clean and reinstall the parts removed in steps 2 and 3 e Be sure the vent pipe has a minimum upward pitch of 1 4 per foot 2 cm m of length and is sealed as necessary Restore electrical power and gas supply to boiler e Check for gas leaks and proper boiler and vent operation HEAT EXCHANGER MAINTENANCE 1 Shut down the boiler e Turn Off gas to the boiler Do not drain the boiler unless it will be exposed to freezing temperatures If using freeze prevention fluid in system do not drain 2 Ensure the boiler cools down to room temperature 3 Remove the nut
8. Operation used to perform daily or frequent functions with the burner control such as setpoint adjustment etc Diagnostic used to view burner control diagnostic information Details used to view burner control detail status information History used to view burner control history Pump used to expand the pump status information Modulation used to toggle between status displays pump setpoints and modulation Boller 1 wer 8 g FIGURE 22 SUMMARY STATUS PAGE 21 CONFIGURE BUTTON Pressing the Configure button bottom left on the Status page opens the Configuration page The S7999B Configuration page does not have a Display Setup button The configuration page allows the user to view and set parameters that define how the connected R7910A functions in the hydronic heating system All parameters are factory configured and only a Field Service Agent must perform the configuration settings The configuration page contains a menu of parameters grouped into functional areas that the user selects for configuration see Figure 23 No specific order for configuration is required All parameters are enabled for editing though some may not be applicable e g a configuration parameter may disable a control feature Selecting a parameter group from the menu displays parameters exclusively applicable for the functional group on the page see Figure 24 These parameters can be edited and when
9. Manual in Run I Manual in Run amp Standby a 2 a sisi oue FIGURE 14 FIRING RATE PAGE 11 HIGH FIRING RATE SETTING Set the boiler to the high firing rate by setting the High Firing Rate RPM as described below Check combustion readings using a combustion analyzer combustion readings are not in accordance with the chart below adjust the gas valve as follows remove the flat round blue plastic cap from the cover Using a 3 mm 7 64 hex wrench turn the adjustment screw counterclockwise to increase or clockwise to decrease gas flow and achieve the desired CO level Refer to the Table 19 for correct settings There will be a slight time delay between the adjustment and the response of the CO measuring instrument Adjust the settings in small increments and allow the combustion readings to stabilize before readjusting When desired adjustments are complete reinstall the blue plastic cap on the cover Combustion samples should be taken in the stack within two feet of the boiler The carbon monoxide CO values in the combustion sample should not exceed 150 PPM under any circumstances Contact OEM for any abnormal conditions leading to excessive CO above 150 PPM TABLE 4 HIGH FIRE RATE RPM CO MANIFOLD PRESSURE APPROXIMATE FACTORY SET INCHES W C MODELS XB XW NATURAL PROPANE NATURAL PROPANE NATURAL GAS PROPANE GAS GAS 1000 920 000 4450 4750 8 5 9 2 9 3 10 2 Qo on 1300 4850 51
10. Read and understand this manual and all Warnings and Cautions within before installing and using this appliance e Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance Place these instructions adjacent to boiler and notify owner to keep for future reference A R Untempered hotwater can cause Flammable Vapors severe burns instantly resulting in severe injury or death Children elderly and the T physically or mentally disabled WARNING are at highest risk for scald injury Explosion Hazard Feel water before bathing or eee showering Temperature limiting Overheated water cause valves are available To water tank explosion Read instruction manual for safe temperature setting Properly sized temperature and pressure relief valve must be installed ADANGER Fire or Explosion Hazard Do not store or use gasoline or other flammable vapors and AWARN liquids in the vicinity of this or any other appliance v Breathing Hazard Carbon Monoxide Gas Avoid all ignition sources if you smell gas Do not expose boiler control to excessive gas pressure gas with installation above 4500 feet Use only gas shown on rating plate e Please contact an A O Smith qualified Maintain required clearances to combustibles service agent to obtain the proper Keep ignition sources away from faucets after ext
11. Extreme Performance MODEL APPLICATION e XB Hydronic Heating Boiler e XW Domestic Hot Water Supply Boiler e 1000 920 000 Btu hr input e 1300 1 300 000 Btu hr input 1700 1 700 000 Btu hr input e 2000 2 000 000 Btu hr input e 2600 2 600 000 Btu hr input e 3400 3 400 000 Btu hr input FUEL N Natural gas P Propane NOTE XB models are equipped with 50 psi pressure relief valve pump is optionally installed XW models are factory installed circulating pump standard with 125 psi pressure relief valve XB models can be special ordered with a factory installed pump and XW models can be special ordered without the factory installed pump These factory configurations can also be changed in the field by installing circulation pumps and changing pressure relief valves to accommodate domestic and hydronic hot water system requirements Properly installed and maintained it should give you years of trouble free service ABBREVIATIONS USED Abbreviations found in this Instruction Manual include e ANSI American National Standards Institute ASME American Society of Mechanical Engineers NEC National Electrical Code NFPA National Fire Protection Association UL Underwriters Laboratory e CSA Canadian Standards Association AHRI Air Conditioning Heating and Refrigeration Institute QUALIFICATIONS QUALIFIED INSTALLER OR SERVICE AGENCY Installation and service of this boiler requir
12. is necessary to loosen and slide the rubber coupling on the blower adaptor in order to move the blower 45 5 Loosen the seven bolts on the blower adapter at the base and move the burner ground wire Green aside 6 Lift the blower adapter and remove the manifold assembly up from the 6 studs located on the cover plate and remove the burner gasket 7 Remove any loose foreign material such as dust or lint with a vacuum Check all ports for blockage Dislodge any foreign material causing blockage Remove any soot or carbon deposits with a rag making sure to remove any lint left on the burner by vacuuming again Reverse the steps to reassemble the unit Restore electrical power and gas supply to the boiler e Put the boiler back in operation by following the Lighting and Operating instructions in this manual Check for gas leaks and proper boiler and vent operation PRESSURE RELIEF VALVE The pressure relief valve should be opened at least twice a year to check its working condition This will aid in assuring proper pressure relief protection Lift the lever at the top of the valve several times until the valve seats properly and operates freely DANGER e Burn hazard e Hot water discharge Keep hands clear of drain valve discharge A WARNING Should overheating occur or the gas supply fail to shut off turn off the manual appliance gas control valve to the BLOWER COMPARTMENT The blower compa
13. its slave Control Systems To do this it adds and drops stages to meet changes in load and it sends firing rate commands to those that are firing The LL master turns the first stage on and eventually turns the last stage off using the same criteria as for any modulation control loop e When the operating point reaches the Setpoint minus the On hysteresis then the first Control System is turned on e When the operating point reaches the Setpoint plus the Off hysteresis then the last slave Control System or all slave Control Systems are turned off The LL master PID operates using a percent rate 0 is a request for no heat at all and 100 means firing at the maximum modulation rate This firing rate is sent to the slaves as a percentage but this is apportioned to the slave Control Systems according to the rate allocation algorithm selected by the Rate allocation method parameter For some algorithms this rate might be common to all slave Control Systems that are firing For others it might represent the total system capacity and be allocated proportionally For example if there are 4 slaves and the LL master s percent rate is 3096 then it might satisfy this by firing all four slaves at 30 or by operating the first slave at 80 20 of the system s capacity and a second slave at 40 10 of the system s capacity The LL master may be aware of slave Control System s minimum firing rate and use this information for some of
14. limit Not Applicable HorL Heat exchanger high limit Not Applicable HorL Sensor Faults O 83 84 85 87 88 1 Inlet sensor fault 1 9 Check wiring and correct any possible errors Replace the Inlet sensor If previous steps are correct and fault persists replace the module 92 Outlet sensor fault Check wiring and correct any possible errors Replace the Outlet sensor If previous steps are correct and fault persists replace the module 93 DHW sensor fault Check wiring and correct any possible errors Replace the DHW sensor If previous steps are correct and fault persists replace the module 31 CODE DESCRIPTION RECOMMENDED TROUBLESHOOTING OF NOTE LOCKOUT CODES 94 Header sensor fault Check wiring and correct any possible errors Replace the header sensor lf previous steps are correct and fault persists replace the module 95 Stack sensor fault Check wiring and correct any possible errors Replace the stack sensor If previous steps are correct and fault persists replace the module Outdoor sensor fault Check wiring and correct any possible errors Replace the outdoor sensor If previous steps are correct and fault persists replace the module Internal Fault A2D mismatch Internal Fault BO Internal Fault Exceeded VSNSR voltage Reset Module If fault repeats replace module ES Internal Fault Exceeded 28V voltage tolerance 100 Pressure Sensor Fault Verify the Pressur
15. main manual gas shutoff valve to the boiler CHECK CONTROL WATER HARDNESS XW Model XP Boilers are approved for use in Domestic Water Heating Systems with a water supply hardness of O grains per gallon to a maximim of 12 grains per gallon Refer to Table 18 for recommend flow rate to maintain scale free operation with up to a medium water hardness For scale free operation in hard water systems with a water hardness greater than 12 grains per gallon a water softener must be installed and maintained TABLE 2 WATER HARDNESS MEDIUM 0 12 GRAINS PER GALLON AP FEET 25 AT F Temperature rise F at the specified GPM GPM Flow rate in gallons per minute AP Pressure loss through the heat exchanger in feet of head For systems over 5 grains per gallon and for scale free operation boiler setpoint should not exceed 140 F Note The factory installed supplied pump on the above listed model boilers is sized to maintian a 25 F AT through the boiler when the boiler is firing at 100 fire In addtion to the pressure loss through the heat exchanger the factory supplied pump is sized for an additional 50 feet of equivalent feet of piping between the boiler and a storage tank All piping between the boiler and the storage tank must be of a pipe size equal to the inlet outlets of the boiler Installation differences may slightly change these parameters FREEZE PROTECTION HYDRONIC HEATING INSTALLATION 1 Determine freeze
16. monitors these sensors to determine water temperature at various points in the system INLET AND OUTLET TEMPERATURE SENSORS All models have two inlet and two outlet temperature sensors for each heat exchanger factory installed to monitor the water temperature entering and leaving the boiler The Inlet Probe is a temperature sensor only and has two leads The Outlet Probe also contains the manual reset high temperature limit switch and has four leads The control system displays the Inlet and Outlet water temperatures sensed from these two sensors on the default Temperatures screen REMOTE SENSORS All models are supplied from the factory with a remote sensor The remote sensor is used to control system water temperature for a single boiler in a domestic hot water storage tank or in the return line from a primary secondary hydronic heating system The boiler will modulate its firing rate in response to the actual system temperature and load conditions The control system displays the temperature sensed from the remote sensor as the Lead Lag temperature on the default Temperatures screen LOW WATER CUTOFF DEVICE LWCO Low water cutoff device is normally a closed switch that opens when water drops below a preset level Each model is equipped with a factory installed LWCO LWCO board is connected to the electronic panel whereas the sensor probe is connected to the heat exchanger FIGURE 9 LWCO BOARD AND PROBE BOILER START U
17. operating instructions A WARNING The flow of combustion air to the boiler must not be obstructed The boiler area must be kept clear and free from combustible materials gasoline and other flammable vapors and liquids Any safety devices including low water cutoffs used in conjunction with this boiler should receive periodic every six months inspection to assure proper operation A low water cutoff device of the float type should be flushed every six months Periodic checks at least twice a year should be made for water leaks More frequent inspections may be necessary depending on water conditions The boiler mounted gas and electrical controls have been designed to give both dependable service and long life However malfunction can occur as with any piece of equipment It is therefore recommended that all components be checked periodically by a qualified serviceman for proper operation BURNER MAINTENANCE Qualified service agent should follow this procedure when the boiler s burner needs cleaning 1 Turn off the electrical power to the boiler and close the main manual gas shutoff valve s Allow the boiler parts to cool before disassembly 2 Loosen the flange and separate the gas train from the manifold assembly 3 Separate the burner from the blower adapter by first removing the four 4 bolts and subsequently the blower gaskets The blower should be free to move at this point 4 For Direct Vent units It
18. protection fluid quantity using system water content following fluid manufacturer s instructions 2 Local codes may require a backflow preventer or actual disconnect from city water supply 3 When using freeze protection fluid with automatic fill install a water meter to monitor water makeup Freeze protection fluid may leak before the water begins to leak causing concentration to drop reducing the freeze protection level INSPECT FILL CONDENSATE SYSTEM Inspect check condensate lines and fittings 1 Inspect the condensate drain line condensate PVC fittings and condensate trap Fill condensate trap with water 1 Remove the 2 inch PVC cap with switch located at top of trap 2 Fill with fresh water until the water begins to pour out of drain 3 Replace the cap Press the cap onto the trap until the cap makes contact with the drain The condensate trap must be filled with water during all times of boiler operation to avoid flue gas emission from the condensate drain line Failure to fill the trap could result in severe personal injury or death TABLE 3 OPERATING CHARACTERISTICS Manifold Pressure Maximum Supply Pressure Minimum Supply Pressure XB XW Type of Gas Inches W C kPa Inches W C 0 2 to 0 3 0 05 to 0 07 Natural 1000 1300 1700 2000 2600 3400 Propane 14 0 3 0 to 3 9 0 75 to 0 97 0 1 to 0 3 0 025 to 0 07 14 0 3 6 to 4 9 0 90 to 1 22 9 LIGH
19. pump will be switched off LEAD LAG Burner Control System devices contain the ability to be a stand alone control operate as a Lead Lag Master control which also uses the burner control function as one of the slaves or to operate solely as a slave to the lead lag system Control System devices utilize two ModBus ports MB1 and MB2 for communications One port is designated to support a system S7999B display and the other port supports communications from the LL Master with its slaves The Lead Lag master is a software service that is hosted by a Control System It is not a part of that control but is an entity that is above all of the individual burner controls including the one that hosts it The Lead Lag master sees the controls as a set of Modbus devices each having certain registers and in this regard it is entirely a communications bus device talking to the slave buner controls via Modbus The LL master uses a few of the host Buner Control s sensors header temperature and outdoor temperature and also the STAT electrical inputs in a configurable way to provide control information LEAD LAG LL MASTER GENERAL OPERATION The XP Boiler is a multiple burner application and it works on the basis of the Lead Lag Operation The XB Boiler is factory configured for Hydronic Central Heating application whereas the XW Boiler is factory configured for Domestic Hot Water application The LL master coordinates the firing of
20. purge fan RPM is changed to the Lightoff Rate or if used the damper motor is driven to the Low Fire Position 6 As soon as the fan rpm is equal to the light off rpm or the Low Fire Switch closes the Trial for Ignition or Pre lgnition Time is started depending on configuration 7 Pre lgnition Time will energize the ignitor and check for flame 8 Trial for Ignition Specifics for timings and device actions defined by the OEM or installer 9 The ignition and the gas valve are switched on 10 The ignition is turned off at the end of the direct burner ignition period or for a system that does use a pilot at the end or optionally at the middle of the Pilot Flame Establishing Period PFEP For an interrupted pilot system this is followed by a Main Flame Establishing Period MFEP where the pilot ignites the main burner For an intermittent pilot there is no MFEP 11 The fan is kept at the lightoff rate during the stabilization timer if any 12 Before the release to modulation the fan is switched to minimum RPM for the DHW Forced Rate and Slow Start Enable if the water is colder than the threshold 13 At the end of the DHW heat request the burner is switched off and the fan stays on until post purge is complete 14 Anew DHW request is blocked for the forced off time set by the Anti Short Cycle if enabled 15 The pump stays on during the pump overrun time if enabled 16 At the end of the pump overrun time the
21. the user is finished control returns back to the configuration menu page Each parameter is displayed in its group If there are more parameters than will fit on the screen a vertical scroll bar allows the user to scroll up and down to view all parameters The parameter name is displayed on the left and the current setting is displayed in the text box on the right 1 Configuration Select Configuration Group System Identification amp Access CH Central Heat Configuration Outdoor Reset Configuration DHW Domestic Hot Water Configuration Modulation Configuration Pump Configuration Statistics Configuration Boller 1 Central Heat Configuration Disabled Modulation sensor o Disabled FIGURE 24 SAMPLE CONFIGURATION PAGE CONFIGURATION PASSWORD Some parameters require a valid configuration password be entered by the user before the parameter can be changed The password need only be entered once while the user remains on the configuration pages Leaving the configuration pages ends the scope of the password Three levels of access to Burner Control parameters are permitted Each access level has defined rights when interfacing with configuration and status parameters within the controls e End user The end user can read or view the control parameters and be allowed to change some operating parameters CH setpoint as an example Installer The installer can read all control parameters a
22. was initialized Internal error cycle count address was invalid Internal error EEPROM days count address was invalid ae Tut 473 Internal error PM parameter address was invalid Internal error PM safety parameter address was invalid Internal error Invalid record in lockout history was removed Internal error EEPROM write buffer was full 477 Internal error Data too large was not written to EEPROM Internal error EEPROM hours count address was invalid Internal error Lockout record EEPROM index was invalid Internal error Request to write PM status was 42 wxEms 506 Mix ODR time of day setpoint exceeds normal setpoint Mix 10 J10 7 temperature was invalid Mix 5 J8 11 temperature was invalid Mix modulation sensor type was invalid 526 Mix min water temperature setpoint was invalid Heat exchanger high limit wasn t allowed due to 574 bon pads il wasn t allowed due to configured for recycle response DHW Prate Heat Exchanger Eros 548 Delta T rate limit enable was invalid 48 _ DHW plate preheat setpoint was invalid 549 Delta T exchanger outlet wasn t allowed due to stack limit setting DHW plate preheat ON hysteresis was invalid Delta T inlet outlet limit was exceeded DHW plate preheat OFF hysteresis was invalid Delta T exchanger outlet limit was exceeded Tap detect degrees was out of range Delta T inlet exchanger limit wa
23. which changes to unlocked on the page The installer may begin to change safety parameters or any other parameters at that time See Figure 29 If the Burner Control is in an unconfigured or new state then this warning doesn t appear All parameters that need changes should be changed during the login Boiler 1 Safety Parameter Verification A fam Ki ILE FIGURE 29 EDIT SAFETY DATA If the safety configuration session is terminated after it has started in the Edit or Verify stages the Burner Control is left in an unconfigured unrunnable state The installer can terminate the session by pressing the Menu button or by attempting to leave the Verification page with the Home or Back buttons top left and right screen corners respectively However leaving the session at this point leaves the control in an unrunnable state and confirms whether the installer still wants to do so The settings of all parameters in each safety block must be verified to save them in the control When the installer is done changing safety parameters pressing the Verify button on the configuration screen begins the Verification process The settings for all safety parameters in each changed block are presented and Verified by the installer see Figure 24 Holler 1 Safety Parameter Verification VE 1 ILE FIGURE 30 SAFETY PARAMETER CONFIRMATION Press the Yes button to confirm each safety parameter blo
24. 0 J10 terminal 7 sensor was invalid LagParameterenors n 39 No Lead Lag add stage method was specified No Lead Lag drop stage method was specified 219 Using backup lead lag header sensor due to sensor failure Frost Protection Fas 227 DHW priority override time was not derated due to invalid outdoor temperature 228 Warm weather shutdown was not checked due to invalid outdoor temperature Lead Lag slave communication timeout RESERVED CODE DESCRIPTION CODE DESCRIPTION Lead Lag CH setpoint was invalid 274 Abnormal Recycle Demand off during Pilot Flame Lead Lag CH time of day setpoint was invalid Establishing Period LL outdoor temperature was invalid 275 Recycle LCI during Drive to Purge ate n Lead Lag ODR time of day setpoint was invalid 276 Abnormal Recycle off during Measured Purge Lead Lag ODR time of day setpoint exceeded Time normal setpoint Abnormal Recycle off during Drive to Lightoff Lead Lag ODR max outdoor temperature was Rate invalid 278 Abnormal Recycle LCI during Pre lgnition test Lead Lag ODR min outdoor temperature was invalid 279 Abnormal Recycle LCI off during Pre Ignition time 238 Lead Lag ODR low water temperature was invalid 260 Abnormal Recycle LCI off during Main Flame Establishing Period Lead Lag ODR outdoor temperature range was ili too small minimum 12 C 22 F Abnormal Recycle LCI off during Ignition period Lead Lag ODR water temperature
25. 00 8 5 9 2 9 3 10 2 3 0 1700 5700 5700 8 5 9 2 9 3 10 2 3 6 2000 4700 4750 8 5 9 2 9 3 10 2 2600 5700 5100 8 5 9 2 9 3 10 2 3400 5700 5700 8 5 9 2 9 3 10 2 LOW FIRING RATE SETTING Set the boiler to the low firing rate by setting the Low Firing Rate RPM as described below Check combustion readings using a combustion analyzer If combustion readings are not in accordance with the chart shown below adjust as follows remove the cap on the gas regulator using a slotted screwdriver This will expose the offset adjustment screw Using a TORX T40 or a 5 mm hex wrench carefully adjust the low fire gas setting to achieve the CO level prescribed in Table 20 Note The rotation of the Low Fire adjustment is opposite of the High Fire as follows Clockwise rotation increases gas flow counterclockwise rotation decreases gas flow Adjustments to the offset pressure regulators should not exceed 1 4 turn at a time before allowing the readings to respond and stabilize After proper low fire offset adjustment is made reinstall the slotted cap on the regulator Following all gas valve adjustments check for proper light off and verify correct fuel air mix and combustion quality throughout the entire firing range from lowest to highest fan speed Note Make sure the Manual Mode is set back to Automatic Mode to each of the burners once the required settings are done Turn off the individual burner before proceeding to t
26. ARNING indicates a potentially hazardous WARNING situation which if not avoided could result in injury or death CAUTION indicates a potentially hazardous pp CAUTION used without the safety alert erp property damage All safety messages will generally tell you about the type of hazard what can happen if you do not follow the safety message and how to avoid the risk of injury The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances known to the State of California to cause cancer birth defects or other reproductive harm and requires businesses to warn of potential exposure to such substances This product contains a chemical known to the State of California to cause cancer birth defects or other reproductive harm This boiler can cause low level exposure to some of the substances listed in the Act IMPORTANT DEFINITIONS Gas Supplier The Natural Gas or Propane Utility or service who supplies gas for utilization by the gas burning appliances within this application The gas supplier typically has responsibility for the inspection and code approval of gas piping up to and including the Natural Gas meter or Propane storage tank of a building Many gas suppliers also offer service and inspection of appliances within the building APPROVALS A ore At CERTIFIED www ahridirectory org CERTIFIED GENERAL SAFETY AWARNING DANGER
27. DOWN OF BURNER CONTROL FUNCTIONS Safety Shutdown Lockout occurs if any of the following occur during the indicated period INITIATE PERIOD line power errors occurred Four minute INITIATE period has been exceeded STANDBY PERIOD Flame signal is present after 240 seconds Preignition Interlock is open an accumulative time of 30 seconds Interlock Start check feature is enabled and the Interlock String including Airflow Switch is closed for 120 seconds with the controller closed jumpered or welded Interlock Main Valve Terminal is energized Internal system fault occurred PREPURGE PERIOD Preignition Interlock opens anytime during PREPURGE period Flame signal is detected for 10 seconds accumulated time during PREPURGE Purge Rate Fan RPM or High Fire Switch fails to close within four minutes and fifteen seconds after the firing rate motor is commanded to drive to the high fire position at the start of PREPURGE Light off Rate Fan RPM or Low Fire Switch fails to close within four minutes and fifteen seconds after the firing rate motor is commanded to drive to the low fire position at the end of PREPURGE Lockout Interlock if programmed does not close within 10 seconds Lockout Interlock opens during PREPURGE Pilot Valve terminal is energized Main Valve terminal is energized Internal system fault occurred PRE IGNITION TIME Lockout Interlock opens IAS Purge and I
28. Frequency fluctuations vary 5 57 to 63 Hz e f Demand LCI or Stat interrupt open during the Prepurge Period e After the reset button is pressed or fault is cleared at the displays The Initiate sequence also delays the burner motor from being energized and de energized from an intermittent AC line input or control input If an AC problem exists for more than 240 seconds a lockout will occur HYDRONIC CENTRAL HEATING Start up sequence central heating request system in standby T 2 3 Heat request detected On Setpoint On Hysteresis The CH pump is switched on After a system Safe Start Check the Blower fan is switched on after a dynamic ILK switch test if enabled After the ILK switch is closed and the purge rate proving fan RPM is achieved or High Fire Switch is closed prepurge time is started When the purge time is complete the purge fan RPM is changed to the Lightoff Rate or if used the damper motor is driven to the Low Fire Position As soon as the fan rpm is equal to the light off rpm or the Low Fire Switch closes the Trial for Ignition or Pre lgnition Time is started Pre Ignition Time will energize the ignitor and check for flame Trial for Ignition Specifics for timings and device actions are defined by the OEM or installer The ignition and the gas valve are switched on 10 The ignition is turned off at the end of the direct burner ignition period or for a system that doe
29. LLBE MADE ON BEHALF OFTHE WARRANTOR WITH RESPECTTO THE MERCHANTABILITY OF THE BOILER ORTHE INSTALLATION OPERATION REPAIR OR REPLACEMENT OF THE BOILER THE WARRANTOR Should NOTBE RESPONSIBLE FOR WATER DAMAGE LOSS OF USE OFTHE UNIT INCONVENIENCE LOSS OR DAMAGETO PERSONAL PROPERTY OR OTHER CONSEQUENTIAL DAMAGE THE WARRANTOR Should NOT BE LIABLE BY VIRTUE OF THIS WARRANTY OR OTHERWISE FOR DAMAGE TO ANY PERSONS OR PROPERTY WHETHER DIRECT OR INDIRECT AND WHETHER ARISING IN CONTRACT OR TORT a Some states and provinces do not allow the exclusion or limitation of the incidental or consequential damage so the abov mitations or exclusions may not apply to you b This warranty gives you specif c legal rights and you may also have other rights which vary from state to state or province to province Fill in the following for your own reference Keep it Registration is not a condition of warranty The model and serial number are found on the boiler s rating plate Owner Installation Address City and State Zip Code Date Installed Model No Serial No Dealer s Name Phone No Dealer s Address FILL IN WARRANTY AND KEEP FOR FUTURE REFERENCE 49 fe Smith 25589 Highway 1 McBee SC 29101 Technical Support 800 527 1953 Parts 800 433 2545 Fax 800 644 9306 www hotwater com
30. P AND OPERATIONS IMPORTANT Only anA O Smith Certified Start up Agent must perform the initial firing of the boiler At this time the user should not hesitate to ask the start up agent any questions regarding the operation and maintenance of the unit If you still have questions please contact the factory or your local A O Smith representative Contact Technical Support noted on the back cover for the name of your closest Certified Start Up Agent Lighting and Operating instructions are included with this manual By using these instructions the user may be able to make minor Operational adjustments and save unnecessary service calls However the user should not attempt repairs but should contact a service technician or gas supplier GENERAL Never operate the boiler without first making sure the boiler and system are filled with water in addition Make sure a temperature and pressure relief valve is installed in the storage tank for hot water supply installations Make sure that the boiler and system have been purged of air and checked for leaks Also ensure to check the gas piping for leaks before beginning the initial firing of the boiler FILLING AND PURGING OF HEATING BOILER INSTALLATION 1 Fast fill system through bypass until pressure approaches desired system pressure Close bypass valve and permit pressure to be established by the pressure reducing valve 2 Vent all high points in system to purge syste
31. RE CONNECTIONS Take the manifold pressure refer to Table 3 by removing the pipe plug and inserting a suitable 1 8 NPT hose barb for connection to the manometer pressure gauge Upon completion of measurements and adjustments remove the hose barb and replace the pipe plug Check for gas leaks and insure all connections are gas tight see Figure 10 A CAUTION Should overheating occur or the gas supply fail to shut off turn off the gas supply at a location external to the boiler I e main manual gas shutoff valve Light the boiler in accordance with the instructions provided on the label affixed to the boiler s front door on the inside WATER TEMPERATURE REGULATION DANG ER Untempered hotwater can cause severe burns instantly resulting in severe injury or death Children elderly and the physically or mentally disabled are at highest risk for scald injury Feel water before bathing or showering Temperature limiting valves are available Read instruction manual for safe temperature setting HOT WATER CAN SCALD Boilers are intended to produce hot water Water heated to a temperature which will satisfy space heating clothes washing dish washing and other sanitizing needs can scald and permanently injure you upon contact Some people are more likely to be permanently injured by hot water than others These include the elderly children the infirm or physically mentally disabled If anyone using hot wat
32. TING AND OPERATING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE OPERATING A EQUIPPED WITH AN IGNITION DEVICE WHICH AUTOMATICALLY LIGHTS THE BURNER DO NOT TRY TO LIGHT THE BURNER BY HAND BEFORE LIGHTING SMELL ALL AROUND THE APPLIANCE AREA FOR GAS BE SURE TO SMELL NEXT TO THE FLOOR BECAUSE SOME GAS IS HEAVIER THAN AIR AND WILL SETTLE ON THE FLOOR WHAT TO DO IF YOU SMELL GAS DO NOT TRY TO LIGHT ANY APPLIANCE DO NOT TOUCH ANY ELECTRIC SWITCH DO NOT USE ANY PHONE IN YOUR BUILDING IMMEDIATELY CALL YOUR GAS SUPPLIER FROMA NEIGHBOR S PHONE FOLLOW THE GAS SUPPLIER S INSTRUCTIONS IF YOU CAN NOT REACH YOUR GAS SUPPLIER CALL THE FIRE DEPARTMENT GAS FLOW 1 W STOP READ THE SAFETY INFORMATION ABOVE ON THIS LABEL SET SYSTEM TEMPERATURE CONTROLLER TO LOWEST SETTING TURN OFF ELECTRIC POWER TO THE BOILER GLOSE MAIN VALVE TURN MAIN MANUAL GAS VALVE TO OFF OR CLOSED POSITION THE VALVE IS OFF WHEN THE HANDLE IS PERPENDICULAR TO THE GAS FLOW DIRECTION WAIT FIVE 5 MINUTES TO CLEAR OUT ANY GAS THEN SMELL FOR GAS INCLUDING NEAR THE FLOOR IF YOU SMELL GAS STOP FOLLOW B IN THE SAFETY INFORMATION ABOVE ON THIS LABEL IF YOU DO NOT SMELL GAS GO TO THE NEXT STEP SET SYSTEM TEMPERATURE CONTROLLER TOLOWEST C SETTING TURN OFF ELECTRICAL POWER TO BOILER WARNING IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE PER SONAL INJURY OR LOSS OF LIFE
33. User s Manual MODELS XB XW x 1000 1300 1700 A t h 2000 2600 3400 SERIES 100 101 25589 Highway 1 OPERATION MAINTENANCE McBee SC 29101 LIMITED WARRANTY An a CERTIFIED w ahridirectory org WARNING If the information in these instructions is not followed exactly a fire or explosion may result causing property damage personal injury or death Do notstore or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS e Do not try to light any appliance e Do not touch any electrical switch do not use any phone in your building e Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions e f you cannot reach your gas supplier call the fire department AWA RN Installation and service must be Read and understand this manual performed by qualified installer and all Warnings and Cautions within before installing and using service agency or the gas supplier Place these instructions adjacent i to boiler and notify owner to keep Thank you for buying this energy efficient boiler for future reference We appreciate your confidence in our products PRINTED IN THE U S A 0811 320820 001 TABLE OF CONTENTS TABLE OF CONT ENTS rasesscroscecatcstucenneseiceanrectacsaamanenaensacdocepnatenexeneniens 2 Installation Instructions S7999B OI Display
34. XCEPTIONS This warranty should apply only when the boiler is installed in accordance with local plumbing and building codes ordinances and regulations the printed instructions provided with it and good industry practices In addition a pressure relief valve certi fed by C S A and approved by the American Society of Mechanical Engineers must have been installed and fresh water used for f lling and make up purposes a This warranty should apply only when the boiler is used 1 with outlet water temperatures not exceeding the maximum setting of its operative and or high limit control 2 at water pressure not exceeding the working pressure shown on the boiler 3 when flled with boiler water free to circulate at all times and with the heat exchanger free of damaging scale deposits 4 in a non corrosive and non contaminated atmosphere 5 in the United States its territories or possessions and Canada 6 ata water velocity f ow rate not exceeding or below the boiler s designed rates 7 indoor installation only b Any accident to the boiler any misuse abuse including freezing or alteration of it any operation of it in a modif ed form or any attempt to repair leaks in the heat exchanger will void this warranty 3 SERVICE AND REPAIR EXPENSE Under this limited warranty the warrantor will provide only a replacement part The owner is responsible for all other costs Such costs may include but are not limited to a Labor charges for servic
35. all digital I O data FIGURE 40 DIAGNOSTICS PAGE DIGITAL I O The control analog I O can also be viewed on the OI Display A snapshot of the diagnostic status is displayed and updated as it changes in the control The analog I O data is displayed as bar charts with I O level represented the I O range see Figure 41 Analog that is not enabled for the installation displays a blank I O level Not all analog I O can be displayed at the same time on the page so a horizontal scroll bar is used to move the view left and right to show all analog status Roller 1 Status FIGURE 41 DIAGNOSTIC PAGE ANALOG I O 27 SYSTEM CONFIGURATION S7999B OI DISPLAY ONLY The OI Display has some functions related to general configuration for the control in the end user installation Pressing the Display Refresh button invokes a search procedure see Figure 42 A new R7910A Hydronic Control or R7911 Steam Control is identified by Unknown status next to its name in the boiler system list see Figure 43 Unknown indicates that configuration data has not been retrieved from the control yet System Configuration FIGURE 42 SYSTEM REFRESH gt sen n istem Configuration 15 01 Boiler 1 Slave FIGURE 43 SYSTEM CONFIGURATION PAGE The control connected to the Modbus network is indicated to the user after the search procedure has concluded Once the control is locate
36. ameter errors continued IAS open step rate was invalid Steam setpoint source parameter was invalid MIX max modulation rate was invalid vs RPM 151 Minimum water temperature parameter was 113 MIX max modulation rate was gt absolute max or lt greater than setpoint absolute min rates 38 CODE DESCRIPTION CODE DESCRIPTION Minimum water temperature parameter was greater than time of day setpoint 153 Minimum pressure parameter was greater than setpoint 154 Minimum pressure parameter was greater than time of day setpoint CH modulation rate source parameter was invalid Steam modulation rate source parameter was invalid DHW modulation sensor was not compatible for AUTO mode Operation Fauts SSS 195 Lead Lag backup modulation sensor setting was invalid when Remote Stat is enabled Lead Lag Operation Faus Program Module installed Incompatible Lead Lag slave was discovered No base load rate was set for Lead Lag slave 213 Lead Lag slave unable to fire before demand to fire delay expired 214 Adding Lead Lag slave aborted due to add requirement change No Lead Lag slaves available to service demand 176 DHW sensor type was not compatible for AUTO 216 No Lead Lag active service was set due to mode demand priority conflicts DHW priority source setting was invalid DHW priority method setting was invalid CH Operation Faults continued CH 5 J8 terminal 11 sensor was invalid CH 1
37. and Rate interval time was Establishing Period valid uM bi dera Main Valve off after 10 364 Internal error Factory calibration parameter for p modulation was invalid Recycle Pilot Valve off after 10 seconds Inns En CH BID BE es ala Abnormal Recycle Safety Relay off after 10 Internal error CH PID I scaler was invalid seconds of RUN Internal error CH PID D scaler was invalid 324 Abnormal Recycle Hardware flame bias Internal error DHW PID P scaler was invalid x Abnormal Recycle Hardware static flame Internal error DHW PID I scaler was invalid Abnormal Recycle Hardware flame current invalid Internal error DHW PID D scaler was invalid 373 Internal error Lead Lag master PID D scaler was P L PID Decr 332 Abnormal Recycle Hardware SLO flame bias ange Abnormal Recycle Hardware flame bias low Abnormal Recycle Hardware SLO flame bias heat Abnormal Recycle Hardware flame bias delta high 378 Abnormal Recycle Hardware flame bias dynamic 576 Revie Hardware fame bias dynamic 41 461 Abnormal Recycle Demand lost in run from application 462 Abnormal Recycle Demand lost in run due to high limit 463 Abnormal Recycle Demand lost in run due to no flame 464 LCI lost in Combustion Pressure Establishing Period 465 LCI lost in Combustion Pressure Stabilization Period RESERVED ann Internal Data Faults 467 Internal error EEPROM write was attempted before EEPROM
38. are 20 mismatch Abnormal Recycle ILK off during Pre Ignition test Abnormal Recycle Hardware VSNSR A2D Abnormal Recycle ILK off during Pre Ignition time Abnormal Recycle Hardware 28V A2D Establishing Period 347 Abnormal Recycle Hardware HFS IAS shorted Abnormal Recycle ILK off during Ignition period Abnormal Recycle Hardware PII INTLK shorted weer Abnormal Recycle Hardware HFS LCI shorted 311 Run was terminated due to interrupted air flow Abnormal Recycle Hardware HFS LFS shorted switch was off Abnormal Recycle Invalid zero crossing Stuck reset switch Abnormal Recycle fault stack sensor Run was terminated due to fan failure Abnormal Recycle stack limit 314 Abnormal Recycle Fan failed during Drive to Abnormal Recycle delta T limit Purge Rate Abnormal Recycle fault outlet sensor 315 cae d Fan failed during Measured Abnormal Recycle outlet high limit 357 Abnormal Recycle fault DHW sensor Abnormal Recycle Fan failed during Drive to 37 _ Lightoff Rate Abnormal Recycle DHW high limit Abnormal Recycle Fan failed during Pre lgnition Abnormal Recycle fault inlet sensor test Abnormal Recycle Check Parameters Failed m Abnormal Recycle Fan failed during Pre lgnition Internal Errors 361 Internal error No factory parameters were Abnormal Recycle Fan failed during Ignition detected in control pornoa Internal error PID iteration frequency was invalid Ses cnm REC e 363 Internal error Dem
39. ata synchronization no timestamps are assigned since the times that the lockouts occurred are unknown All new lockouts that occur after the synchronization are assigned timestamps 25 Boiler 1 Annunciation FIGURE 36 CONTROL EXPANDED ALERT DETAIL FIGURE 38 PROGRAMMABLE ANNUNCIATION OPERATION BUTTON The operation button displays the Burner Control running Boller 1 operation including setpoint and firing rate values From this WF Annunciation the user can change setpoints manually control the boiler s firing rate manually turn pumps on view annunciation information and switch between hydronic heating loops Central Heat and Domestic Hot Water as shown in Figure 37 If a password is required to change any of the settings on this page the user can press the Login button to enter the password Annunciation information is shown in Figure 38 and Figure39 Boller 1 Central Heat FIGURE 39 FIXED ANNUNCIATION FIGURE 37 HYDRONIC OPERATION PAGE 26 DIAGNOSTICS BUTTON The Diagnostics button displays analog and digital I O status of the Burner Control A snapshot of the diagnostic status is displayed and updated once per second as it changes in the control The digital data is displayed as LEDs that are either on green off red See Figure 40 Not all digital I O can be displayed at the same time on the page so a horizontal scroll bar is used to move the view left and right to show
40. aults 80 Fan pulses per evolution was invalid Fan PWM frequency was invalid bird rate was gt CH modulati 82 83 RESERVED 121 Modulation commanded rate was gt DHW max Modulation Parameter Errors modulation rate Lead Lag CH 4 20 mA water temperature setting 122 Modulation commanded rate was lt min No Lead Lag add stage error threshold was modulation rate configured Modulation rate was limited due to outlet limit jal No Lead Lag add stage detection time was Modulation rate was limited due to Delta T limit configured No Lead d t Modulation rate was limited due to stack limit o Lead Lag drop stage error threshold was a configured 5 Modulation rate was limited due to anticondensation No Lead Lag drop stage detection time was configured Fan Speed out of range in RUN 89 RESERVED Modulation rate was limited due to IAS was open 90 Modulation output type was invalid Slow start ramp setting of zero will result in no modulation rate change Firing rate control parameter was invalid 3 chearr n 96 start was ended due to outlet sensor fault 2 CH max modulation rate was invalid vs RPM Kan CH M an range max minus min was too ih max modulation rate was invalid vs RPM DHW max modulation rate was absolute max 103 range max minus min was too Min modulation rate was invalid vs RPM CHOperationFauis Manual rate was invalid vs RPM Par
41. ck If the No button is selected the safety parameter block remains unconfirmed and the Configuration menu page is displayed The control remains in an unconfigured state in this case After all safety parameter blocks have been confirmed the installer is asked to press and hold the Reset button on the Burner Control to complete the safety verification session see Figure 31 PF Safety Parameter FIGURE 31 SAFETY PARAMETER RESET When the Reset button is pressed and held for 3 seconds the confirmed safety parameters are saved in the control The above Reset dialog box automatically closes when this step is completed If this step is not performed the control remains in a safety lockout state until the installer resolves the unverified safety parameters FAULT ALARM HANDLING Each Burner Control reports to the OI display when a safety lockout or an Alert occurs 24 Safety lockouts are indicated on each configuration page as an alarm bell symbol At the status page for S7999B the History button turns red If the S7999B is displaying the system status icons the control in alarm will turn red The lockout history can be displayed by pressing on the History button The state information about each lockout is displayed along with the date time that the lockout occurred refer to Table 6 Current date time stamp is a display setup feature NOTE In the event of a power interruption the date time must be rese
42. d The user is not required to enter a configuration password for a parameter that has a lower access level than the access level achieved by an earlier password entry for any configuration group as long as the user stays in the configuration pages The user only needs to enter a password once until a parameter that has a higher access level is selected Boller 1 Central Heat Configuration H nabled Sensor ony Outlet sensor OF 1 i T L A B mi ac 4 s dm 1 o11 nySteresis FIGURE 25 LOGIN REQUIRED 22 KEYBOARD Some pages request user entry of characters When this type of input is required a keyboard page appears as shown in Figure 26 The text box at the top of the screen displays the current or default setting of the user input The user can add to this text clear it or change it The Shift key on the left side of the screen shifts between upper and lowercase characters Pressing the Shift key toggles the keyboard from one mode to the other continuous pressing of the Shift button is not required The OK button should be pressed when the user is done entering the text input The Cancel button on the bottom of the screen allows the user to ignore any text changes that have been made and keep the original text value Pressing the OK or Cancel buttons returns the user to the page displayed prior to the keyboard page LOGIN Pressi
43. d it must be synchronized with the Ol Display before it can be displayed New controls are not displayed on the Home page until this synchronization is performed SYSTEM SYNCHRONIZATION S7999B DISPLAY ONLY The user can manually synchronize configuration data from the connected controls at any time A new control is visible when configuration and status data is gathered from it This collection procedure takes a few minutes The control is marked as Unknown when no configuration information exists Normally control configuration data collection only needs to be performed when the control is initially installed However a re synchronization is necessary after the OI Display is reset See Figure 44 The user presses the Synchronize button to begin synchronization with the control See Figure 44 System Co Our ati On FIGURE 44 SYSTEM SYNCHRONIZATION Status of the synchronization is reflected in the dialog box The synchronization can be aborted by selecting the Cancel button 28 CONFIGURATION The Burner Control can be configured from the OI Display The control configuration is grouped into the functional groups as shown in Table 8 TABEL 8 FUNCTIONAL CONFIGURATION GROUPS HYDRONIC CONTROL Access Lead Lag Master Configuration Burner Control Ignition Burner Control Flame Failure Most of this configuration is performed by the Service Agent or at A O Smith Each functional group is di
44. ded by the R7910A1138 include automatic boiler sequencing flame supervision system status indication firing rate control load control CH DHW control limit control system or self diagnostics and troubleshooting The R7910 maximum version of the controller offers 1 NTC temperature sensor for Outlet Limit And Temperature DHW Domestic Hot Water Limit and Temperature Stack Temperature Limit and Temperature Inlet Temperature Outdoor Temperature R7910 only Modulating output PWM driven rotation speed controlled DC fan for optimal modulation control Three Pump Outputs with 5 selectable operation modes 24VAC Output control of gas valve Pilot and Main and External Ignition Transformer Digital inputs for room limit control high limit control Air pressure switch Gas pressure switch low water cutoff valve proof of closure switch Optional external spark transformer Optional combined ignition and flame sensing Test jacks for flame signal measurement from either a flame rod or UV flame sensor Alarm Output OUTDOOR FLAME SIGNAL INTERLOCK S PII LIMIT S ANNUNCIATION 8 O REMOTE RESET IGNITOR BOILER PILOT VALVE gt lt MAIN VALVE S TOD STAT CH LOOP BUILDING AUTOMATION SYSTEM KEY 4 COMMUNICATION INPUTS ss LOCAL DISPLAY oo SYSTEM DISPLAY OUTPUTS WATER FIGURE 16 GENERAL R7910A1138 BOILER SCHEMATIC The ab
45. dsheet Audible Alarm COM 2 Modbus port for Building Automation System applications LED indicators e Power e Network e 2 e COM 1 Model used e 5799981067 has Black Border e Allows for commissioning Locates attached boiler s e Allows boiler naming e Color 3 5 in x 4 625 in 5 7 in diagonal user interface display e Graphic user interface e Touch screen e Communication between the Displays and the Burner Control Systems uses Modbus e Flush mounting e ouch screen disable for screen cleaning e 12 VDC power supply included e Screen saver e Contrast control e Volume control SPECIFICATIONS 1 Electrical Ratings 12 VDC input maximum of 500 mA current drain Included Power Supply for S7999B Inputs 85 to 264 VAC 47 to 63 Hz 120 to 370 VDC Output 12 VDC 0 to 2 1 A Power 25 W 2 Operating Temperature 32 to 122 F 0 C to 50 3 Storage Shipping Temperature 40 F to 158 F 40 C to 70 4 Humidity 85 maximum relative humidity 5 Approvals FCC Part 15 Class A Digital Device Underwriter s Laboratories Inc UL Component Recognized for non continuous operation File Number MH20613 MCCZ Canada ICES 003 INSTALLATION INSTRUCTIONS S7999B DISPLAY MOUNTING THE 7999 OI DISPLAY AND POWER SUPPLY The OI Display can be mounted on the door panel of an electrical enclosure 1 Select the location on t
46. e removal repair or reinstallation of the component part b Shipping delivery handling and administrative charges for forwarding the replacement part from the nearest distributor ad returning the claimed defec tive part to such distributor C All cost necessary or incidental for any material and or permits required for installation of the replacement 4 LIMITATIONS ON IMPLIED WARRANTIES Implied warranties including any warranty of merchantability imposed on the sale of this boiler under state or provincial law limited to 1 year duration for the boiler or any of its parts Some states and provinces do not allow limitations on how long an implied warrany lasts so the above limitation may not apply to you 5 CLAIM PROCEDURE Any claim under this warranty should be initiated with the dealer who sold the boiler or with any other dealer handling the w arrantor s products If this is not practicable the owner should contact U S Customers Canadian Customers A O Smith Corporation A O Smith Enterprises Ltd 500 Tennessee Waltz Parkway 599 Hill Street West Ashland City TN 37015 Fergus N1M 2X1 Telephone 800 527 1953 Telephone 1 888 479 8324 a The warrantor will only honor replacement with identical or similar parts thereof which are manufactured or distributed by the warrantor b Dealer replacements are made subject to in warranty validation by warrantor 6 DISCLAIMERS NO OTHER EXPRESS WARRANTY HAS BEEN OR WI
47. e Sensor is 4 20 ma source Check wiring and correct any possible errors Test Pressure Sensor for correct operation Replace the Pressure sensor If previous steps are correct and fault persists replace the module 105 Flame detected out of sequence Check that flame is not present in the combustion H or L chamber Correct any errors Make sure that the flame detector is wired to the correct terminal Make sure the F amp wires are protected from stray noise pickup Reset and sequence the module if code reappears replace the flame detector Reset and sequence the module if code reappears replace the module Flame lost in MFEP Check pilot valve Main Valve for DSI wiring and 107 lost early i operation correct any errors ro Check the fuel supply 108 Flame lost in run Check fuel pressure and repeat turndown tests 109 Ignition failed Check ignition transformer electrode flame detector flame detector siting or flame rod L position If steps 1 through 4 are correct and the fault persists replace the module 110 Ignition failure occurred Hold time of recycle and hold option Will not be a H lockout fault Hold Only H 111 Flame current lower than WEAK threshold Internal hardware test Not a lockout 112 Pilot test flame timeout Interrupted Pilot or DSI application and flame lost L when system in test mode 1 Reset the module to restart 113 Flame circuit timeout Flame sensed d
48. e test failed Soe 296 Abnormal Recycle Interrupted air flow switch was DHW setpoint was invalid off during Drive to Purge Rate 262 DHW time of day setpoint was invalid 297 Abnormal Recycle Interrupted air flow switch was DHW storage setpoint was invalid off during Measured Purge Time STAT may not be a DHW demand source when Abnormal Recycle Interrupted air flow switch was Remote Stat is enabled off during Drive to Lightoff Rate 265 266 RESERVED Abnormal Recycle Interrupted air flow switch was 267 STAT may not be a CH demand source when or dang 55 Remote Stat is enabled Abnormal Recycle Interrupted air flow switch was CH 4mA water temperature setting was invalid Tae tne 301 Abnormal Recycle Interrupted air flow switch was CH 20mA water temperature ne was off during Main Flame Establishing Period Steam 4mA water temperature setting was invalid 302 failed dU TO Steam 20mA water temperature setting was invalid interrupted air flow switch was off Abnormal Recycle Pressure sensor fault 303 Abnormal Recycle ILK off during Drive to Purge Abnormal Recycle Safety relay drive test failed Rate 40 CODE DESCRIPTION CODE DESCRIPTION 304 Abnormal Recycle ILK off during Measured Purge Abnormal Recycle Hardware SLO electronics Time Abnormal Recycle Hardware processor clock 305 Abnormal Recycle ILK off during Drive to Lightoff 343 Abnormal Recycle Hardware AC phase see 343 yc p Abnormal Recycle Hardw
49. ended BP ames o setup and instructions before lighting period of non use E y ki z e Failure to implement the proper setup will AM result in improper and inefficient operation 45 of the appliance resulting in production of Read instruction manual before Ass increased levels of carbon monoxide gas installing using or servicing 4 in excess of the safe limits which could result in serious personal injury or death Breathing carbon monoxide can cause brain damage death Always read and understand instruction manual AWARNING CAUTION isi Improper installation and use may result risk of fire in property damage Do not install boiler on Donotoperate boiler ifflood damaged carpeted floor Installin location with drainage e Fill boiler with water before operation e Do not operate boiler if flood e Bealertforthermal expansion damaged Refer to instruction manual for installation and service INTRODUCTION This Instruction Manual covers XP Boiler models XB XW 1000 1300 1700 2000 2600 3400 Series 100 101 The instructions and illustrations contained in this Instruction manual will provide you with troubleshooting procedures to diagnose and repair common problems and verify proper operation MODEL IDENTIFICATION Check the rating plate affixed to the Boiler The following information describes the model number structure SERIES 100 101 DESIGNATION e XP
50. er in your home fits into one of theses groups or if there is a local code or state law requiring a specific temperature water at the hot water tap then you must take special precautions In addition to using the lowest possible temperature setting that satisfies your hot water needs a means such as a mixing valve should be used at the hot water taps used by these people or at the hot water supply tank Mixing valves are available at plumbing supply or hardware stores Follow the manufacturer s instructions for installation of the valves Before changing the thermostat setting on the hot water system controller see Table 1 Hot water temperatures required for automatic dishwasher and laundry use can cause scald burns resulting in serious personal injury and or death The temperature at which injury occurs varies with the person s age and time of exposure The slower response time of children aged or disabled persons increases the hazards to them Never allow small children to use a hot water tap or to draw their own bath water Never leave a child or disabled person unattended in a bathtub or shower The boiler should be located in an area that is inaccessible to the general public TABLE 1 RISK OF SCALDS Time to Produce 2nd amp 3rd Degree Burns on Adult Skin 180 F 82 Nearly instantaneous 170 77 Nearly instantaneous Water Temperature Should overheating occur or the gas supply fail to shut off turn off the
51. es ability equivalent to that of a Qualified Agency as defined by ANSI below In the field involved Installation skills such as plumbing air supply venting gas supply and electrical supply are required in addition to electrical testing skills when performing service ANSI Z21 13 CSA 4 9 Qualified Agency Any individual firm corporation or company that either in person or through a representative is engaged in and is responsible for a the installation testing or replacement of gas piping or b the connection installation testing repair or servicing of appliances and equipment that is experienced in such work that is familiar with all precautions required and that has complied with all the requirements of the authority having jurisdiction If you are not qualified as defined by ANSI above and licensed or certified as required by the authority having jurisdiction to perform a given task do not attempt to perform any of the procedures described in this manual If you do not understand the instructions given in this manual do not attempt to perform any procedures outlined in this manual This product requires a formal Start Up by an authorized service start up provider that has been approved by the manufacturer for this specific product Call 1 800 527 1953 to locate the nearest authorized start up provider and arrange a factory start up Please provide as much notice as possible preferably 2 weeks Please have the model a
52. es between the 9 pin connector and the controller are properly wired and secure WARNING Electrical Shock Hazard Can cause severe injury death or equipment damage Line voltage is present at the 120 VAC power supply 3 Make sure the power supply is connected securely to the 120 VAC power source STARTING UP THE 7999 OI DISPLAY POWER UP VALIDATION The Home page will appear and the Power LED will be blinking when the device is properly powered Select the Setup button to adjust the contrast and sound as desired If the screen is dim check the pin 1 and 2 wiring connections NOTE An Advanced Startup screen displays for five seconds after power up before the Home page displays This screen allows the user to upgrade the software in the System Display and should normally be bypassed Three LEDs exist for traffic one for the Ethernet network port and two for Modbus ports Modbus Com Port 2 is not active on this device 1 Make sure the Power and 1 LEDs are blinking 2 Ifthe LEDs are not blinking Make sure the proper connections have been made between the Modbus COM Port and the first controller device in the Modbus network e Ensure proper wiring of the Ol Display 9 pin Header Connections If connected to a BAS application COM2 LED will blink indicating BAS traffic HOME PAGE S7999B OI DISPLAY Make sure a screen similar to Figure 19 appears after the OI Display has completely powered up 3
53. esulting in death There must be sufficient load to operate the boiler at high fire to perform the following adjustments Start the boiler and observe proper operating parameters for the system Required Tools e TORX T40 or 5 mm hex wrench mm or 7 64 inch hex wrench e Combustion analyzer These boilers are equipped with a combined gas air control and gas safety shut off control valves The valve functions in parallel with the variable speed combustion blower to supply the correct gas air ratio for optimum performance and efficiency The combustion blower speed is controlled automatically and determines the amount of negative pressure experienced by the gas safety shut off control valves The gas air regulator adjusts gas flow to maintain the proper pressure at the outlet nozzle of the associated valve SETTING OF THE TEST MODE On the Burner Home screen select any individual boiler which will guide to Burner Information screen 155F LOU B ww LEAD LAG mbH TRAY AN TH Hr boe ebb Matant ae k FIGURE 11 BURNER HOME SCREEN Boiler 1 FIGURE 12 BURNER INFORMATION SCREEN Click on Operation button and under the Modulation Menu set the required Firing rate High Low by setting the RPM Baller 1 Central Heat FIGURE 13 OPERATION SCREEN On the Firing Rate page set the Firing rate RPM by selecting the Manual in Run check box F ills lingid 2000 RPM
54. failed during ignition Change the VFD Fan movement detected during standby Ifthe fault persists replace the module Fan speed failed during run 136 Interrupted Airflow Switch failed to close Check wiring and correct any possible wiring errors Check Interrupted Airflow switch es to assure proper function Verify voltage through the airflow switch to the IAS input with a voltmeter If steps 1 3 are correct and the fault persists replace the module ILK failed to close Check wiring and correct any possible shorts Check Interlock ILK switches to assure proper function Verify voltage through the interlock string to the interlock input with a voltmeter If steps 1 3 are correct and the fault persists replace the module 138 142 IRESERVED RESERVED nn Jo NE FAULT CODES 149 THROUGH 165 ARE OEM SPECIFIC FAULT CODES 143 mtemalfautlametiascutotramge Contacrhesemiceproessona 144 intemal fault Flame bias out ofrange2 Contact the service professional 145 intemal faut Flame bias out ofrange 3 Contact the service professional _ 149 Flame detected OEM Specific HorL HorL HorL HorL HorL 1 Holds if flame detected during Safe Start check up to Flame Establishing period 33 CODE DESCRIPTION RECOMMENDED TROUBLESHOOTING OF NOTE LOCKOUT CODES Flame not detected OEM Specific 1 Sequence returns to standby and restarts sequence at the beginning of Purge after the HF
55. gnition enabled and the Interlock opens Preignition Interlock opens Pilot Valve terminal is energized Main Valve terminal is energized PILOT FLAME ESTABLISHING PERIOD PFEP Lockout Interlock opens if enabled Pilot Valve terminal is not energized No flame is present at the end of the PFEP or after programmed number of retry attempts Main valve terminal is energized Internal system fault occurred D aoo A zma Q MAIN FLAME ESTABLISHING PERIOD Lockout Interlock opens if enabled Pilot valve terminal is not energized Main valve terminal is not energized No flame present at the end of MFEP Internal system fault occurred RUN PERIOD No flame is present or flame is lost if enabled lockout Lockout Interlock opens if enabled IAS Purge and Ignition enabled and the Interlock opens Pilot terminal energized if programmed as Interrupted Pilot Main valve terminal is not energized Internal system fault occurred POSTPURGE PERIOD Preignition Interlock does not close in five seconds Pilot Valve terminal is energized Main Valve terminal is energized Internal system fault occurred Flame sensed 240 seconds accumulated time after the RUN period o SAFETY SHUTDOWN 1 If the lockout interlocks open or a sensor designated as a safety limit are read as defective Con
56. hat boiler area is free of any combustible materials gasoline and other flammable vapors and liquids 2 Verify that air intake area is free of any of the contaminants If any of these are present in the boiler intake air vicinity they must be removed If they cannot be removed reinstall the air and vent lines per this manual Inspect boiler interior 1 Remove the front access cover and inspect the interior of the boiler 2 Vacuumany sediment from inside the boiler and components Remove any obstructions GENERAL MAINTENANCE This is a pre mix burner system The flame is not supposed to be directly on the burner The flame should be just above the burner deck approximately 1 8 and blue in color see Figure 46 NORMAL BURNER FLAME ABNORMAL BURNER FLAME FIGURE 45 BURNER FLAMES Visually check flame characteristics through the view port located on the top head of the boiler Figure 45 shows the normal flame condition These boilers are designed to give many years of efficient and satisfactory service when properly operated and maintained To assure continued good performance the following recommendations are made The area around the unit should be kept clean and free from lint and debris Sweeping the floor around the boiler should be done carefully This will reduce the dust and dirt which may enter the burner and heat exchanger causing improper combustion and sooting MAIN BURNER Check main burner every three mont
57. he door panel to mount the display note that the device will extend into the enclosure at least one inch past the mounting surface 2 Provide an opening in the panel door 8 1 8 in wide by 5 7 8 in high 3 Place the OI Display in the opening and use it as a template to mark the location of the four mounting screw holes Remove the device 4 Using pilot holes as guides drill 1 4 in holes through the door panel 5 Place the display in the opening aligning the mounting holes in the device with the drilled holes in the panel 6 Secure the display to the panel with four 6 32 screws and nuts provided 7 Select a location inside the enclosure for mounting the power supply 8 Using the power supply as a template mark the locations of the two mounting holes in the enclosure 9 Remove the power supply 10 Drill 1 4 in holes through the panel at the marked locations and secure the power supply with the two 6 32 screws and nuts provided 11 Remove the 9 pin connector plug from the back of the Ol Display 12 Wire the connector to the power supply and the RS 485 cables 13 Ensure the 9 pin connector plug is aligned with the header pins when inserting the 9 pin connector plug back onto the Display Secure firmly COMMON FIGURE 18 S7999B OI DISPLAY CONNECTOR TERMINALS QUICK SETUP S7999B Ol DISPLAY 1 Make sure the S7999B 9 pin connector is properly aligned and pressed firmly in place 2 Make sure the wir
58. he next burner settings TABLE 5 LOW FIRE RATE RPM MANIFOLD PRESSURE APPROXIMATE FACTORY SET INCHES W C MODELS XB XW NATURAL PROPANE NATURAL PROPANE NATURALGAS PROPANE GAS GAS 1000 920 000 1650 1540 7 3 8 2 8 4 8 8 NOTE Values listed in Table 19 and Table 20 are tested under laboratory conditions with minimum vent length Values may slightly vary depending on ambient conditions and field equipment accuracy CONTROL SYSTEM BURNER CONTROL SYSTEM FIGURE 15 R7910A1138 CONTROL SYSTEM The R7910A1138 is a burner control system that provide heat control flame supervision circulation pump control fan control boiler control sequencing and electric ignition function It will also provide boiler status and error reporting Multiple boilers can be joined together to heat a system instead of a single larger burner or boiler Using boilers in parallel is more efficient costs less reduces emissions improves load control and is more flexible than the traditional large boiler Control System consists of R7910A1138 Control Device S7999B Touchscreen Display required for setup and ModBus communication but not required for the system to operate once the R7910A1138 is programmed S7910A Local Keyboard Display Module Flame Rod Temperature Sensor NTC Type 10 at 77 25 or 12KQ at 77 F 25 Limit Sensor NTC Type 10KQ at 77 F 25 24V Digital I O OVERVIEW Functions provi
59. hs for proper flame characteristics The main burner should display the following characteristics Provide complete combustion of gas Cause rapid ignition and carry over of flame across entire burner Give reasonably quiet operation during initial ignition operation and extinction Cause no excessive lifting of flame from burner ports If the preceding burner characteristics are not evident check for accumulation of lint or other foreign material that restricts or blocks the air openings to the burner or boiler To check burners 1 Shut off all gas and electricity to unit Allow unit to cool Remove main burners from unit 2 3 Check that burner ports are free of foreign matter 4 Clean burner with vacuum cleaner Do not distort burner ports Reinstall burners in unit Ensure that all the screws on the burner flange are tightened securely so that the gasket will provide a good seal Also check for good flow of combustion and ventilating air to the unit After placing the boiler in operation check the ignition system safety shut off devices for proper operation To accomplish this with the main burner operating close the valve on the manifold Within four seconds the main burners should extinguish If this does not occur immediately discontinue gas supply by closing main manual shut off and call a qualified serviceman to correct the situation If the burners extinguish then light boiler in accordance with lighting and
60. inal wiring and correct any errors 2 Resetand sequence the module If fault persist replace the module 160 Ignition ON OEM Specific 161 Ignition OFF 1 Check Ignition terminal wiring and correct any errors 2 Resetand sequence the module If fault persist replace the module Pilot valve ON OEM Specific 163 Pilot valve OFF 1 Check Pilot Valve terminal wiring and correct any errors ME or L or L L 2 Reset and sequence the module If fault persist replace the module 34 CODE DESCRIPTION RECOMMENDED TROUBLESHOOTING OF NOTE LOCKOUT CODES Block intake ON OEM Specific 165 Block intake OFF Check wiring and correct any errors Inspect the Block Intake Switch to make sure it is working correctly Reset and sequence the module During Standby and Purge measure the voltage across the switch Supply voltage should be present If not the Block Intake Switch is defective and needs replacing If the fault persists replace the relay module TO 2 ffault repeats replace module 1918 RESERVED OOOO S Return to Configuration mode and recheck selected parameters reverify and reset module If fault repeats verify electrical grounding If fault repeats replace module 191 Invalid interrupted air switch start check enable setting Return to Configuration mode and recheck selected parameters reverify and reset module
61. its algorithms but when apportioning rate it may also assign rates that are less than this In fact the add stage and drop stage algorithms may assume this and be defined in terms of theoretical rates that are possibly lower than the actual minimum rate of the Burner Control System A Control System that is firing and is being commanded to fire at less than its minimum modulation rate will operate at its minimum rate this is a standard behavior for a Buner control system in stand alone non slave mode If any slave under LL Master control is in a Run Limited condition then for some algorithms the LL master can apportion to that stage the rate that it is actually firing at Additionally when a slave imposes its own Run limited rate this may trigger the LL Master to add a stage if it needs more capacity or drop a stage if the run limiting is providing too much heat for example if a stage is running at a higher than commanded rate due to anti condensation By adjusting the parameters in an extreme way it is possible to define add stage and drop stage conditions that overlap or even cross over each other Certainly it is incorrect to do this and it would take a very deliberate and non accidental act to accomplish it But there are two points in this 1 LL master does not prevent it and more important 2 It will not confuse the LL master because it is implemented as a state machine that is in only one state at a time For example
62. ixture of safety data and non safety data All parameters within the safety group undergo a verification process A safety parameter group is identified on the display to indicate when the configuration parameters are safety related Each safety parameter group is verified one at a time until all have been verified See Figure 28 SAFETY FLOW SWITCH TEE PADDLE FIGURE 28 SAFETY VERIFICATION Like operating parameters safety parameters can be viewed without the need to enter a password Safety parameter blocks that have been changed require verification The verification steps do not have to be completed immediately the installer can move between and change parameter groups before the verification is done A Verify button is enabled that allows the installer to conduct verification sessions the example of the Verify button in Figure 21 is not yet enabled because the installer hasn t logged in 23 NOTE When the installer proceeds with the safety parameter configuration the control unlocks the safety parameters in this group and marks them unusable Failure to complete the entire safety configuration procedure leaves the control in an un runnable state lockout 2 All safety configuration parameters in the group should have the same access level If this condition isn t so the user is asked to enter another password when a higher access level is needed Successful login is noted by the lock icon
63. l fault Safety relay test failed due to safety relay OFF 17 Internal fault Safety relay test failed due to safety relay not OFF 18 Internal fault Safety relay test failed due to feedback not ON 23 Internal fault Bias changed since heating cycle starts Internal fault Spark voltage stuck low or high 25 Internal fault Spark voltage changed too much during flame sensing time Internal fault Static flame ripple 27 Internal fault Flame rod shorted to ground detected Internal fault A D linearity test fails Internal fault Flame bias cannot be set in range HorL HorL 29 CODE DESCRIPTION RECOMMENDED TROUBLESHOOTING OF NOTE LOCKOUT CODES 30 Internal fault Flame bias shorted to adjacent pin Internal Fault 31 Internal fault SLO electronics unknown error 1 Reset Module 2 If fault repeats replace module 32 46 Internal fault Safety Key 0 through 14 enn System Errors AT Flame Rod to ground leakage Static flame not flickering 24 VAC voltage low high Check the Module and display connections Check the Module power supply and make sure that both frequency voltage and VA meet the specifications Modulation fault Internal sub system fault 51 Pump fault 1 Review alert messages for possible trends Correct possible problems Lu Motor tachometer fault 2 3 If fault persists replace module AC inputs phase reversed 1 2 Check the Module and display connections Check the Mod
64. lert by alarm condition Alert Code This History dialog box provides an exploded view of the status NOTE The system time be set in the display to ensure information displayed in the History button the font is larger that correct timestamps are given to the controls lockouts and One of the four buttons OK Lockouts Alerts or Silence can alerts Power interruptions will require the time to be reset as the be selected If none of these buttons are selected the dialog box display DOES NOT have a time backup means closes after 30 seconds The Clear Lockout button allows the user to acknowledge and clear reset the lockout when in lockout state much the same Boller 1 f as pressing the reset button on the front of the Burner Control The user can toggle between displaying the controls lockout history and alert log by pressing the Alerts or Lockouts button on the bottom of the pages boiler 1 Alert 32 Program Module PM Alert Loa was removed from socket 1 29 08 12 29 52am 115 Fan was limited to its minimum duty 31 00 29 8 01 29am 64 Burner control rate nonfiring was 281 Abnormal Recycle LCI off during Ic FIGURE 32 EXAMPLE HYDRONIC HISTORY Two types of historical data can be displayed on the history page lockout history and alert log 12 31 The entire 15 fault code history is displayed in a scrollable list Lockou iiit n with the most recent fault displayed first foll
65. m of air Provisions should be made to permit manual venting of radiators or convectors FILLING HOT WATER SUPPLY BOILER INSTALLATION 1 Close the system s drain valve by turning handle clockwise 2 Open a nearby hot water faucet to permit the air to escape 3 Fully open the cold water inlet pipe valve allowing the boiler and piping to be filled 4 Close the hot water faucet as water starts to flow PURGING GAS LINE Gas line purging is required with new piping or systems in which air has entered INLET GAS PRESSURE The inlet gas pressure is measured by removing the 1 8 NPT Plug located on the upstream side of the supply gas valve and insert a 1 8 NPT hose barb fitting to be connected to a manometer or pressure gauge Once pressure has been checked and or adjusted replace the plug and check for leaks The maximum value specified in Table 3 must not be exceeded The minimum values shown in Table 3 must be maintained under both load and no load conditions static and firing conditions The combination gas valves supplied with the boiler are for low pressure service If upstream pressure exceeds 13 0 W C an intermediate gas pressure regulator of the lockup type must be installed BLOWER FLAPPER BURNER MO VENTURI FLEX GAS MANIFOLDS MANUAL SHUT OFF f MODULATING VALVE VALVE P ad e m NS 7 FIGURE 10 GAS TRAIN ASSEMBLY DIFFERENTIAL MANIFOLD PRESSURE TAP MANIFOLD PRESSU
66. n the lines which trap a small amount of condensate and the exit point of the vent collector drain Condensate in portions of the line other than the loop area indicates a blockage in the drain line Flush the lines with air or water and clear or replace the blocked portions of the line as necessary Note that areas of the drain line which include a sag or low spot in the line will also form a condensate trap which can be removed by levelling the tube and does not indicate a blocked system Inspect the metal vent drain and vent collector drain connectors at six month intervals Remove the hoses from the connections then check with a small wooden dowel or plastic rod passed up through the metal connection to insure the passage is clear using caution to not bend or damage the connector Call a qualified service agent to inspect and correct the problem if any obstructions are found in the connectors Replace all hoses and clamps immediately after inspection and before starting the boiler in accordance with the Lighting and Operating Instructions Do not operate the boiler unless all condensate drain lines are properly connected and working When a means to neutralize condensate has been installed you must also follow operating inspection and maintenance procedures specified by the manufacturer of the product Inspect the installed device to insure that it does not cause condensate to remain in the boiler or vent for any reason VENTING MAINTENANCE
67. nd change default allowed parameters This access level is used to customize the control for a particular installation OEM The OEM can read and change all parameters change sensor limits and burner control safety parameters Different passwords exist in the Burner Control for each access level The end user level requires no password but the installer and OEM levels have unique passwords defined for them The installer and OEM passwords can be changed in the Burner Control after logging in with the current password When the password is changed it is saved for all future logins NOTE For the S7999B System OI display each boiler in a multi boiler configuration has its own set of installer and OEM passwords To avoid user confusion the passwords should be changed to the same password in each control but there is no requirement to do so Make sure to record your password The user is notified that a new password is needed to change a parameter or until a password is entered successfully see Figure 25 The user can continue viewing the configuration parameters regardless of whether a password is entered successfully The Burner Controls maintain a password time out that limits the scope of the password entry Once a password is successfully entered the control starts an internal timer that expires after 10 minutes of inactivity After the timer expires the user is required to re enter a password before a parameter can be change
68. nd serial number ready when you call This start up is required to activate the warranty and ensure safe efficient operation Warranty on this product is limited and could be void in the event the unit is not installed per the instructions in this manual and or not started up by an authorized factory trained service start up provider CONTROL COMPONENTS THE CONTROL SYSTEM The R7910A1138 is a burner control system that provides heat control flame supervision circulation pump control fan control boiler control sequencing and electric ignition function It will also provide status and error reporting FIGURE 1 BURNER CONTROL SYSTEM SPARK IGNITER The spark igniter is a device that ignites the main burner When power is supplied to the igniter electrode an electric arc is created between the electrode and the ground terminal which ignites the main burner FIGURE 2 SPARK IGNITER LOW HIGH GAS PRESSURE SWITCH This XP boiler is equipped with a Low Gas Pressure Switch which meets the CSD 1 code requirements The Low Gas Pressure Switch is normally open and remains open unless the pressure falls below the preset pressure The High Gas Pressure Switch is normally closed and is used to detect excessive gas pressure FIGURE 3 LOW HIGH GAS PRESSURE SWITCH GAS VALVE The gas valve is a normally closed servo regulated gas valve The valve opens only when energized by the burner control and closes when the powe
69. ng the Login button allows entering the password from a keyboard as shown in Figure 26 After the password is entered the OK button is selected The Cancel button aborts the password login Login Boiler 1 tar bf nfm Jie shit S Cancel FIGURE 26 DEVICE LOGIN SCREEN WARNING Explosion Hazard Improper configuration can cause fuel buildup and explosion Improper user operation may result in property loss physical injury or death Using the Displays to change parameters must be attempted by only experienced and or licensed burner boiler operators and mechanics CHANGE PARAMETER SETTINGS Change parameter settings by selecting the parameter on the page A dialog box displays for the parameter with controls allowing the user to change the value see Figure 27 After changing the setting to a new value press the OK button Pressing the Cancel button leaves the parameter unchanged The changed setting is reflected on the screen and sent to the control when the OK button is pressed Boiler 1 i CO 100 EL LE LL 5 C Bso FIGURE 27 EXAMPLE OF CHANGE CONFIGURATION PARAMETER PAGE VERIFY Pressing the Verify button displays safety configuration parameters for an additional verification step to commit the changes Safety parameters are grouped into blocks that include only safety parameters not a m
70. on that allows the user to view status information on a system wide that is multiple boiler basis The user can choose which status information to compare from the Burner Controls in the system Pressing the Setup button on the Home page displays miscellaneous setup and diagnostic functions It also contains the setup configuration for BAS applications under the Advanced Setup button Pressing the Control System icon opens that control s status page PAGE NAVIGATION The Burner Control System OI Displays present information and options in a paged manner Pages are displayed in a tree structure in which the user navigates up and down to arrive at the desired Function see Figure 20 The page descriptions are provided below so that you can understand the purpose of each and view the selections parameters and information that is available or required on each COMMON OI DISPLAY PAGE SYMBOLS Most pages have a Home button in the top left corner of the screen and a Back button in the top right corner of the screen The Home button returns the user to the Home page and terminates any operation in progress The Back button returns the user to the previous page Two other icons may be noticed near the boiler name A bell will be displayed if the system is in Lockout that reset will be required A padlock will be shown on screens that require a password to change the parameter An unlocked padlock indicates the password has been entered
71. onfiguration parameters were restored from factory defaults Parameter PCB in Program Module is too large for roduct Invalid Factory Invisibility PCB was detected l 41 Range PCB in Program Module was too large for Invalid Factory Range PCB was detected product 6 Invalid range PCB record has been dropped 42 Alert PCB in Program Module was too large for EEPROM lockout history was initialized product 8 Switched application annunciation data blocks IAS start check was forced on due to IAS enabled 9 Switched application configuration data blocks System Operation Faults Configuration was restored from factory defaults Low voltage was detected in safety processor Backup configuration settings was restored from High line frequency occurred active configuration Low line frequency occurred Annunciation configuration was restored from Invalid subsystem reset request occurred factory defaults ae 48 Write large enumerated Modbus register value 13 Annunciation configuration was restored from Hohallowad backup Maximum cycle count was reached Safety group verification table was restored from defaults Maximum hours count was reached 15 Safety group verification table was updated mE Ilegal Modbus write was attempted Invalid Parameter PCB was detected Modbus write attempt was rejected NOT ALLOWED Invalid Range PCB was detected ann Same ae Illegal Modbus read was attempted stem Parameter Errors 4 Safety processor brown ou
72. or type setting 238 Invalid Stack connector type setting 239 Invalid 2 J8 6 connector type setting 240 Invalid S5 J8 11 connector type setting 242 Invalid DHW auto detect configuration L 241 Exchanger sensor not allowed with stack Not Applicable connector setting 243 Invalid UV with spark interference not compatible Contact the service professional L with Ignitor on throughout PFEP 244 Internal fault Safety relay test invalid state Contact the service professional L 245 Invalid Outlet connector type setting for Trise Contact the service professional L 246 4 20mA cannot be used for both modulation and Contact the service professional L setpoint control 247 Invalid ILK bounce detection enable Not Applicable L 248 Invalid forced recycle interval Not Applicable L 249 STAT cannot be demand source when Remote Not Applicable L Stat is enabled 250 Invalid Fan speed error response 1 Check fan cables secured properly If fault L persists contact the service professional 251 255 6 TABLE 10 ALERTS CODE DESCRIPTION CODE DESCRIPTION EEN EE Management Faults 37 Program Module application parameter revision None No alert differs from application processor Alert PCB was restored from factory defaults 38 Program Module safety parameter revision differs from safety processor 2 Safety configuration parameters were restored from factory defaults 39 PCB incompatible with product contained in Program Module 3 C
73. ove figure shows two loops of heat control Central Heating CH and an optional second loop for Domestic Hot Water DHW can be configured on each R7910A The DHW loop transfers heat from the boiler outlet to hot water appliances conjunction with the primary system heat loop Priority assignment to each heat loop can be configured to specify which loop gets serviced first COMMUNICATIONS AND DISPLAYS Two modes of communications are available to the R7910 1 The R7910 has two RS485 communication ports for ModBus that allows for interfacing to one or all R7910s of a system and presents them individually to the user The S7999B System Operator interface is a color touchscreen displays used for configuration and monitoring of the R7910A Control Operation and display status in both test and graphical modes can be shown along with the ability to setup The R7910 can also be remotely reset through the S7999B display Either ModBus RS485 communication port can be used to allow configuration and status data to be read and written to the R7910 Support a Master S7999B or a Building Automation master to control the R7910 to respond to a single ModBus address to service the requests of the ModBus master in a Lead Lag arrangement The local S7910 Keyboard display the S7999B System Operator interface and the S7999C Local Operator Interface are optional components The S7999B or the DSP3944 which is a portable S7999B or is required configura
74. owed by the next most recent fault Summary information is displayed for each FIGURE 34 EXAMPLE OF ALERT SHOWN fault entry including the burner cycle count fault code and fault number with description Detailed information for a specific fault see additional detail about a lockout or alert touching on the entry that also includes burner control sequence state burner lockout or alert in the list expands the view of that lockout or alert run time hours annunciation status etc is viewed by selecting as shown in Figure 33 and Figure 34 touching the History line the lockout entry in the list Boiler 1 Lockout ae an Lockout History Cycle Description 1 29 08 12 29 38am 20 105 Flame detected out of seque in Preignition Test state 20 105 Flame detected out of seque in Standby state 19 109 Ignition failed in Pilot Flame Establishing Pe 19 109 Ignition failed api Ete 112908 Po FIGURE 35 CONTROL EXPANDED LOCKOUT DETAIL FIGURE 33 EXAMPLE OF LOCKOUT HISTORY The date and time that each fault occurred is displayed in the lockout history The lockout timestamp displays in both the lockout Summary and detail information The Burner Control does not maintain date or time of day information The date and time stamp is assigned by the Ol display When the display first obtains the lockout and alert history from the control during the display d
75. r Research on Cancer IARC has concluded Crystalline silica in the form of quartz or cristobalite from occupational sources is carcinogenic to humans Group 1 Normal operating temperatures in this boiler are below the level to convert ceramic fibers to cristobalite The ceramic fiber material used in this boiler is an irritant hence when handling or replacing the ceramic materials it is advisable that the installer follow these safety guidelines 1 Avoid breathing dust and contact with skin and eyes Use NIOSH certified dust respirator N95 This type of respirator is based on the OSHA requirements for cristobalite at the time this document was written Other types of respirators may be needed depending on the job site conditions Current NIOSH recommendations can be found on the NIOSH website at http www cdc gov niosh homepage html NIOSH approved respirators manufacturers and phone numbers are also listed on this website Wear long sleeved loose fitting clothing gloves and eye protection 47 2 Apply enough water to the combustion chamber lining to prevent airborne dust 3 Remove the combustion chamber lining from the boiler and place it in a plastic bag for disposal 4 Wash potentially contaminated clothes separately from other clothing Rinse clothes washer thoroughly NIOSH stated First Aid Eye Irrigate immediately Breathing Fresh air REPLACEMENT PARTS Replacement parts may be ordered th
76. r is removed The burner control supplies 24 volts to the gas valve during operation FIGURE 4 GAS VALVE WATER FLOW SWITCH The water flow switch activates when sufficient water flow has been established Switch will not close when water flow is not present FIGURE 5 WATER FLOW SWITCH FLAME SENSOR Each burner is equipped with a flame sensor to detect the presence of the burner flames at high and low fire conditions If no flame is sensed the gas valve will close automatically The voltage sensed by the flame sensor will also be displayed on the Burner Screen FIGURE 6 FLAME SENSOR WATER TEMPERATURE LIMIT CONTROLS Limit controls are safety devices and to be used as an operating device thermostat The XB XW models incorporate an outlet water sensor having dual sensors that are factory set at 210 F 99 MAIN POWER SUPPLY SWITCH The main power supply switch is a padlockable switch This switch provides 120V from the power supply to the boiler This switch needs to be turned off when servicing the boiler NOTE The Enable Disable Switch on the front of the boiler does not interrupt electrical power to the boiler FIGURE 7 MAIN POWER SUPPLY SWITCH WATER TEMPERATURE SENSORS FIGURE 8 WATER TEMPERATURE SENSORS Temperature sensors are threaded immersion probes Temperature probes have embedded temperature sensors thermistors The boiler s control system
77. range was too Abnormal Recycle Demand off during Drive to small minimum 12 22 F Purge Rate Lead Lag DHW setpoint was invalid Demand during Measured U i Lead Lag Mix setpoint was invalid d 284 Abnormal Recycle Demand off during Drive to Lead Lag CH demand switch was invalid Lightoff Rate Lead Lag CH setpoint source was invalid 285 Abnormal Recycle Demand off during Pre Ignition RESERVED test CH setpoint was invalid Abnormal Recycle Demand off during Pre Ignition CH time of day setpoint was invalid time CH outdoor temperature was invalid Recycle Flame was on during Safe CH ODR ti fd tpoint invalid 249 ODR time of day setpoint was invalid no A REFE e A W CH ODR time of day setpoint exceeds normal Purge Rate tpoint Abnormal Recycle Flame was on during 251 CH max outdoor setpoint was invalid Measured Purge Time 252 CH min outdoor setpoint was invalid Abnormal Recycle Flame was on during Drive to CH min water setpoint was invalid Lightoff Rate CH outdoor temperature range was too small 291 Abnormal Recycle Flame was not on at end of CH water temperature range was too small Ignition period Steam setpoint was invalid 292 Abnormal Recycle Flame was lost during Main Flame Establishing Period EON Abnormal Recycle Flame was lost early in Se ee eee Abnormal Recycle Flame was lost during Run CH ODR min water temperature was invalid Abnormal Recycle Leakag
78. rol Systems are in the Use First category then one of these the one with the lowest sequence number will always be the first boiler to fire If there is no Control System in the Use First category and one or more are in the Equalize Runtime category then the First boiler is also the Lead boiler LOCAL OPERATOR INTERFACE DISPLAY SYSTEM Honeywell FIGURE 17 BURNER CONTROL S7999B DISPLAY SYSTEM The S7999B is a microprocessor based touchscreen Operator Interface Ol display that provide an operator interface for monitoring and configuring parameters in the Burner Control system The 7999 can be used to monitor an individual boiler but is primarily used for multiple boiler applications in a lead lag arrangement COM 2 port is available for Building Automation applications The S7999B display is flush mounted into a panel cutout 8 1 8 in W x 5 7 8 in H Wiring connections to the S7999B are through a removable 9 pin wiring header FEATURES Individual diagnostics boiler status configuration history and Allows configuration and monitoring of the Burner Control Controls burner control sequence flame signal diagnostics historical files and faults S7999B OI Display only Allows switching view between multiple boilers Allows viewing Lead Lag Master Ethernet port for downloading software upgrades when required Real time data trending analysis and transferring saved trend data to Excel sprea
79. rough A O Smith dealers authorized servicers or distributors Refer to the Yellow Pages for where to call or contact in United States the A O Smith Water Products Company 500 Tennessee Waltz Parkway Ashland City TN 37015 1 800 433 2545 or in Canada A Smith Enterprises Ltd 599 Street West Fergus ON N1M2X1 1 888 599 2837 When ordering parts be sure to state the quantity part number and description of the item including the complete model and serial number as it appears on the product Refer to the parts list for more information For Technical Assistance call A O Smith Technical Information Center at 1 888 479 8324 NOTES 48 LIMITED WARRANTY A O Smith Corporation the warrantor extends the following LIMITED WARRANTY to the owner of this boiler 1 If within TEN years after initial installation of the boiler a heat exchanger or gas burner should prove upon examination by the warrantor to be defective in material or workmanship the warrantor at his option will exchange or repair such part or portion This term is reduced to FIVE years if this boiler is used for water heating purposes other than hydronic space heating a This warranty is extended to the owner for all other parts or portion during the FIRST year following initial installation of this boiler b The warranty on the repair or replacement of the part or portion will be limited to the unexpired term of the original warranty 2 CONDITIONS AND E
80. rtment should be cleaned annually to remove any dirt and lint that may have accumulated in the compartment or on the blower and motor Buildups of dirt and lint on the blower and motor can create excessive loads on the motor resulting in higher that normal operating temperatures and possible shortened service life AIR FILTER BOX The air filter box should be cleaned every three months to remove any dust and debris that may have accumulated in the air filter or the filter housing Buildups of dust on the air filter can block the air intake into the boiler Air filter can washed and cleaned with water CONDENSATE REMOVAL SYSTEM Due to the highly efficient operation of this boiler condensate is formed during operation and must be removed by the condensate drain systems Inspect the condensate drains and tubes at least once a month and insure they will allow the free flow of condensate at all times The system must be inspected more frequently in cold weather if the drain system is located in an area such as along the floor where freezing temperatures are likely to occur The condensate drain system must be protected against freezing Contact a qualified service agent to inspect and correct the condition if freezing of the condensate lines is a problem The transparent drain lines and condensate drain on the bottom of the vent collector should be visually inspected at one month intervals for blockage particularly in the areas of the loops i
81. s exceeded Tap detect ON hysteresis was invalid Inlet outlet inversion occurred Inlet DHW tap stop degrees was out of range 59 inversion occurred 596 Outlet Inlet tap stop degrees was out of range 555 Inlet exchanger i inversion occurred DHW tap detect on threshold was invalid Delta T exchanger outlet wasn t allowed due to DHW plate preheat detect on threshold was invalid stack connector setting Delta T inlet exchanger wasn t allowed due to stack limit setting 558 Delta inlet exchanger wasn t allowed due to stack connector setting DHW plate preheat detect off threshold was invalid Delta T delay was not configured for recycle response 56 566 Heat exchanger T rise wasn t allowed due to stack limit setting 567 Heat exchanger T rise wasn t allowed due to stack connector setting 568 Outlet T rise wasn t allowed due to outlet connector setting 569 T rise delay was not configured for recycle response Heat Exchanger High Limit Errors 570 Heat exchanger high limit setpoint was out of range MAINTENANCE PROCEDURES MAINTENANCE SCHEDULES Yearly procedures for Qualified Service Agent Check for reported problems Check the interior clean and vacuum if needed Clean the condensate trap and fill with fresh water Check for water gas flue condensate leaks Ensure flue and air lines in good condition and sealed tight Check system water pressure system piping expansion tank Check con
82. s securing the heat exchanger access cover to the heat exchanger and set aside 4 Remove the heat exchanger access cover burner and gas train assembly NOTE The boiler contains ceramic fiber materials Failure to comply could result in severe personal injury 5 Remove the condensate hose from the heat exchanger end Connect a field supplied 3 4 diameter hose to a drain pan 6 Use a vacuum cleaner to remove any deposits debris on the boiler heating surfaces Do not use any solvent 7 Brush the heat exchanger while dry using a nylon bristle brush Re vacuum the heat exchanger 8 Finish cleaning using a clean cloth dampened with warm water Rinse out debris with a low pressure water supply 9 Allow the heat exchanger to dry completely 10 Remove the rear refractory cover from the back of the combustion chamber of the heat exchanger and reassemble 11 Close isolation valves on piping to isolate the boiler from system Attach a hose to the boiler drain and flush boiler thoroughly with clean water by using purging valves to allow water to flow through the water make up line to the boiler 12 Replace the access cover and restore the boiler for operation HANDLING CERAMIC FIBER MATERIALS Removal of combustion chamber lining The combustion chamber insulation in this appliance contains ceramic fiber material Ceramic fibers can be converted to cristobalite in very high temperature applications The International Agency fo
83. s use a pilot at the end or optionally at the middle of the Pilot Flame Establishing Period PFEP For an interrupted pilot system this is followed by a Main Flame Establishing Period MFEP where the pilot ignites the main burner For an intermittent pilot there is no MFEP The fan is kept at the lightoff rate during the stabilization timer if any 11 12 Before the release to modulation the fan is switched to minimum RPM for the CH Forced Rate and Slow Start Enable if the water is colder than the threshold 13 Atthe end of the CH heat request the burner is switched off and the fan stays on until post purge is complete 14 A new CH request is blocked for the forced off time set by the Anti Short Cycle if enabled The pump stays on during the pump overrun time if enabled 19 16 At the end of the pump overrun time the pump will be switched DOMESTIC WATER Start up sequence DHW request system in standby 1 Heat request detected either DHW Sensor Only DHW Sensor and Remote Command or DHW Switch and Inlet Sensor whichever applies 2 The pump is switched on after the DHW Pump Start Delay 3 After a system Safe Start Check the Blower fan is switched on after a dynamic ILK switch test if enabled 4 After the ILK switch is closed and the purge rate proving fan RPM is achieved or High Fire Switch is closed prepurge time is started 5 When the purge time is complete the
84. splayed on the Configuration menu page Parameters in functional groups that are not applicable for the installation can be ignored In some cases features in a functional group are disabled by default and are enabled when needed for the installation TROUBLESHOOTING To support the recommended Troubleshooting the R7910 has an Alert File Review the Alert history for possible trends that may have been occurring prior to the actual Lockout Note Column H Hold message L Lockout message H or L either Hold or Lockout depending on Parameter Configuration TABLE 9 TROUBLESHOOTING CODES CODE DESCRIPTION RECOMMENDED TROUBLESHOOTING OF NOTE J CODES Safety Data Faults Unconfigured safety data New Device complete device n and safety verification If fault repeats replace module 2 Waiting for safety data verification Device in Configuration mode and safety parameters need verification and a device needs reset to complete verification Configuration ended without verification re enter configuration verify safety parameters and reset device to complete verification If fault repeats replace module Dee oo 2 ffault repeats replace module Internal fault Unstable power DCDC output 5 Intemal faut Invalid processor cock 8 intema faut Zero crossing not detected __ o faut Flame bias out ofrange __ 15 Internal fault Safety relay test failed due to feedback ON 16 Interna
85. ssure proper HorL function 3 Verify voltage through the interlock string to the interlock input with a voltmeter If steps 1 3 are correct and the fault persists replace the module Pilot test hold 1 Verify Run Test is changed to Run 2 Reset Module 3 1 If fault repeats replace module 70 Wait for leakage test completion Internal Fault Reset Module 2 If fault repeats replace module 78 Demand Lost in Run Check wiring and correct any possible errors If previous steps are correct and fault persists replace the module Outlet high limit Check wiring and correct any possible errors HorL Replace the Outlet high limit If previous steps are correct and fault persists replace the module DHW high limit Check wiring and correct any possible errors Replace the DHW high limit df previous steps are correct and fault persists replace the module Delta T limit Check Inlet and Outlet sensors and pump circuits for proper operation Recheck the Delta T Limit to confirm proper setting df previous steps are correct and fault persists replace the module HorL HorL Oo Oo l W or L Stack limit Check wiring and correct any possible errors Replace the Stack high limit If previous steps are correct and fault persists replace the module Outlet T rise limit 1 Check for adequate flow HorL Exchanger T rise limit Not Applicable HorL Inlet exchanger inversion
86. switch opens If flame detected during Safe Start check up to Flame Establishing period High fire switch ON OEM Specific HorL Check wiring and correct any potential wiring errors Check High Fire Switch to assure proper function not welded or jumpered Manually drive the motor to the High Fire position and adjust the HF switch while in this position and verify voltage through the switch to the HFS input with a voltmeter If steps 1 3 are correct and the fault persists replace the module OEM Specific Check wiring and correct any errors Inspect the Combustion Pressure Switch to make sure it is working correctly Reset and sequence the relay module During STANDBY and PREPURGE measure the voltage between Terminal J6 5 and L2 N Supply voltage should be present If not the lockout switch is defective and needs replacing If the fault persists replace the relay module Purge Fan switch On ia Specific HorL Purge Fan switch Off Purge fan switch is on when it should be off Combustion pressure and Flame ON OEM Specific HorL 157 Combustion pressure and Flame OFF Check that flame is not present in the combustion chamber Correct any errors Make sure that the flame detector is wired to the correct terminal Make sure the F amp G wires are protected from stray noise pickup Reset and sequence the module if code reappears replace the flame detector Main valve ON OEM Specific 159 Main valve OFF 1 Check Valve term
87. t The Display does NOT have a backup means TABLE 6 BURNER CONTROL LOCKOUT HISTORY DATA COMMENT Lockout time Set by display Fault Code Unique code defining which lockout occurred Annunciator first out First interlock in limit string results in a shutdown Burner Lockout Hold Source reason for lockout hold Burner control state Burner control state timer at time of fault Cycle Burner control cycle Run Hours Burner control hours I O All digital I O status at time of fault Annunciator 1 8 states All annunciator I O status at time of fault Fault data Fault dependent data An alert log can be displayed for each control by pressing the Alert button on the bottom of the history status page A description of the alert is displayed along with the time when the alert occurred refer to Table 7 TABLE 7 BURNER CONTROL ALERT LOG DATA COMMENT Alert Line Set by display Unique Code defining which fault occured HISTORY BUTTON The History button on the Home page serves not only as a button but also displays Burner Control lockouts holds and alerts as they occur The History button can be selected at any time regardless of which type of information is displayed to view history information Pressing the History button displays a dialog box see Figure 25 that allows the user to select the type of history to view The user can also silence an audible alarm generated by the control during a lockout or a
88. t reset occurred 18 Alarm silence time exceeded maximum ie Application processor watchdog reset occurred Invalid safety group verification table was detected Nopiicat on E FAS occured 20 Backd P d Id t be determined 20 Safety processor watchdog reset occurred 21 Invalid safety group verification table was not t bv th t th trol accept d Alarm was rese y ne usera contro 22 CRC errors were found in application configuration Demand Rate Command Faults data blocks Burner control firing rate was gt absolute max rate Backup Alert PCB was restored from active one 60 Burner control firing rate was absolute min rate Burner control firing rate was invalid 9o vs RPM 63 Burner control rate nonfiring was absolute max 64 ae control rate nonfiring was absolute min Burner control rate nonfiring was absent Burner control rate nonfiring was invalid Program Module PM was inserted into socket a vs RPM 68 Setpoint was overridden due to sensor faut 69 Modulation was overridden due to sensor faut Range PCB was configured 70 No demand source was set due to demand priority Program Module PM incompatible with product conflicts was inserted into socket 71 73 RESERVED 37 CODE DESCRIPTION CODE DESCRIPTION Fan Parameter Errors 114 MIX modulation range max minus min was too Periodic Forced Recycle small lt 4 or 40 RPM Absolute max fan speed was out of range Modulation Operation F
89. tion of the parameters of the R7910 but is not needed for the operation of the system once configured SPECIFICATIONS 1 Electrical Ratings Operating voltage e 24VAC 20 to 30 VAC 60 Hz 5 e 30 amps Single Heat Exchanger e 60 amps Double Heat Exchanger Connected Load for Valve and annunciator functions e 24VAC 60Hz 120VAC 10 15 60Hz 5 Model Specific 2 Corrosion e R7910A must not be used in a corrosive environment 3 Operating Temperature 4 F to 150 F 20 C to 66 C 4 Storage Shipping Temperature 40 F to 150 F 40 C to 66 C 5 Humidity e Up to 95 Relative Humidity noncondensing at 104 F for 14 days Condensing moisture may cause safety shutdown 6 Vibration 0 0 to 0 5g Continuous V2 level 7 Enclosure Nema 1 IP40 8 Approvals Underwriters Laboratories Inc UL Component Recognized File No MP268 MCCZ e R7910 is certified as UL372 Primary Safety Controls The R7910 is certified as UL353 Limit Rated device when using part number 50001464 dual element limit rated NTC sensors CSD 1 Acceptable Meets CSD 1 section CF 300 requirements as a Primary Safety Control Meets CSD 1 section CW 400 requirements as a Temperature Operation control Meets CSD 1 section CW 400 requirements as a Temperature High Limit Control when configured for use with 10 kohm NTC sensors Federal Communications Commission Part 15 Class B Emissions BURNER CONTROL OPERATION SAFETY SHUT
90. to change the parameter 51404135 NOLWINdOW DANOGOD WALSAS NIJADIS NYv312 JINON INVHOOHd eoue s AJOLSIH 40195 FEcCL sisAjeuy A Lag saung A amp HVININITS Ajuan A jnoBo I qos pen L s ge sdnauc uogeunBiyuo7 NOLIV3dO JjH19IHNO2 j9Vvd JWOH 3HL OL SIVIL SAVANTV 3INOH NODI MOV8 MO14 Noung FIGURE 21 S7999B DISPLAY PAGE FLOW 20 STATUS OR HOME PAGE A status Summary page Figure 22 is displayed when the S7999B display is connected This status page appears on the S7999B when the Burner control icon is pressed on the Home page The status page displays the current condition of the burner control and displays some of the more important configuration settings The boiler name associated with the burner control is displayed in the title on the status page NOTE When the burner control has no boiler name defined Modbus address is used to identify the boiler The initial status page displayed contains summary status information as shown in Figure 22 Any status information not applicable for the installation is grayed blanked out on the screen Buttons on this screen include Configure used to configure the burner control password protected
91. trol System will lockout and the blower motor will be de energized If these open during the firing period all fuel valves will be de energized the system will complete postpurge and will lockout indicated by an alarm 2 f the pilot flame is not detected by the end of the last 3 number recycle attempt pilot trial for ignition period the pilot valve and ignition transformer will be de energized the system will complete post purge and will lockout indicated by an alarm If the main flame is not detected at the end of the last recycle attempt of the main flame establishing period all fuel valves will be de energized the device will complete postpurge and will lockout indicated by an alarm If the flame sensing signal is lost during the run period if lockout is selected all fuel valves will be de energized within 4 seconds after the loss of the flame signal the device will complete postpurge and will lockout indicate by an alarm Manual reset is required following any safety shutdown Manual reset may be accomplished by pressing the push button on the device pressing the remote reset wired into connector J10 or through an attached display Interrupting power to Control System will cause electrical resets but does not reset a lockout condition GENERAL OPERATIONAL SEQUENCE INITIATE The R7910 enters the Initiate sequence on Initial Power up or e Voltage fluctuations vary less than 20VAC or greater than 30VAC
92. trol settings Check spark igniter and flame sensors Clear and clean any deposits Check wiring and connections Perform start up checkout and performance verification Flame inspection stable uniform Flame signal at least 10 microamps at high fire Clean the heat exchanger if flue temperature is more than 54 F 30 C above return water temperature Test low water flow conditions Clean the heat exchanger Remove and clean burner using compressed air Maintenance by Owner Daily Check boiler area Check pressure temperature gauge Monthly Check vent piping Check air intake piping Direct Vent Check air and vent termination screens Check relief valve Check condensate drain system Check automatic air vents Every 6 months Check boiler piping gas and water for leaks Check and operate the pressure relief valve End of season months e Shut the boiler down unless boiler used for domestic hot water Make sure the maintenance of the boiler must be performed to assure maximum boiler efficiency and reliability Failure to service and maintain the boiler and system could result in equipment failure Make sure to turn off power to the boiler before any service operation on the boiler except as noted otherwise in this instruction manual Failure to turn off electrical power could result in electrical shock causing severe personal injury or death 44 INSPECT BOILER AREA 1 Verify t
93. ule power supply and make sure that both frequency and voltage meet the specifications On 24 VAC applications assure that J4 10 and J8 2 are connected together Safety GVT model ID does not match application s Contact the service professional model ID 55 __ data Beck CRC amm Cortacttne sovice proessa f n po 65 Fault HESshoredioLFS Will not be a lockout fault Hold Only sr reset LCI OFF Check wiring and correct any faults 2 Check Interlocks connected to the LCI to assure proper function Reset and sequence the module monitor the LCI status lf code persists replace the module PII OFF Check wiring and correct any faults 2 Check Preignition Interlock switches to assure proper functioning Check the valve operation Reset and sequence the module monitor the status lf code persists replace the module 05 _ If fault repeats replace module HorL Interrupted Airflow Switch OFF Check wiring and correct any possible shorts Interrupted Airflow Switch ON 2 Check airflow switches to assure proper functioning Check the fan blower operation HorL HorL Reset and sequence the module monitor the airflow status If code persists replace the module 30 CODE DESCRIPTION RECOMMENDED TROUBLESHOOTING OF NOTE LOCKOUT CODES ILK OFF 1 Check wiring and correct any possible shorts ILK ON 2 Check Interlock ILK switches to a
94. uring Initiate or off cycle hold 240 seconds if present after 240 seconds lockout Rate Proving Faults Lightoff rate proving failed Check wiring and correct any potential wiring errors Check VFDs ability to change speeds 122 123 Purge rate proving failed Change the VFD If the fault persists replace the module 32 CODE DESCRIPTION RECOMMENDED TROUBLESHOOTING OF NOTE LOCKOUT CODES 424 High fire switch OFF Check wiring and correct any potential wiring 125 High fire switch stuck ON UL NM Check High Fire Switch to assure proper function not welded or jumpered Manually drive the motor to the High Fire position and adjust the HF switch while in this position and verify voltage through the switch to the HFS input with a voltmeter If steps 1 3 are correct and the fault persists replace the module Low fire switch OFF Check wiring and correct any potential wiring 127 Low fire switch stuck ON Check Low Fire Switch to assure proper function not welded or jumpered Manually drive the motor to the High Fire position and adjust the LF switch while in this position and verify voltage through the switch to the LFS input with a voltmeter If steps 1 3 are correct and the fault persists replace the module Fan speed failed during prepurge Check wiring and correct any potential wiring Fan speed failed during preignition Check VFDs ability to change speeds Fan speed

Operation Manual 08/2011

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