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197373-004 BTH 300-500 Instruction Manual

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72. FIGURE 21 SUMMARY STATUS PAGE CONFIGURE BUTTON The configuration page allows the user to view and set parameters that define how the connected Burner Control System R7910 functions 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 qualified service technician must perform the configuration settings Boiler 1 Configuration Menu Select Configuration Group System Identification amp Access CH Central Heat Configuration Outdoor Reset Configuration DHW Domestic Hot Water Configuration DHW Storage Configuration DHW Plate Heat Exchanger Warm Weather Shutdown Configuration Demand Priority Configuration FIGURE 22 CONFIGURATION MENU 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 and stays active The display times out after 10 minutes of inactivity User will have to login again if another secure parameter needs to be changed by pressing the Padlock button 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
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100. 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 qualified service technician 251 255 33 TABLE 8 ALERTS CODE DESCRIPTION CODE DESCRIPTION ERN EE Management Faults of 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 Configuration parameters were restored from factory defaults Parameter PCB in Program Module is too large for roduct Invalid Factory Invisibility PCB was detected 41 Range PCB in Program Module was too large for Invalid Factory Range PCB was detected product 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 Wa System Operation Faults Configuration was restored from factory defaults Low voltage was detected in safety processor Backup configuration settings was restored fr
101. 3638 e np 4nejdeo 269 ue siuuJed sed unejeuo ep ossedop e 9 ep TT ep eJnjeJeduuo e ep 1819 ep ep e 1819 e ed GZS 1819 1 8 GS 27 Eee ee eee e eS jusuisupuspuser ep ej nod agunByuoo 699 ep 1nejoeuuoo np Be 6 1 uosieJ ue eun p Jn o uuoo np eDej69J np uosieJ ue esiuued E I 5 ep 9 ep ep essneu 198 9 97 o S p e uosies ue esiuued sed eu ep 9 ep ep essneu 996 Jnod 591915 4 JnesseooJd ep sduu OLS 5 3002 5 3002 ep siou p ue
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103. ep eun p uoisue eun p uosieJ ue Jne nJq np np uoisue 5109 snos esiui e epJejeJ uonesijeniui p eouenbas U8J29 INS uonesi eniurgJ ep uoinog ns o ndde eDund eJd ep epoued e juepued 1915 153 IS ZH e GF ep seouenbayJ sep suonenjonj 59 A 06 ep e A OZ SUIOW zuanean UOISUS suonenjon se nO 9yeniul ue e e uonesi eniui p eouenboes QL6Z7H 91 NOILVSITVILINI ILN3W3NNOILLONOH ATWYANAS 39N3nO03s 6 uonipuoo eun sed esi erjuioJ eu siew e ep 5 5 ne ep uondnulejuil 9119 un Jed 0 suep eoueljsip e uonesi eniulioJ e ans jue ndde ue jnisodsip e uns 9 ins jue ndde ue 159 uonesi eniuigJ 27 9 op ej e s nb 159 uonesi eniuioJ 27 euueje eun juenbipur ue ne eDund 59149
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106. 3 3 GENERAL SAFE uuu uuu u uu 4 P8 97TH 5 Model 5 Abbreviations Used 5 ATIC A UGS u LLL 5 CONTROL COMPONENTS EUROS EDU 6 BOILER START UP AND OPERATIONS 8 LIGHTING AND OPERATING INSTRUCTIONS 9 CONTROL Sy M 12 Burner Control System 12 CREE 12 Communications and displays 12 OCC er IIo i RR y 12 Burner control operation 13 General operational sequence 14 Pel u 14 Local Operator Interface Display System 15 C AUO EE D 16 Installation Instructions S7999D OI Display 16 Quick setup 579990 oi display 16 Starting Up The S7999D OI Display 16 Page EN T u 17 TROUBLESHOOTING u u uuu u 26 MA
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108. 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 The end user does not need password Installer The installer can read all control parameters and 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 S7999D 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 23 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 sco
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113. If the fault persists replace the relay module Purge Fan switch On OEM Specific Purge Fan switch Off 1 Purge fan switch is on when it should be off Combustion pressure and Flame ON Combustion pressure and Flame OFF Main valve ON Main valve OFF Ignition ON Ignition OFF Pilot valve ON Pilot valve OFF OEM Specific 1 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 OEM Specific 1 Check Main Valve terminal wiring and correct any errors Reset and sequence the module If fault persist replace the module OEM Specific 1 Check Ignition terminal wiring and correct any errors Reset and sequence the module If fault persist replace the module OEM Specific 1 Check Pilot Valve terminal wiring and correct any errors Reset and sequence the module If fault persist replace the module 2 2 2 31 NOTE HorL HorL HorL HorL HorL HorL L L L 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
114. Internal Fault A2D mismatch Internal Fault 98 Internal Fault Exceeded VSNSR voltage Reset Module If fault repeats replace module 99 Internal Fault Exceeded 28V voltage tolerance 100 Pressure Sensor Fault Verify the Pressure Sensor is a 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 or L 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 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 I7 EM Check the fuel supply 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 position If steps 1 through 4 are correct and the fault L 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 Flame current lower than
115. Ueuouje ep jO eosiuoJuou S eje eesieoo s eun nb seq euoJeuoaJ ep e euiuuej 59 48 jnejesi nn e jse sngpo y neesoJ ne e9j euuoo epueuluoo AWALSAS NOILVSITIVALOV uoneunBuuo 03005 ssaJppy snapo Wd auey 80087 puno s log p Ssoppy 3 T WOO C T WOO 1 T WOO Sselpp pv 1104 jouoo e sed juo u s uuop 59 enb enbipui nuuoou gt uwouxuf gt Gz 9660 ej e Ly ainbi4 ep 9151 e suep WOU uos 2102 e nuuoou gt umouyun gt un Jed eaunuepti 159 167 ep eun no VOLBZY enbiuoup u euf1 6 e 1104 eenboAur1se ep eunpoooud eun 1esijenjoy gt gt Jns jue ndde unejesi nn suep uoneunDuuoo e ue suonouo seureueo eyuoduioo jO 7 LNaWwadnas 066625 IO 39 VHOIJJV 3N31SAS NOILVYNSISNOD S3n01901VNV S 3 SOILSONDVIG 9 66
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122. ALNOL 39IAH3S 13 NOILLVTIVLSNI A S3M3liviN 200 667 LZE 21 90 NTA XNV sou suep suoiooJdde snow I9J49 A eJnjnj e2u849J9J Jnod JepJeB e eJireyoudouJd 9 795 eJeipneuo e 5914 suononujsul 595 7928 14 Ieedde Zeb 9 no 901195 op jue e eun aylyenb 5 un s n 5 JJ je sjueuiessnieAe Sno sudujoo A zeueJduioo 2981 HOS a tk asd a id BDIAIOS 9 Zajadde 226 op 9 sed 2 eu IS 226 suomnonJjsul 59 Z9AInS UISIOA un p 226 JnessiuJnoj 9 Zojaddy uoud unone enbiujoeJo unone zeuinj e N ZVO 3d ANN ZALNAS SNOA IS AND ep no
123. ANN 3IGN3ONI 3 SNOILONYLSNI S39 SVd 2 AN SNOA 15 LNSINASSILYSAV SIIN3ONIG SOIAMAS 2373 279 YNASSINYNOA 38 LOA SVd ZAANOd AN SNOA IS dd YNASSINYNOA SNOILONALSNI 2 NISIOA 3NOHd3 191 V ZV9 LNAWALVIGANI Za lddav LNAWILYE SY LOA ANOHdA TAL 1 2 ANDIYLOATA YNALVLAWNOS NNONV ZAHONOL AN NNONV ZANNTIV N 279 AG ANN Z31N3S SNOA IS AND SN 1d 153 2 9 ANOSINd AS 270 AG 1 VI NOA 10S Sud dILN3S SNOA ZAYNSSV 279 Wnod lasvaav l V1 YNOLAV 1101 Z31N3S LINY NIVIA V d 310388 31 Svd 2 nal LN3W3nolLLVINOLnV AWNTIV IND 39vINPTTIV G sAILISOdSIG 3109 153 3snarildA SVd V N 139 NOILVSITILN 31001 LNVAV 5 2 ALIMNDAS AYNSAW V 9 V INSAWANNOILONOG L3 J VWNTIV dA SNOILONYLSNI 1 seJnsse q sep JeujeJjue op 1nejop sjesuepuoo ep np ep 226 UOISSIUJ9
124. CE 6 0 Operating System 8 pin connector back up battery and mounting hardware are provided SPECIFICATIONS Electrical Ratings Input Voltage 18 30 Vac 24Vac nominal 50 60 Hz Input Current 500 mA max Power consumption 12W max Operating Temperature 4 to 158 F 20 to 70 C Storage Shipping Temperature 22 to 176 F 30 to 80 C Humidity 9096 RH non condensing Enclosure rating IP10 NEMA 1 Approvals FCC Part 15 Class A Digital Device Underwriters Laboratories Inc UL cUL Recognized for non continuous operation MH17367 MJAT2 MJATS8 oo m Component File Number INSTALLATION INSTRUCTIONS S7999D OI DISPLAY The OI Display can be mounted on the door panel of an electrical enclosure 1 Select the location on the 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 wide X 5 1 2 high for front panel mount or 7 1 8 wide X 4 11 16 high for rear panel mount 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
125. Clear Annunciation FIGURE 14 FIRING RATE PAGE 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 If combustion readings are not in accordance with the chart below adjust the gas control valve as follows remove the flat round blue plastic cap from the cover see Figure 4 Page 6 Using a mm 7 64 hex wrench turn the adjustment screw counterclockwise to increase or clockwise to decrease gas flow and achieve the desired CO level Make sure to close the boiler door after adjusting the gas valve for direct vent configurations Refer to the Table 1 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 1 HIGH FIRE RATE RPM CO MANIFOLD PRESSURE APPROXIMATE FACTORY SET INCHES W C KPA MODELS XB NATURAL PROPANE NATURAL PROPANE NATURAL GAS PROPA
126. OPERATION CONTROL ICON MODULATION SETPOINTS CONFIGURE DETAILS ADVANCED SETTINGS CONTROL V SYNCHRONIZE SETUP DISPLAY leif CONTROL DIAGNOSTICS SNAPSHOT CALIBRATION _ SCREEN DISPLAY SETUP CHANGE ADDRESS 7 pare mwe RENAME CONTROL REMOVE VIDEO omoi Lou SCREEN SNAP SHOT DIAGNOSTICS ANALYSIS F Uuone npouu ep 5 5 199 59 JejnuuuJoo uone npo Ny eduJod ep 59 199019 Jnod esi nn Jne nuq ep enbuoijsiu JesijensiA ne nJq ep sep s l ie p 59 Jesi ensiA osi nn 1 queuienbiun eunjejeduue ep eBeJ69J 005 suy sep Jne nJq ep epueuuuJoo ep sonsouDeip suoneuuoJul 59 Jesi ensiA si i n 9r souDeiq 919 ep np Be 6 1 9 enb 519 seuuaeipnonb no suonouo sop Jnod esi nn jueuieuuonouo J uonededo enBuuoo 919 assed ep e esi nn 494nBjuo 9 JUBUUBIGWOD UeJ99 195 118 seuono 597
127. 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 Iffault repeats replace module 1918 RESERVED x I lC _ C _ _ 00000000 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 If fault repeats verify electrical grounding If fault repeats replace module 32 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 22 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
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129. and exhaust piping need cleaning 43 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 5 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 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 nuts 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 Use a vacuum cleaner to remove any deposits debris on the boiler heating surfaces Do not use any solvent 7 Brush
130. covers XP Boiler models XB 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 XP Extreme Performance MODEL APPLICATION XB Hydronic Heating Boiler SIZE 1000 920 000 Btu hr input 1300 1 300 000 Btu hr input 1700 1 700 000 Btu hr input 2000 1 999 900 Btu hr input 2600 2 600 000 Btu hr input 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 XB models can be special ordered with a 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 ANSI American National Standards Institute ASME American Society of Mechanical Engineers NEC National Electrical Code NFPA National Fire Protecti
131. data 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 NOTE The system time can be set in the Ol display to ensure that correct timestamps are given to the controls lockouts and alerts Power interruptions will require the time to be reset as the display does not have a time backup means The Clear Lockout button allows the user to acknowledge and clear reset the lockout when in lockout state much the same 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 AA Boiler 2 Alert Log a Time Description 03 17 11 04 25 12 PM 58 Alarm was reset by the user at the control 303 Abnormal Recycle ILK off during Drive to Purge 310 Run was terminated due to ILK was off 3 17 11 Clear Alert Filter x 4 46 19 PM Lockouts gt gt FIGURE 32 EXAMPLE OF ALERT SHOWN To see additional detail about a lockout or alert touching on the lockout or alert in the list expands the view of that lockout or alert as shown in Figure 31 on Page 22 and Figure 32 7 mins 40 secs Timer First Out None 3 17 11 4 53 37 PM FIGURE 33 CONTROL EXPANDED LOCKOUT DETAIL eje Time Description 03 71 D 03 17 11 u
132. 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 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 The fan is kept at the lightoff rate during the stabilization timer if any 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 At the end of the CH heat request the burner is switched off and the fan stays on until post purge is complete A new CH 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 16 At the end of the pump overrun time the 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
133. located 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 Li Setup Current control Boiler 2 Port Address Name COM2 1 Boller 2 Not synchronized x Control Display Display x Setup Setup Diagnostics FIGURE 41 SYSTEM CONFIGURATION PAGE SYSTEM SYNCHRONIZATION 579990 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 Ol Display is reset See Figure 42 The user presses the Synchronize button to begin synchronization with the control See Figure 42 Setup Current control Boiler 2 Port Address Name COM2 1 Boiler 2 Not synchronized x Control Display Display x ee Setup Setup Diagnostics FIGURE 42 SYSTEM SYNCHRONIZATION Status of the synchronization is reflected in the dialog box The synchronization can be aborted by selecting the Cancel button 25 CONFIGURATION The Burner Control can be configured from the
134. 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 43 NORMAL BURNER FLAME ABNORMAL BURNER FLAME FIGURE 43 BURNER FLAMES Visually check flame characteristics through the view port located on the top head of the boiler Figure 43 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 months for proper flame characteristics The main burner should display the following characteristics Provide complete combustion of gas e Cause rapid ignition and carry over of flame across entire burner Givereasonably 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
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136. nuts provided 7 Wire the 24VAC power supply and the RS 485 cables 8 Ensure the 8 pin connector plug is aligned with the header pins when inserting the 8 pin connector plug back onto the Display Secure firmly 9 Please make sure resistive spark cable is used with the display system and route the wires away from the display as much as possible FIGURE 17 579990 OI DISPLAY CONNECTOR TERMINALS QUICK SETUP 579990 OI DISPLAY Make sure the S7999D 8 pin connector is properly aligned and pressed firmly in place Make sure the wires between the 8 pin connector and the controller are properly wired and secured WARNING Electrical Shock Hazard It can cause severe injury death or equipment damage Line voltage is present at the 120 VAC power supply 3 2 Make sure the power supply is connected securely to the 120 VAC power source STARTING UP THE 579990 OI DISPLAY POWER UP VALIDATION The Home page will appear 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 7 and 8 wiring connections A camera icon on the left top corner is for screen snapshot use Up to 16 snapshots can be stored in the display and can be copied to a USB memory stick 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
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139. setting Unconfigured DHW high limit setpoint setting 223 Unconfigured Stack limit setpoint setting 224 225 226 Invalid Outlet high limit setpoint setting 22 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 connector type setting 238 Invalid Stack connector type setting 239 Invalid S2 J8 6 connector type setting 240 Invalid S5 J8 11 connector type setting 241 Exchanger sensor not allowed with stack Not Applicable connector setting 242 Invalid DHW auto detect configuration Not Applicable L 243 Invalid UV with spark interference not compatible Contact the qualified service technician with Ignitor throughout PFEP 244 Internal fault Safety relay test invalid state Contact the qualified service technician L 245 Invalid Outlet connector type setting for Trise Contact the qualified service technician 246 4 20mA cannot be used for both modulation and Contact the qualified service technician L setpoint control 247 Invalid ILK bounce detection enable Not Applicable
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141. should normally be bypassed Three LEDs exist for I O 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 COM1 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 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 579990 OI DISPLAY Make sure a screen similar to Figure 18 appears after the Ol Display has completely powered up Burner 1 Master Burner 2 FIGURE 18 579990 HOME PAGE BOILER 1 IN NORMAL OPERATION Lead Lag Active service Central Heat Temperature 81 F Setpoint 1109F Outdoor 849F 096 096 096 096 On leave On leave On leave On leave FIGURE 19 579990 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 burner 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 20 on Page 18 The Control System icons
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143. 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 boiler contains ceramic fiber material Ceramic fibers can be converted to cristobalite in very high temperature applications The International Agency for 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
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145. will appear in one of four colors indicating the boiler status Blue Normal operation Red Lockout condition Gray Communication error disconnected or powered off Yellow Holding mode Up to 8 Systems can be displayed on the Home page The name of each burner 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 buttons for Lead Lag configuration when lead lag master and slave in the Burner control is enabled Pressing the Setup button on the Home page displays miscellaneous setup and diagnostic functions It also contains the setup configuration for BAS applications The Control snapshot button allows the user to dump the current status and or configuration settings of any Burner controller into a text document The text document can be viewed on the display saved to flash for later viewing and can be written to a USB stick for viewing on a PC or file transfer Pressing the Burner control icon opens that control s status page Go to Configure button to continue 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 navigat
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147. 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 service technician to correct the situation If the burners extinguish then light boiler in accordance with lighting and 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 l
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154. 90 DISPLAY SYSTEM The 579990 is a microprocessor based color touch screen Operator Interface Ol display that provides an operator interface for monitoring and configuring parameters in the Burner Control system The S7999D can be used to monitor an individual boiler but is also used for multiple boiler applications in a lead lag arrangement It consists of 2 RS485 ports COM 1 amp COM 2 and USB port The S7999D display can be flush front or behind mounted into a panel cutout Wiring connections to the S7999D are through a removable 8 pin wiring connector 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 S7999D OI Display only Allows switching view between multiple burners Allows viewing Lead Lag Master Real time data trending analysis and transferring saved trend data to Excel spreadsheet 7 800 x 480 24 bit high resolution color LCD touch screen for clarity Audio output with integral speaker for sound output Adjustable backlight control Real time clock with coin cell battery back up CR2032 S7999D has Black Border Volume control Screen Capture function to capture screen images USB port for file transfers and software updates 2 RS 485 COM1 amp 2 ports for Modbus interface to Burner controls and BAS Gateway Windows
155. 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 S7999D System Operator interface is a color touchscreen display used for configuration and monitoring of the R7910A Though configuration can be done through the display it is not recommended as all the parameters are pre configured by the manufacturer Any custom configuration required by the field should be done in consultation with the A O Smith qualified service technician 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 S7999D 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 S7999D 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 SPECIFICATIONS 1 Electrical Ratings Operating voltage 24VAC 20 to 30 VAC 60 Hz 5 30 amps Single Heat Exchanger 60 amps Double Heat Exchanger Connected Load for Valve and annunciator functions 24VAC 60Hz 120VAC 10 15 60Hz 5 Model Specific Corrosion R7910A must not be used in a corrosive environment Op
156. Annunciation 56 LCI Load Control Input ON PH Pre Ignition ILK Other Unused Unused Unused Unused Unused Unused Unused Unused FIGURE 37 PROGRAMMABLE ANNUNCIATION CONT DIAGNOSTICS BUTTON The Diagnostics button displays analog and digital I O status of the Burner Control and is meant only for diagnostics and troubleshooting purposes 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 or off gray see Figure 38 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 all digital I O data 1 0 Status B Digital 1 0 Pump A INTERLOCK Alarm Pump B COSTAT OLOW WATER CUT OFF Blower HSI CH remote STAT Flap valve closed Pilot valve Pilot test hold Condensate not Main valve ENABLE SWITCH Time Of Day OLCI FLOW SWITCH HIGH GAS PRESSURE Safety Relay Pre Ignition LOW GAS PRESSURE DHW remote STAT Burner Digital Analog Control 1 0 1 0 1 0 Diagnostic ON FIGURE 38 DIAGNOSTICS PAGE DIGITAL I O Tests OFF 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 anal
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158. INTENANCE PROCEDURES 41 Maintenance schedules 41 INSPECT 41 General maintenance a 41 Man RE RU mE E 41 Burner Maintenance 42 Pressure relief valve a 42 Blower compartment a 42 AIR FICIER PO ERECTO 42 Condensate removal system 43 Venting maintenance 43 Heat exchanger maintenance 43 Handling Ceramic Fiber Materials 44 Replacement 2 2 44 e9Ilpcom I 45 46 LIMITED VRAIN ste eau opto than 47 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
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160. 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 Abnormal Recycle Fan failed during Measured 356 Ab IR le outlet hiah limit Purge Time 356 _ normal Recycle outlet high limi Abnormal Recycle Fan failed during Drive to Abnormal Recycle Fan failed during Pre Ignition Abnormal Recycle Fan failed during Pre Ignition Internal Errors ume 361 Internal error No factory parameters were Abnormal Recycle Fan failed during Ignition detected in control pence Internal error PID iteration frequency was invalid nomma nee 363 Internal error Demand Rate interval time was Establishing Period K E Main Valve off after 10 364 Internal error Factory calibration parameter for pd modulation was invalid le Recycle Pilot Valve off after 10 seconds Com CH PID hawana Abnormal Recycle Safety Relay off after 10 Internal error CH PID I scaler was invalid 8 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 m Abnormal Recycle Hardware static flame Internal error DHW PID l scaler was invalid Abnor
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162. LL NOT OPERATE FOLLOW THE INSTRUCTIONS TO TURN OFF GAS TO APPLIANCE CALL YOUR SERVICE TECHNICIAN OR GAS SUPPLIER TO TURN OFF GAS TO APPLIANCE SET SYSTEM TEMPERATURE CONTROLLER TOLOWEST C SETTING TURN OFF ELECTRICAL POWER TO BOILER 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 a sn Failure to make accurate adjustments could cause improper combustion resulting in death x gt t d P s gt ote 2 67 E tot us m ow Breathing carbon monoxide can cause brain damage or death Always read and understand instruction manual 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 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
163. NE GAS GAS 350087 ATAT 3 0 075 36 0 80 35 087 4 4 4 09 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 see Figure 4 on Page 6 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 2 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 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 Also 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 the next burner settings Check the flame voltage during high fire amp low fire settings Depending on th
164. OI Display The control configuration is grouped into the functional groups as shown in Table 6 TABLE 6 FUNCTIONAL CONFIGURATION GROUPS High Limit Stack Limit Delta T Limits Lead Lag Master Configuration Most of this configurations are already performed by the qualified service technician or at A O Smith Each functional group is displayed 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 7 TROUBLESHOOTING CODES CODE DESCRIPTION RECOMMENDED TROUBLESHOOTING OF NOTE wu CODES Safety Data Faults Unconfigured safety data New Device complete device yyy 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 fau
165. TRIC POWER TO THE BOILER CLOSE 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 FLAMMABLE A THIS APPLIANCE DOES NOT HAVE A PILOT IT 15 C 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 WI
166. User s Manual MODELS XB h 1000 1300 1700 e rn h 2000 2600 3400 SERIES 100 101 25589 Highway 1 OPERATION MAINTENANCE McBee SC 29101 LIMITED WARRANTY LA C CERTIFIED Low Lead Content 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 5 Installation and service must be Read and understand this manual performed by a qualified installer and all Warnings and Cautions within before installing and using service agency or the gas supplier Place these instructions adjacent 2 to boiler and notify owner to keep Thank you for buying this energy efficient boiler tor tuture referente We appreciate your confidence in our products PRINTED IN THE U S A 0513 32 00 TABLE OF CONTENTS TABLE OF 2 SAFE INSTALLATION USE AND SERVICE
167. WEAK threshold Internal hardware test Not a lockout 112 Pilot test flame timeout Interrupted Pilot or DSI application and flame lost when system in test mode 8 1 Reset the module to restart 113 Flame circuit timeout Flame sensed during Initiate or off cycle hold 240 L seconds if present after 240 seconds lockout 117 Condensate Fault 1 Check the condensate trap at the back of the boiler for any blockage 2 Check the exhaust vent piping for any blockage 29 CODE DESCRIPTION RECOMMENDED TROUBLESHOOTING OF NOTE LOCKOUT CODES me Lightoff rate proving failed Check wiring and correct any potential wiring 123 Purge rate proving failed 7 Check VFDs ability to change speeds Change the VFD If the fault persists replace the module High fire switch OFF Check wiring and correct any potential wiring 125 High fire switch stuck ON oe 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 adju
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169. able vapors and Breathing Hazard Carbon Monoxide Gas liquids in the vicinity of this or any other appliance e Special consideration must be taken with installations above 2000 feet 610 m Avoid all ignition sources if you smell gas Do not expose boiler control to excessive gas pressure Please contact an A O Smith qualified service agent to obtain the proper Use only gas shown on rating plate setup and instructions before lighting Maintain required clearances to combustibles Keep ignition sources away from faucets after extended CAE Sesh Failure to implement the proper setup period of non use will result in improper and inefficient operation of the appliance resulting in production of increased levels Read instruction manual before carbon monixide gas excess of the installing using or servicing safe limits which could result in serious personal injury or death Always read and understand instruction manual AWARNING CAUTION For continued protection against Improper installation and use may result risk of fire property damage ae etait si COR Donotoperate boiler ifflood damaged carpeted floor Install inlocation with drainage Do not operate boiler if flood Fill boiler with water before operation damaged Bealertforthermal expansion 4 Refer to instruction manual for installation and service INTRODUCTION This Instruction Manual
170. ain 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 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 WARNING Do notuse 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 technician should follow this procedure when the boiler s intake
171. arge boiler Control System consists of R7910A1138 Control Device S7999D Touchscreen Display required for setup and ModBus communication but not required for the system to operate once the R7910A1138 is programmed 57910 Local Keyboard Display Module Flame Rod Temperature Sensor NTC Type 10KQ at 77 F 25 C or 12KQ at 77 F 25 C Limit Sensor NTC Type 10KQ at 77 F 25 C 24V Digital I O OVERVIEW Functions provided 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 3 Three Pump Outputs with 5 selectable operation modes 24 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 5 External spark transformer 6 Flame sensor 7 Test jacks for flame signal measurement from a flame sensor 8 Alarm Output COMMUNICATIONS
172. ate 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 more Control 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 16 BURNER CONTROL 5799
173. ate was invalid vs RPM 63 Burner control rate nonfiring was gt absolute max 64 nd control rate nonfiring was absolute min Burner control rate nonfiring was absent Burner control rate nonfiring was invalid 9o Program Module PM was inserted into socket 68 ___ Setpoint was overridden due to sensor faut _ Modulation was overridden due to sensor fault 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 34 CODE DESCRIPTION CODE DESCRIPTION Fan Parameter Errors 114 MIX modulation range max minus min was too Periodic Forced Recycle small 496 or 40 RPM Absolute max fan speed was out of range Modulation Operation Faults 80 Fan pulses per revolution was invalid Fan PWM frequency was invalid eee rate was gt CH max 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 min No Lead Lag add stage error threshold was modulation rate configured Modulation rate was limited due to outlet limit No Lead Lag add stage detection time was Modulation rate was limited due to Delta T limit configured No Lead Laa d t Modulation rate was limited due to stack limit o Lead Lag drop stage er
174. ature 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 Shut the boiler down unless boiler used for domestic hot water 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 41 INSPECT BOILER AREA 1 Verify that boiler area is free of any combustible materials gasoline and other flammable vapors and liquids 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 Vacuum any sediment from inside the boiler and components Remove any obstructions GENERAL MAINTENANCE This is a pre
175. ay setpoint was invalid Establishing Period LL outdoor temperature was invalid 275 Recycle LCI off during Drive to Purge ate Lead Lag ODR time of day setpoint was invalid 2 6 Abnormal Recycle LCI off during Measured Purge Lead Lag ODR time of day setpoint exceeded Time normal setpoint Abnormal Recycle LCI off during Drive to Lightoff Lead Lag ODR max outdoor temperature was Rate invalid 278 Abnormal Recycle LCI off during Pre Ignition test Lead Lag ODR min outdoor temperature was invalid 29 Abnormal Recycle LCI off during Pre Ignition time 288 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 dili too small minimum 12 C 22 F Abnormal Recycle LCI off during Ignition period Lead Lag ODR water temperature range was too Abnormal Recycle Demand off during Drive to small minimum 12 C 22 F Purge Rate 241 Lead Lag DHW setpoint was invalid A Demand off during Measured u i Lead Lag Mix setpoint was invalid 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 duri
176. burner LOW FIRING RATE SETTING 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 2 SPARK IGNITER LOW HIGH GAS PRESSURE SWITCH This XB 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 if the pressure is below the preset pressure It closes as soon as the gas supply pressure is above the minimum supply pressure FIGURE 5 WATER FLOW SWITCH The High Gas Pressure Switch is normally closed and is used to detect excessive gas pressure 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 CAUTION Limit controls are safety devices and are NOT to be used as an operating device thermostat The XB models incorporate an outlet water sensor having dual sensors that are factory set at 210 F 99 C 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 boi
177. 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 in 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 dr
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179. e control when the OK button is pressed 20 250 OF U ganid Clear FIGURE 25 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 mixture 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 26 AN Boiler 1 D Safety Parameter Verification 8 Verification ID VERIFICATION FINISHED Select Begin to start verification EL Like operating parameters safety parameters can be viewed without the need to enter a password FIGURE 26 SAFETY VERIFICATION 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 22 on Page 19 is not yet enabled because the installer has not logged in NOTE When the installer proceeds with
180. e boiler size and capacity the flame voltage will be between 10 15 volts for low fire and 25 32 volts for high fire settings Check for gas valve settings and combustion for varied voltage levels TABLE 2 LOW FIRE RATE RPM CO MANIFOLD PRESSURE APPROXIMATE FACTORY SET INCHES W C KPA MODELS XB NATURAL PROPANE NATURAL PROPANE NATURAL GAS PROPANE GAS GAS 026005 0 14 003 023 005 NOTE Values listed in Table 1 and Table 2 are tested under laboratory conditions with minimum vent length Values may slightly vary depending on ambient conditions and field equipment accuracy TABLE 3 OPERATING CHARACTERISTICS Models Manifold Pressure Maximum Supply Pressure Minimum Supply Pressure XB Type of Gas Inches kPa Inches W C Inches kPa Natural 14 0 3 49 4 0 1 0 Propane 14 0 3 49 4 0 1 0 1000 1300 1700 0 11 2000 2600 0 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 l
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183. eaks 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 service technician for proper operation BURNER MAINTENANCE Qualified service technician 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 is necessary to loosen and slide the rubber coupling on the blower adaptor in order to move the blower 42 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 an
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187. erating Temperature 4 F to 150 F 20 C to 66 C Storage Shipping Temperature 40 F to 150 F 40 C to 66 C Humidity Up to 95 Relative Humidity noncondensing at 104 F for 14 days Condensing moisture may cause safety shutdown Vibration 0 0 to 0 5g Continuous V2 level Enclosure Nema 1 IP40 8 Approvals Underwriters Laboratories Inc UL Component Recognized File No MP268 MCCZ 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 SHUTDOWN OF BURNER CONTROL FUNCTIONS Safety Shutdown Lockout occurs if any of the following occur during the indicated period 1 INITIATE PERIOD a A C line power errors occurred b Four minute INITIATE period has been exceeded STANDBY PERIOD a Flame signal is present after 240 seconds b Main Valve Terminal is energized c Internal system fault occurred PREPURGE PERIOD a Flame signal is detected for 10 seconds accumulated time durin
188. es 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 camera button is for screen snapshot use Up to 16 snapshots can be stored in the display and can be copied to a USB memory stick A padlock indicates the operator is not currently logged in may have been timed out and a password is needed to change the setting An unlocked padlock indicates the password has been entered and the operator has logged into system successfully STATUS OR HOME PAGE A status summary page Figure 21 on Page 19 is displayed when the S7999D display is connected This status page appears on the S7999D 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 initial status page displayed contains summary status information as shown in Figure 21 Any status information not appl
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190. eters are saved in the control The above Reset dialog box automatically closes when this step is completed 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 Safety lockouts are indicated on each configuration page as an alarm bell symbol At the status page for S7999D the History button turns red If the S7999D 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 4 on Page 22 Current date time stamp is a display setup feature NOTE In the event of a power interruption the date time must be reset The Ol Display does NOT have a backup means TABLE 4 BURNER CONTROL LOCKOUT HISTORY COMMENT Set by display Unique code defining which lockout occurred First interlock in limit string results in a shutdown Fault description Source reason for lockout hold Burner control state timer at time of fault Burner control cycle Burner control hours All digital I O status at time of fault All annunciator I O status at time of fault Fault data Fault dependent data An alert log can be displa
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192. ever 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 28 m Boiler 2 Salety Parameter Verification Verification ID VERIFICATION FINISHED Verification is complete No more verification needed Begin FIGURE 28 SAFETY PARAMETER CONFIRMATION 21 Press the Yes button to confirm each safety parameter block 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 29 Burner 1 Safety Parameter Verification Verification ID PRESS RESET BUTTON AT DEVICE NOW Reset at device is needed Reset must be completed in 26 seconds Begin x FIGURE 29 SAFETY PARAMETER RESET When the Reset button is pressed and held for 3 seconds the confirmed safety param
193. 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 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 through 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 Corporation 500 Tennessee Waltz Parkway Ashland City TN 37015 1 800 433 2545 or in Canada A O Smith Enterprises Ltd 599 Hill Street West Fergus ON N1M2X4 1 888 479 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 t
194. g PREPURGE b 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 c 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 d Lockout Interlock if programmed does not close within 10 seconds e Lockout Interlock opens during PREPURGE f Main Valve terminal is energized g Internal system fault occurred PRE IGNITION TIME a Lockout Interlock opens b IAS Purge and Ignition enabled and the Interlock opens c Preignition Interlock opens d Pilot Valve terminal is energized e Main Valve terminal is energized PILOT FLAME ESTABLISHING PERIOD PFEP a Lockout Interlock opens if enabled b Pilot Valve terminal is not energized c No flame is present at the end of the PFEP or after programmed number of retry attempts d Main valve terminal is energized e Internal system fault occurred MAIN FLAME ESTABLISHING PERIOD MFEP a Lockout Interlock opens if enabled b Pilot valve terminal is not energized c Main valve terminal is not energized d No flame present at the end of MFEP e Internal system fault occurred RUN PERIOD a No flame is present or flame is lost if enabled lockout b Lockout Interlock open
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197. he parts list for more information For Technical Assistance call A O Smith Technical Information Center at 1 800 527 1953 44 NOTES 45 NOTES 46 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 EXCEPTIONS 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 tempe
198. icable for the installation is grayed blanked out on the screen Buttons on this screen include Configure used to configure the burner control password protected and all pre configured 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 for servicing and temperature setting purpose only 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 4 JOHLNOJ 4 13334 AW Id S10 LOHS d NS sJILSONSVI AW 1510 OF NVATY i 51015 TITIOIN L NOLVH3dO MIND sud 3H1 AVM 3INOH 5 NOJ HOWE FIGURE 20 5799902 DISPLAY PAGE FLOW 18 Boiler 1 a Demand OFF Firing rate 0 RPM Burner state Standby Fan speed LOW Setpoint Inlet Outlet Stack DHW Flame Setpoints Modulation Demand rate 0 RPM Limited rate Minimum modulation 1000 RPM Override rate Burner Control 0 RPM History Configure Operation x
199. ired 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 Voltage fluctuations vary less than 20VAC or greater than 30VAC Frequency fluctuations vary 5 57 to 63 Hz If Demand LCI or Stat interrupt open during the Prepurge Period 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 1 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 Ignition Time
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202. ler 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 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 Tem
203. lt repeats replace module 7 7 r r r 2 If fault repeats replace module Internal fault Unstable power DCDC output 5 ____ Internal faut Invalid processor cook _______ 8 ____ Internal faut Zero crossing not detected Internal faut Flame bias out 15 Internal fault Safety relay test failed due to feedback ON 16 Internal 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 H or L H or L 26 CODE DESCRIPTION RECOMMENDED TROUBLESHOOTING OF NOTE LOCKOUT CODES 3 Internal fault Flame bias shorted to adjacent pin Internal Fault 3 Internal fault SLO electronics unknown error 1 Reset Module 2 If fault repeats replace module 32 46 Internal fault Safety Key 0 through 14 s System Errors 47 Flame Rod to ground leakage Static flame not flickering 24 VAC voltage low high Check the Module and display connections Check the Module power
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205. mal Recycle Hardware flame current invalid Internal error DHW PID D scaler was invalid 373 Internal error Lead Lag master PID D scaler was 39 207122 Lag master PID Dealer was 332 Abnormal Recycle Hardware SLO flame bias rage Abnormal Recycle Hardware flame bias low Abnormal Recycle Hardware SLO flame bias heat Abnormal Recycle Hardware flame bias delta high 376 Abnormal Recycle Hardware flame bias dynamic 5 fame Has dynamic 38 _ 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 ww Internal Data Faults 467 Internal error EEPROM write was attempted before EEPROM was initialized Internal error EEPROM cycle count address was invalid Internal error EEPROM days count address was invalid le 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 written to EEPROM Internal error EEPROM hours count address was invalid Internal error Lockout record EEPROM index was invalid Internal error Request to w
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207. n bert toe 03 17 11 04 25 12 Alert 58 ve to Purge off Alarm was reset by the user at the control Cycle 14 Hours 4 Data 0 3 17 11 Clear x Lockouts gt Alert Filter 4 53 55 PM FIGURE 34 CONTROL EXPANDED ALERT DETAIL 23 OPERATION BUTTON The operation button displays the Burner Control running operation including setpoint and firing rate values From this page 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 as shown in Figure 35 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 36 and Figure 37 on Page 24 4L Boiler 2 Central Heat Operation Burner state Burner enable ON Demand Normal Central Heat Time Of Day 1600F Firing rate 6000 RPM Source Normal Outlet sensor 1390F Annunciation x FIGURE 35 HYDRONIC OPERATION PAGE Burner 1 Annunciation SYS ENABLE SWITCH OFF WC LOW WATER CUT OFF OFF LCI LCI FLOW SWITCH OFF ILK HGF HIGH GAS PRESSURE OFF LGP LOW GAS PRESSURE OFF ILK INTERLOCK OFF Other APS Unused OFF Unused OFF FVS Flap Valve Switch ON CS Condensate Switch ON FIGURE 36 PROGRAMMABLE ANNUNCIATION Boiler 2
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209. ng Safe CH ODR ti fd tpoint invalid 249 CH ODR time of day setpoint was invalid ODR time of day setpoint exceeds normal Purge Rate tpoint oe 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 O Abnormal Recycle Flame was lost early in Run scs eee Abnormal Recycle Flame was lost during Run CH ODR min water temperature was invalid Abnomia eade Leakage tesi aed eee 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 curing ie Remote Stat is enabled Abnormal Recycle Interr
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214. 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 Burner 2 Burner 1 Master View Lead Lag FIGURE 11 BURNER HOME SCREEN 8 1 a Demand OFF Firing rate 0 RPM Burner state Standby Fan speed LOW Setpoint Inlet Outlet Stack DHW Flame Setpoints Modulation 0 RPM Minimum modulation 1000 RPM Burner Control 0 RPM History FIGURE 12 BURNER INFORMATION SCREEN Demand rate Limited rate Override rate Click on Operation button and under the Modulation Menu set the required Firing rate High Low by setting the RPM Burner 1 Central Heat Operation L Burner state Standby Burner enable ON Normal 180 F Lead Lag Slave Time Of Day 1600F Firing rate 1700 RPM Source Unknown Outlet sensor 8009F Annunciation x FIGURE 13 OPERATION SCREEN On the Firing Rate page set the Firing rate RPM by selecting the Manual in Run check box 6 Firing rate Firing rate control Manual firing rate Automatic BE ena 4000 Time Of Da Manual in Run amp Standby Source OK Cancel Delete
215. og I O data is displayed as bar charts with I O level represented in the I O range see Figure 39 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 I O status 24 AN Boiler 2 e 4 8 Status Analog Outlet F Inlet F Firing rate RPM Flame signal uA V m i i Burner Digital E Tests Control 1 0 1 0 FIGURE 39 DIAGNOSTIC PAGE ANALOG I O SYSTEM CONFIGURATION S7999D 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 40 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 41 on Page 25 Unknown indicates that configuration data has not been retrieved from the control yet ole Current control Burner 1 Port Address Na COM 1 Bur 6 Boiler Search Address 8 4 Boiler s Found COM 1 4 Bur Change Rename Remove PM Modbus Address Control Control Configuration Configuration FIGURE 40 SYSTEM REFRESH The control connected to the Modbus network is indicated to the user after the search procedure has concluded Once the control is
216. om High line frequency occurred active configuration Low line frequency occurred Annunciation configuration was restored from Invalid subsystem reset request occurred factory defaults x 7 7 48 Write large enumerated Modbus register value 13 Annunciation configuration was restored from Safet ficationtabi tored f Maximum cycle count was reached afety group verification table was restored from Maximum hours count was reached 15 Safety group verification table was updated C Illegal Modbus write was attempted Invalid Parameter PCB was detected Modbus write attempt was rejected NOT ALLOWED Invalid Range PCB was detected co Illegal Modbus read was attempted stem Parameter Errors y Safety processor brown out reset occurred 18 Alarm silence time exceeded maximum 8 Application processor watchdog reset occurred Invalid safety group verification table was detected 20 Id t be determined 20 7 77 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 user a e 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 lt absolute min rate Burner control firing r
217. on Association UL Underwriters Laboratory e 5 Canadian Standards Association AHRI Air Conditioning Heating and Refrigeration Institute QUALIFICATIONS QUALIFIED SERVICE TECHNICIAN OR QUALIFIED AGENCY Installation and service of this boiler requires 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
218. oneoiunuuuJloo sep SUuluo OLN S4nejdeo S9 uonesi nn eunjeJeduuo ep ep 007 GSD xne euuo0Juo2 JUBLUBUUONOUO ep 007 Uuomnoes GSD xne 5 9oyunoos ep 008 40 uomnoes 052 xne euuojuo2 e qe deooe qSO Y9v LOO0S 92918 ep oJeuunu e jueuod ejqnop e OLN eju ep Jnejdeo e esi nn nbsJo ese ep JIISOdSIP un wwo 159 OLGZY 21 CLE IN ep 159 01624 91 ZOOW Jeissop nuuoooiJ JUeSOdWOD 9u seuoje1oqe 7 8 OPdl Jeniog ZA nunuoo ue 0 e 0 0 uoneJqiA eyunooes Joe un Jenbo oJd jned ep lipiuinu 1 sunof y 3uepued 4 YOL Op uonesuepuoo sues 66 2 Z 9 S PIWNH S 4 OGL Ot 7 99 5 Op uonipedxe p 4 OSL do 99 5 O OZ 1
219. 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 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 r
220. 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 ON 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 WILLBE 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 state
221. p oJeuunu un suoje JeiueJd ue Jesi n gt ednoJD suep 1s epueuuuloo snjd IS lt 1951 gt ep uonnooxe p gt Jeiueud Jesi n gt 590006 sioJ seo ep un e ep 5 5 2 eJeipneuo zuene 1 9 jned gt Jeiueud ue Jesi n gt ednoJ4D 9 suep 59 eJeipneuo eun IS ep uonnooxe p e suep quos inb seseud 59 1 9 e eseud e 159 inb op 5 5 9 159 919 oJeipneuo eJ 99 ep eseud e eJos ojuopoooud eseud eJ 1e xnej un e 6195 eseud 9Jeiulep nulup e siojejno uonejnpouJ oseud e 159 1090 eq inb ne 1190981 1459 inb 9 inb epueuJuloo 5 5 97 506 71 eDeuunje Jenjoejie ep euigis s jyeJinod no ejes inb ep eulgjs s 9jueAins
222. pe 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 changed 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 Boiler 2 Burner Control Ignition Pilot test hold OFF Ignition source Pilot ype Direct burner constant ignition Pilot Flame Establishing Period Unknown Main Flame Establishing Igniter on during First half of e Flame threshold 0 Login with proper access level required to change this parameter FIGURE 23 LOGIN REQUIRED KEYBOARD Some pages request user entry of characters When this type of input is required a keyboard page appears as shown in Figure 24 on Page 20 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 continuou
223. peratures 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 UP 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 en
224. 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 nimi WARNING indicates a potentially hazardous WARNING situation which if not avoided could result in injury or death CAUTION indicates a potentially hazardous CAUTION used without the safety alert Verre 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 s
225. preheat detect off threshold was invalid Delta T delay was not configured for recycle response 2 566 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 w 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 control settings Check spark igniter and flame sensors Clear and clean any deposits Check wiring and connections Perform start up checkout and performance verification e 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 temper
226. pted Airflow Switch ON 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 27 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 assure proper HorL function 3 Verify voltage through the interlock string to the interlock input with a voltmeter lf 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 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 If 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 If previou
227. r any leaks 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 LIGHTING AND OPERATING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE OPERATING FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE PER WARNING IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY A SONAL INJURY OR LOSS OF LIFE 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 STOP READ THE SAFETY INFORMATION ABOVE ON THIS LABEL SET SYSTEM TEMPERATURE CONTROLLER TO LOWEST SETTING TURN OFF ELEC
228. ratures 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 service 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
229. re 15 fault code history is displayed in a scrollable list with the most recent fault displayed first followed by the next most recent fault Summary information is displayed for each fault entry including the burner cycle count fault code and fault number with description Detailed information for a specific fault entry that also includes burner control sequence state burner run time hours annunciation status etc is viewed by selecting touching the History line the lockout entry in the list 22 Cm Lockout Detail Cycle 31 Hours 29 79 Outlet high limit 17 hours 30 mins 50 secs First Out None Timer Boiler 2 Lockout History Time Cycle Description 03 17 11 04 12 57 14 108 Flame lost in Run 2 13 109 Ignition failed 10 108 Flame lost in Run 7 2 Waiting for safety data verification 7 2 Waiting for safety data verification 7 2 Waiting for safety data verification 7 2 Waiting for safety data verification 4 33 45 PM 3 17 11 Clear Alerts gt gt FIGURE 31 EXAMPLE 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 OI display When the OI display first obtains the lockout and alert history from the control during the display
230. rite PM status was 39 wxEms 506 Mix ODR time of day setpoint exceeds normal setpoint Mix 10 J10 7 temperature was invalid Mix 55 J8 11 temperature was invalid Mix modulation sensor type was invalid 526 Mix ODR min water temperature setpoint was invalid Heat exchanger high limit wasn t allowed due to 574 aaa wasn t allowed due to configured for recycle response DAW Plate Heat Exchanger 548 Delta T rate limit enable was invalid 548 _ DHW plate preheat setpoint was invalid 549 Delta 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 was exceeded Tap detect ON hysteresis was invalid Inlet outlet inversion occurred Inlet DHW tap stop degrees was out of range 596 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 T inlet exchanger wasn t allowed due to stack connector setting DHW plate
231. ror threshold was s configured 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 ____ 96 ____ start was ended due to outlet sensor fault CH max modulation rate was invalid vs RPM k CH range max minus min was too max modulation rate was invalid vs RPM DHW max modulation rate was gt absolute max 103 range max minus min was too Min modulation rate was invalid vs RPM Operation Manual rate was invalid vs RPM asss CH Parameter errors continued IAS open step rate was invalid I 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 35 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 S
232. s 5 59 sepuooes juepued 159 uonesi eniuirgJ ep uojnoq e 311 038 NN NOILVSIIVILINIAN 62 0298 97 ul pajajdwio2 aq 3snui 32523 si 31352 d MON LY NOLIN 13533 55444 19 4euing Ba en614 e e3unoes ep ep UOISSSS e Ue ep ep uomnesi eniuloJ uojnoq 9 e Je ndde e 159 Jnojej ejsui 2111098 ep ep soo q 59 sno SoJdy seo suep eJnDiuoo uou un suep e7 uoneun6iuo2 9 uou 9junoos 204 eguuonoe es 159 UON gt ON gt euonoj 8 IS 9yunoos 204 enbeuo Inod INQ gt S9A gt euonoj uns Je nddy ALIMNODAS 38 3 Ve Vd NN d NOLLVINHIJNOO 82 x papaau aow ON s Q3HSINH Jaweed come e
233. s if enabled c IAS Purge and Ignition enabled and the Interlock opens d Pilot terminal energized if programmed as Interrupted Pilot e Main valve terminal is not energized f Internal system fault occurred POSTPURGE PERIOD a Preignition Interlock does not close in five seconds b Pilot Valve terminal is energized c Main Valve terminal is energized d Internal system fault occurred e Flame sensed 240 seconds accumulated time after the RUN period SAFETY SHUTDOWN 1 If the lockout interlocks open or a sensor designated as safety limit are read as defective Control 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 Ifthe 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 w
234. s 1euuoisiA Jnod 57 eun ins n d je 1 jueujeuuoisiA nod use j INS abeyoiye Jns euuoisiA jueuinoop jueuunoop un suep ep Jne oJiuoo ep seJjeuleJed se anpe 1819 1 unejesi nn e jeuued euejuejsui gt jousdeus gt 91 Syg ep 59 1uenuoo 5 sonsouDeip suonouo S SI AID uns gt gt e uns jue ndde 59 jne niq np suep e eAe osoe 9 enbsJjo uoneunBuuoo e suojnoq sep issne 9660 2 SsjuesoJd 1uos 59 enbsuo e INS penod eJeipneuo e ep WOU 310HVIN3H sed jse u xng sed enjoeje u 152 9 sep 105 xng 5 5 Jn9jo9j oo e
235. s 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 47 Smith 25589 Highway 1 McBee SC 29101 Technical Support 800 527 1953 Parts 800 433 2545 Fax 800 644 9306 www hotwater com Copyright O 2013 A O Smith Water Heater Company All rights reserved S AJ S 1 S IOJP JejeeH JejeM uius 0 V ELOZ 1uBu doo UJO2 MMM 90 6 v 19 008 9796 667 008 5909 0 2961 229 008 enbiuyos eouejsissv 1016 OS eegoyw AemubiH 6899 IUS 9 LV 1 13 39N3213333 H3AHSSNOO eJleuuoisseouoo 955900 uoud ep 9JIeuuoisseouoo WON ep ON ep ON 1509 99UIAOJQ 19 JIA esseJpy 9Jile3oudoug
236. s 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 Pressing the Login button allows entering the password from a keyboard as shown in Figure 24 After the password is entered the OK button is selected The Cancel button aborts the password login O 1 EL w FIGURE 24 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 Ol 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 25 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 th
237. s steps are correct and fault persists replace the module HorL HorL Co NO co HorL 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 Inlet sensor fault 1 Check wiring and correct any possible errors Replace the Inlet sensor If previous steps are correct and fault persists replace the module Inlet exchanger inversion limit Not Applicable HorL 83 84 85 87 88 1 9 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 28 CODE DESCRIPTION RECOMMENDED TROUBLESHOOTING OF NOTE LOCKOUT CODES 94 Header sensor fault Check wiring and correct any possible errors Replace the header sensor If 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
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239. sep INS sepuos 522 Jed s 5 p 91105 Ned 59 ep 5 jonuew jueujeuueaJ e un snid ep pueJdujoo 9105 ep epuos e si eJunjejeduje ep un 159 epuos juejos juegue oJnjeJeduue 2 euisn e 59 inb enbeuo enjos ep ep suJnejdeo eJnjeJeduJe ep sJnejdeo 59 SILYOS 13 3381N3 G 1VeddIN3 l AG SYNALdVD 5 5 9 suep 5 SJOAIP e e JeuiuJejop ep sepuos 595 ep sJojsiuueu eJnjeJeduje ep sJunejdeo sep juo 9 ep 591 S99 9 J UOISIOLULUI sepuos sep ep sunajdeo 59 nv3 ad 1 AG SUNALdVO 8 NVA SUNALdVD NOILVLNAWINV 0 e uonejueuure sed
240. serting 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 BURNER FLAPPER BLOWER MANUAL GAS SHUTOFF VALVE GAS PRESSURE SWITCH DIFFERENTIAL MANIFOLD PRESSURE TAP MODULATING GAS VALVE FLEX GAS MANIFOLDS FIGURE 10 GAS TRAIN ASSEMBLY 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 FREEZE PROTECTION HYDRONIC HEATING INSTALLATION 1 Determine freeze 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 Repai
241. sn jede Ju An d seugoi xne ejuepoooud e 1 Jnejesi nn e lt 3oeg gt sunoo ue uoneJedo ienooe p 9660 e e ep Jnoejesi nn e gt gt euono 6 uneuoedns suep gt yoeg eun ep suep lenooy gt gt eun 59660 ep yednid 65 39VHOlI33V 1 SLNVYNOD 39Vd unoeuo sinbe sajqiuodsip uos inb seJjeuleJed 59 Jesi ensiA 1 9 ep snoa 59660 sep s 02 91 4 e Jnejesi nn ejjenbe suep eJnjonujs eun suep juos 59660 se eeuiDed uode eun p suondo 59 59 9juesoJd ep ep 5 5 7 S39Vd 530 NOILLVOIAVN Jenunuoo 191 05 gt 6 gt uojnoq 660 np eugoi ins Je nddy ep no in
242. st 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 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 HorL HorL HorL HorL 137 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 FAULT CODES 149 THROUGH 165 ARE OEM SPECIFIC FAULT CODES hear TIT TU Das meme _____ ued ue internal fault Fiame bias out of range 4 Contact tne qualified 147 Internal fault Flame bias out of range 5 Contact
243. suep npJed 157 o unoos suoresiuoJuou S SIND 667 3 eunone p uosieJ ue jueujeuuoruoj mee rupi ne enpJed jeuuoue cor enduJoJ109 e 5 ep 21 SINO Sun p uosiei uo JUSLISUUONSUOJ oynpoud ne enpJed puew q jeuuoue 5 9 5 50 ep un s uu lui 967 jueueuuonouo ue ep 5 5 enpJed puew q jeuuoue Lov o unoos ep sie eJ uonesuodule sin u3 jueujeuuonouo ne 121 ne ep 5 Here oes ep So Sie np euBisuoo ep eyunoes ep e ep t 97 seuJejur suneu3 deje nodi np Jedes np np e7 19 91 3639 Jneje nouro 27 109110001 np enios ep ejun
244. 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 Module 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 qualified service technician model ID ss Apptoston contouraton data Book CRC eros esa bass G internal Fault HFS shoredioLFS IU Will not be a lockout fault Hold Only LCI OFF Check wiring and correct any faults Check Interlocks connected to the LCI to assure proper function Reset and sequence the module monitor LCI status If code persists replace the module PII OFF Check wiring and correct any faults Check Preignition Interlock switches to assure proper functioning Check the valve operation Reset and sequence the module monitor the PII status If code persists replace the module 6 fault repeats replace module HorL Interrupted Airflow Switch OFF Check wiring and correct any possible shorts Interru
245. sure 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 system of air Provisions should be made to permit manual venting of radiators or convectors 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 on Page 11 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 MANIFOLD PRESSURE CONNECTIONS Check the manifold pressure refer to Table 3 on Page 11 by removing the pipe plug located on the back of the boiler near the main gas shutoff valve and in
246. team modulation rate source parameter was invalid DHW modulation sensor was not compatible for AUTO mode DAW OperatonFauts SSCS 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 S5 J8 terminal 11 sensor was invalid CH 510 J10 terminal 7 sensor was invalid Lag Parameter eros 36 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 T Frost Protection 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 d
247. tem is turned on 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 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
248. the qualified service technician 448 Internal fault Flame bias out of range 6 Contact the qualified service technician L 30 T CODE 149 150 191 152 153 154 155 156 157 158 159 160 161 162 163 DESCRIPTION RECOMMENDED TROUBLESHOOTING OF LOCKOUT CODES Flame detected Flame not detected High fire switch ON Combustion pressure ON Combustion pressure Off OEM Specific 1 Holds if flame detected during Safe Start check up to Flame Establishing period OEM Specific 1 Sequence returns to standby and restarts sequence at the beginning of Purge after the HF switch opens If flame detected during Safe Start check up to Flame Establishing period OEM Specific 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
249. 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 which changes to unlocked on the page The installer may begin to change safety parameters or any other parameters at that time see Figure 27 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 2 Burner Control Timings amp Rates Ag Standby rate ORM Prepurge rate Preignition time Lightoff rate Run stabilization time Postpurge rate Postpurge time Bes t m Login with proper access level required to change this parameter FIGURE 27 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 How
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252. 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 and 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 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 power is removed The burner control supplies 24 volts to the gas valve during operation FIGURE 1 BURNER CONTROL SYSTEM HIGH FIRING RATE SETTING 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
253. upplies 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 rx CERTIFIED SP www ahridirectory org CERTIFIED Low Lead Content GENERAL SAFETY DANGER Fire or Explosion Hazard Read and understand this manual and all Warnings and Cautions Do not store or use gasoline or other flammable within before installing and using vapors and liquids in the vicinity of this or any other this appliance appliance Place these instructions adjacent to boiler and notify owner to keep for future reference A DANG ER Untempered hotwater can cause severe burns instantly resulting in severe injury or death Children elderly and the WARNING physically or mentally disabled x Explosion Hazard are at highest riskfor scald injury Z B Overheated water can cause Feel water before bathing or water tank explosion showering Temperature limiting valves are available b M Pieper sed Temperature and ressure relief valve Read instruction manual for safe E must be installed temperature setting ADANGER A WARNING Fire or Explosion Hazard Do not store or use gasoline or other flamm
254. upted air flow switch was CH 4mA water temperature setting was invalid Aang Mon ume 301 Abnormal Recycle Interrupted air flow switch was CH 20mA water temperature alc was off during Main Flame Establishing Period Steam 4mA water temperature setting was invalid 302 Abnormal Recycle onion taled due 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 37 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 cili 343 Abnormal Recycle Hardware A2D 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 308 Abnormal Recycle ILK off during Main Flame wo HES IAS sh Establishing Period 347 bnormal Recycle Hardware shorted Abnormal Recycle ILK off during Ignition period Abnormal Recycle Hardware PII INTLK shorted Run was terminated due to ILK was off Abnormal Recycle Hardware HFS LCI shorted 311 Run was terminated due to interrupted air flow Abnormal Recycle Hardware HFS
255. utilize two ModBus ports MB1 and MB2 for communications One port is designated to support a system S7999D 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 XB 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 The LL master coordinates the firing of 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 When the operating point reaches the Setpoint minus the On hysteresis then the first Control Sys
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258. y 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 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 Burn hazard Hot water discharge Keep hands clear of drain valve discharge 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 compartment 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
259. yed 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 5 TABLE 5 BURNER CONTROL ALERT LOG DATA COMMENT Alert Line Set by display Alert Code Unique Code defining which fault occurred Alert description DATA Lockout time Fault Code Annunciator first out Description Burner Lockout Hold Burner control state Sequence time Cycle Run Hours Annunciator 1 8 states Description 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 30 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 alert by alarm condition This History dialog box provides an exploded view of the status information displayed in the History button the font is larger One of the four buttons OK Lockouts Alerts or Silence can be selected If none of these buttons are selected the dialog box closes after 30 seconds Two types of historical data can be displayed on the history page lockout history and alert log The enti
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