Dunkirk DMG-240 Installation, Operation & Maintenance Manual
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Dunkirk DMG-240 Installation, Operation & Maintenance Manual

Condensing gas fired boiler
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CONDENSING GAS FIRED
BOILER
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
Model
DMG-240
Manufactured by:
ECR International Inc.
2201 Dwyer Avenue, Utica, NY 13501
Tel. 800 253 7900
www.ecrinternational.com
PN 240011656 REV. E [07/30/2018]

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Summary of Contents for Dunkirk DMG-240

  • Page 1 CONDENSING GAS FIRED BOILER INSTALLATION, OPERATION & MAINTENANCE MANUAL Model DMG-240 Manufactured by: ECR International Inc. 2201 Dwyer Avenue, Utica, NY 13501 Tel. 800 253 7900 www.ecrinternational.com PN 240011656 REV. E [07/30/2018]...
  • Page 2 VERIFY CONTENTS RECEIVED Safety Relief Valve (Maximum 50 PSI) Fully Assembled Boiler Metal Wall Bracket Temperature Includes essential documents. TP Gauge and Safety Relief Drain Valve Gas Shutoff Valve Document Package Valve Connections Used for measuring outside Used for connecting temperature condensate piping to boiler Condensate Drain...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS 1 - Important Information ........5 9 - Start Up Procedure ........49 9.1 Fill Condensate Trap With Water ....49 2 - Introduction ............ 6 9.2 Commission Setup (Water) ......49 3 - Component Listing .......... 7 9.3 Commission Setup (Gas) ......50 4 - Locating Boiler ..........
  • Page 4 PHYSICAL DATA Dimensions Front View Table 1: Physical Data Model Width (A) 17-¾" (450mm) Height (B) 31-¹/₁₆" (763mm) Depth (C) 23" (585mm) Bracket (D) Location of Bracket on 15-⅞" (403.2mm) back of unit Top View Size 1" (25.4mm) Vent Connector Location (G) 3-¾"...

  • Page 5: Important Information

    1 - IMPORTANT INFORMATION FOR YOUR SAFETY READ BEFORE OPERATING 1. Safety Information DANGER Boiler installation shall be completed by qualified agency. See glossary for additional information. WARNING Fire, explosion, asphyxiation and electrical shock hazard. Improper installation could result in death or serious injury.

  • Page 6: Introduction

    2 - INTRODUCTION 2 - Introduction 2.5 Designated Use • Hot water heating boiler. 2.1 Installation shall conform to requirements of authority • Indoor installation. having jurisdiction or in absence of such requirements: • United States • Closet or alcove installation. •...

  • Page 7: Component Listing

    3 - COMPONENT LISTING DMG-240 Condensate trap Gas Valve Air/gas Mixer Heat exchanger Burner sight glass Manual air vent Flue sensor Coaxial flue connector Exhaust test port Intake test port Thermal fuse (#6 on wire diagram) Exchanger flange high limit (#4 on...

  • Page 8: Locating Boiler

    Fire Hazard! Do not install on carpeting. Failure to Combustible Dimension Service (1)(2) Materials follow these instructions could result in death or serious injury. DMG-240 Model 4.1 Boiler Location Considerations 11-13/16" Top (A) 0" (0 mm) (300 mm) • Ambient room temperature always above 32°F (0°C) to 1-3/4"...
  • Page 9 4 - LOCATING BOILER FIGURE 4-1a Clearance to Combustible Materials FIGURE 4-2a Service Clearances - Boiler Front (See Table 2, page 8) (See Table 2, page 8) 0" (0mm) 0" (0mm) Boiler Front View 1-3/4" 1-3/4" (45mm) (45mm) Boiler Front View FIGURE 4-2b Service Clearances - Boiler Left side 0"...
  • Page 10 4 - LOCATING BOILER FIGURE 4-3 Wall Mount Bracket (Included) CAUTION Boiler weight exceeds 140 pounds (63.5 kg). Do not lift boiler onto wall without assistance. Center brackets. Avoid overhang on sides of Lift boiler using chassis. Using front jacket, vent Note wall mount bracket.

  • Page 11: Hydronic Piping

    5 - HYDRONIC PIPING • Support system piping and safety relief valve discharge Boiler rated at 50 psig (345 kPa) maximum Note piping. Boiler's internal piping and wall mount bracket can allowable working pressure. Boiler provided with be damaged if subjected to excessive weight. •...

  • Page 12: Safety Relief Valve And Air Vent

    5 - HYDRONIC PIPING FIGURE 5-2 Safety Relief Valve Discharge Piping WARNING Burn and scald hazard. Safety relief valve could discharge steam or hot water during operation. Install discharge piping per these instructions. Safety Relief Valve 5.3 Safety Relief Valve and Air Vent •...

  • Page 13: Trim Piping

    5 - HYDRONIC PIPING 5.5 Trim Piping • Connect supplied condensate trap to a drain. Verify there is continuous slope towards the drain, avoid level horizontal • Temperature - Pressure Gauge. Install temperature sections of tubing. pressure gauge using piping provided with boiler. See figure 5-1.
  • Page 14 5 - HYDRONIC PIPING Piping Legend Illustrations are meant to show system piping Note concept only. Installer responsible for all equipment and detailing required by authority having jurisdiction. Boiler Table 4 - System Piping Configurations Single Boiler/ Zone Valves Figure 5-4 / 5-6 Primary/Secondary Pumping Multiple Boilers Zone Pumps...
  • Page 15 5 - HYDRONIC PIPING FIGURE 5-4 - Primary/Secondary, Zoned, WITH ZONE VALVES, (Optional) Indirect Tank * Hot Water Supply Tempered Tank Sensor Optional Indirect BOILER DHW Tank Cold T & P Relief Water Valve to Supply Drain DHW Pump ASME Relief CH /System Valve...
  • Page 16 5 - HYDRONIC PIPING FIGURE 5-5 - Primary/Secondary, Zoned, WITH ZONE PUMPS, (Optional) Indirect Tank * Hot Water Supply Tempered Tank BOILER Sensor Optional Indirect DHW Tank T & P Relief Cold Valve to DHW Pump Water Drain Supply ASME Relief Valve CH /System...
  • Page 17 5 - HYDRONIC PIPING FIGURE 5-6 - Multiple Boilers Without Manifold, with Common Primary Secondary, Zone Valves and (Optional) Indirect CH/System Pump System Temperature Sensor # Boilers on Pipe PIPE # BOILERS ON Pipe Branch Size PIPE BRANCH SIZE 1-1/4 2-1/2 2½...
  • Page 18 5 - HYDRONIC PIPING FIGURE 5-7 - Multiple Boilers Without Manifold, with Common Primary Secondary, Zone Pumps and (Optional) Indirect DHW Pump System Temperature Sensor # Boilers on Pipe Pipe Branch Size 2½ UP TO 6 BOILERS Refer to pump manufacturer literature for proper pump sizing.

  • Page 19: Combustion Air And Vent Piping

    6 - COMBUSTION AIR AND VENT PIPING WARNING • Vent system shall have unrestricted movement through walls, ceilings and roof penetrations. Fire, explosion, and asphyxiation hazard. Improper • Wall and roof openings must be framed to provide support installation could result in death or serious attachment of termination assemblies.

  • Page 20: Definitions

    6 - COMBUSTION AIR AND VENT PIPING 6.3 Definitions • Turn on appliance being inspected. Follow lighting instructions. Adjust thermostat so appliances will operate Coaxial piping – Figure 6-1 exhaust and air intake pipe continuously. have a common axis. • Test for spillage at draft hood relief opening after 5 minutes of main burner operation.

  • Page 21: Approved Venting Materials

    6 - COMBUSTION AIR AND VENT PIPING • Natalini WARNING • DuraVent ® Manufacturer recommends this condensing boiler • Centrotherm be vented with approved polypropylene venting • Z-Flex ® material. Use only materials listed below for vent Note: Maximum equivalent length may vary between pipe, intake air pipe, and fittings.

  • Page 22: Coaxial

    6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-1 Side Wall Concentric Venting WARNING • Covering non-metallic vent pipe and fittings with thermal insulation shall be prohibited. • Use of cellular core PVC for venting flue gas could 18" Vertical Clearance to result in death, or serious injury.

  • Page 23: Twin Pipe Polypropylene And Cpvc Systems

    6 - COMBUSTION AIR AND VENT PIPING 6.6 Twin Pipe Polypropylene and CPVC Systems FIGURE 6-3 - Two Pipe Polypropylene System Adapter Twin pipe venting allows exhaust flue and intake flue to be separated from each other. Fresh air is drawn in at a different area from the flue terminal location.
  • Page 24 6 - COMBUSTION AIR AND VENT PIPING C. Mechanical Fastener Instructions - See Figure 6-5 FIGURE 6-5 - Mechanical Fasterner Connection for Manufacturer recommends use of a mechanical fastener at Dual Fuel Pipe every push-fit gasket connection when using a polypropylene vent.

  • Page 25: Venting Configurations

    6 - COMBUSTION AIR AND VENT PIPING 6.7 Venting Configurations Use of vent covers may cause freezing. If using Note Various venting configurations can be applied to this boiler. vent covers overall vent length must be considered. For guidance see Venting Configuration Table 5A and Failure to heed this information may compromise corresponding figures.
  • Page 26 6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-6 Two Pipe Roof Vent  12" (205mm) Min. horizontal separation between combustion air intake and vent 12" (205mm) Min. of same appliance.  12" (205mm) Min. 84" (2134mm) Max. 12" (305mm) Min. 15"...
  • Page 27 6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-9 Side Wall Venting Terminal w/T-Terminal Configurations of single pipe vent with flue on the Note sidewall, requires a tee as the vent terminal. See figures 6-17, 6-19 and 6-21 12" (305mm) Min. Separation of Combustion Air and Vent shall be maintained.
  • Page 28 6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-12 Flue on Roof, Indoor Combustion Air Maintain 12"(305mm) US (18"(457mm) Canada) Vent minimum clearance above highest anticipated Combustion air and Vent Piping Length Page 23. snow level maximum 24" (610mm) above roof 24"...

  • Page 29: Side Venting Terminal Requirements

    6 - COMBUSTION AIR AND VENT PIPING 6.8 Side Venting Terminal Requirements of : • USA - National Fuel Gas Code, ANSI Z223.1/NFPA 54. Venting terminal from doors and windows See figure 6-14 Venting terminal from forced air inlet of other appliances See figure 6-15 Venting terminal from snow level See figure 6-16...
  • Page 30 6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-17 Keep vent termination 3’ minimum Vegetation, (914mm) away from vegetation. Position Plants & termination where vent vapors will not Shrubs damage plants/shrubs or air conditioning equipment. Termination Vent termination US only - 4’ (1.2m), Meters, Canada - 6' (1.9m) horizontally from, no Regulators,...
  • Page 31 6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-19 Flue Termination Location Vent Termination Minimum Clearances CANADA Clearance above grade, veranda, porch, deck, or balcony 12" (305mm) 12" (305mm) Clearance to window or door that may be opened 12" (305mm) 3 ft.

  • Page 32: Multiple Boiler Venting - General

    6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-20 Correctly Mounted Piping WARNING Asphyxiation hazard. DO NOT use screws to secure piping together. Failure to follow these instructions USE OF CHECK VALVE IS could cause death or serious injury. MANDATORY WARNING Cascade venting of condensing boilers shall be vented with Duravent...
  • Page 33 6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-23 Secure Clamp around Flue Adapter Connect end cap and condensate trap to horizontal common vent pipe. See Figure 6-22. Connect 90° elbows to horizontal common vent pipe for each boiler in cascade system Connect flue damper to 90°...

  • Page 34: Multiple Boiler Venting - Layout

    6 - COMBUSTION AIR AND VENT PIPING 6.11 Multiple Boiler Venting - Venting Layout Available pressure at flue outlet is 0.40" w.c. (100pa) Maximum Vertical Length Heat Heat Input Number of Capacity Appliances 6 in *6 in / 8 in 8 in (150 mm) (150 / 200 mm)
  • Page 35 6 - COMBUSTION AIR AND VENT PIPING A. Single Line System System consisting of boilers arranged in line each connected to common exhaust manifold. FIGURE 6-26 2 in. per 3 ft. 4 in. (50.0 mm per 1.0 m) 3° B. Back to Back System This system consists of boilers installed back to back connected to a common exhaust manifold.

  • Page 36: Multiple Boiler Venting - Parameter Settings

    6 - COMBUSTION AIR AND VENT PIPING C. Double Line System This system consists of boilers installed on two lines, connected to a common exhaust manifold. FIGURE 6-28 2 in. per 3 ft. 4 in. (50.0 mm per 1.0 m) 3°...

  • Page 37: Condensate Piping

    6 - COMBUSTION AIR AND VENT PIPING FIGURE 6-29 Condensate Drain 6.13 Condensate Piping • Use materials acceptable to authority having jurisdiction. In absence of such authority: • USA - PVC or CPVC per ASTM D1785/D2845 Cement or primer per ASME D2564 or F493. Do not glue cap •...

  • Page 38: Gas Supply Piping

    • Size and install gas piping system to provide sufficient gas supply to meet maximum input at not less than minimum supply pressure. DMG-240 requires a gas rate of 242.59 ft3/h (6.87 m3/h) for Natural Gas (Gas A) and 95.04 ft3/h Gas Connection (2.69 m3/h) for Liquid Propane Gas (Gas E).

  • Page 39: Leak Check Gas Piping

    7 - GAS SUPPLY PIPING FIGURE 7-3 Manual Main Gas Shutoff Valve Outside DANGER Boiler Jacket Fire Hazard. Do not use matches, candles, open flames, or other methods providing ignition source. Failure to comply will result in death or serious injury.

  • Page 40: Electrical Connections

    8 - ELECTRICAL CONNECTIONS WARNING 8.1 General Electrically bond boiler to ground in accordance with Electrical shock hazard. Turn OFF electrical power requirements of authority having jurisdiction. Refer to: supply at service panel before making electrical • USA- National Electrical Code, ANSI/NFPA 70. connections.

  • Page 41: Access To Connection Block

    8 - ELECTRICAL CONNECTIONS 8.4 Access To Connection Block FIGURE 8-2 Remove Front Panel Unscrew two screws located under front panel. Remove panel. Guide controller or thermostat wire through round grommet(s) on right side of boiler's bottom plate right. Tilt control box forward by opening holding clips located on each side of boiler.

  • Page 42: Shutdown Input

    8 - ELECTRICAL CONNECTIONS FIGURE 8-3 Shutdown Input 8.6 Shutdown Input • Boiler has a shutdown input, input is on BL terminals of control board. • Only suitable for potential free contacts. • When using this input remove jumper cable. •...
  • Page 43 8 - ELECTRICAL CONNECTIONS FIGURE 8-7 Analog Temperature Based Control Analog Temperature-Based Control - 0 - 10 V signal controls boiler supply temperature between 32ºF (0ºC )and 176ºF (80ºC). Control modulates on basis of supply temperature, heat output varies between minimum and maximum values based on supply temperature set point calculated by the controller.
  • Page 44 8 - ELECTRICAL CONNECTIONS Connection Option For PCB (SCU-S02) FIGURE 8-9 Analog Output 0-10V If boiler is fitted with control PCB (SCUS02) it will automatically be recognized by the automatic boiler control. If removing this PCB boiler will show fault code E38. To prevent this fault, auto-detect must be done after removing the PCB.

  • Page 45: Outdoor Temperature Sensor

    8 - ELECTRICAL CONNECTIONS FIGURE 8-10 1k Ω Outdoor Temp Sensor Sensors supplied with this product are proprietary Note to the manufacturer. Use of after market sensors will result in diminished performance. 1 K Ω 8.9 1 K Ohm (1K Ω) Outdoor Temperature Sensor Outdoor Temperature Flow Temperature P1 - Supply temperature (maximum)

  • Page 46: Dhw Indirect Water Heater

    8 - ELECTRICAL CONNECTIONS 8.11 10 K Ω DHW Indirect Water Heater FIGURE 8-12 10k Ω Indirect Water Heater Thermostat Connect 10k Ω DHW indirect tank sensor or thermostat (TS) to "T dhw" terminals on control board. 10 K Ω 8.12 Frost Protection Frost protection in combination with ON/Off thermostat.
  • Page 47 8 - ELECTRICAL CONNECTIONS FIGURE 8-14 Example Of Hydronic Circuit With DHW Indirect Water Heater 10 K Ω • Connect Indirect tank sensor to Tdhw terminals as described in section 8.11. • Connect CH (Central Heating) pump on terminal N-L "Pump"...
  • Page 48 8 - ELECTRICAL CONNECTIONS FIGURE 8-16 Wiring Diagram P/N 240011656, Rev. E [07/30/2018]...

  • Page 49: Start Up Procedure

    9 - START UP PROCEDURE FIGURE 9-1 Condensate Drain Assembly 9.1 Fill Condensate Trap with Water WARNING Pour approximately Asphyxiation hazard! Fill condensate trap before 1 cup of water starting boiler to avoid combustion products escaping into flue way of boiler.

  • Page 50: Commission Setup (Gas)

    9 - START UP PROCEDURE FIGURE 9-2 Gas Valve WARNING Fire, explosion, and asphyxiation hazard! Boiler is set for natural gas from the factory. If propane is to be used the gas valve must be adjusted before turning boiler on. Failure to follow these instructions could result in death or serious injury.

  • Page 51: Control Panel

    9 - START UP PROCEDURE 9.5 Control Panel Display [Escape] or RESET button Heating Temperature or [-] button DHW temperature or [+] button [Enter] or cancel lock-out button Setup buttons (press the 2 and 3 buttons simultaneously) [Menu] buttons (press the 4 and 5 buttons simultaneously) ON/OFF switch Symbols...

  • Page 52: Deaeration Function

    9 - START UP PROCEDURE 9.6 Deaeration Function FIGURE 9-3 AERATOR Control performs the Deaeration function at initial Note start and after a reset of a locking error and after power up. Before starting boiler deaeration function must be performed. Rotate black cap on deaerator, located inside the boiler, counter clockwise ...

  • Page 53: Commissioning

    Verify there are no gas leaks. The temperature of combustion air must be measured on the air intake test port (B) by inserting the measurement sensor Natural Gas Propane approximately 3-3/16" (80.00 mm) (C) for the DMG-240. Venturi Nozzle Venturi Nozzle 1 ³/₁₆...

  • Page 54: Combustion Setup (High-Fire)

    9 - START UP PROCEDURE 9.10 Combustion Setup (High-Fire) 9.11 Combustion Setup (Low-Fire) • Unscrew exhaust port plug at exhaust flue test port. • Unscrew exhaust port plug at exhaust flue test port. • Insert combustion analyzer into exhaust flue test port. •...

  • Page 55: User Level Parameters

    9 - START UP PROCEDURE FIGURE 9-9 - User Level Parameters 9.13 User Level Parameters Parameters P1 to P8 can be adjusted by end user to meet heating system and DHW comfort needs. Modification of factory settings may be detrimental to operation of the boiler.

  • Page 56: Parameters Settings

    With these settings, most heating systems operate correctly; however, installer can adjust parameters according to their own preferences. Factory Setting Parameter Description Adjustment Range DMG-240 Max flow temperature during CH mode 68 to 194ºF 176°F/80°C (Set temperature) 20 to 90ºC 104 to 149ºF...
  • Page 57 9 - START UP PROCEDURE Parameters Settings - Continued Factory Setting Parameter Description Adjustment Range DMG-240 Clima point heating curve -22 to 32ºF outside temperature (Only -30 to 0ºC with an outdoor temperature 241= 5ºF/-15ºC sensor) Pump control, CH minimum...
  • Page 58 9 - START UP PROCEDURE Parameters Settings - Continued Factory Setting Parameter Description Adjustment Range DMG-240 Modulate back when dT > 41 to 140ºF 140º/60ºC this parameter 5 to 60ºC DHW stabilization time 10 to 100 seconds 0 = Metric...

  • Page 59: Reading Measured Values

    9 - START UP PROCEDURE 9.16 Reading Measured Values The following current values can be read from the information menu • St = State • Su = Sub-status • t1 = Supply temperature ºF/ºC • t2 = Return temperature ºF/ºC •...

  • Page 60: Status And Sub-Status

    9 - START UP PROCEDURE 9.17 Status And Sub-Status The information menu gives the following status and sub-status information: State (St) Sub-status (Su) Rest Rest Short pre-purge of the fan Control three-way valve Boiler starts (Demand for heat) Start pump sw checks sensor temperatures before the burner starts Open flue gas damper/external gas valve Increase fan speed...

  • Page 61: Return To The Factory Settings

    9 - START UP PROCEDURE 9.18 Return To The Factory Settings: • Press the two Menu buttons simultaneously and then (+) button until symbol flashes on the menu bar. • Select the INSTALLER menu using . "COdE" appears on the display. •...

  • Page 62: Operating Instructions

    10 - OPERATING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE OPERATING 10.2 OPERATING INSTRUCTIONS Stop! Read Safety information above. WARNING • Set thermostat to lowest setting. If you do not follow these instructions • Turn "OFF" all electrical power to appliance. exactly, a fire or explosion may result causing property damage, personal injury or loss of •...

  • Page 63: General Maintenance And Cleaning

    11 - GENERAL MAINTENANCE AND CLEANING FIGURE 11-1 Sight Glass DANGER Before servicing, turn off electrical power to boiler at service switch. Close manual gas valve to turn Sight Glass gas supply OFF to boiler. Failure to comply will result in death or serious injury. CAUTION Label all wires prior to disconnection when servicing controls.
  • Page 64 11 - GENERAL MAINTENANCE AND CLEANING 11.2 Annual Shut Down Procedure • Circulator pump and combustion air blower motor furnished with boiler are permanently lubricated from factory and • Follow instructions “To Turn Off Gas To Appliance” unless require no further lubrication. Lubricate field sourced boiler is also used to supply domestic hot water.
  • Page 65 11 - GENERAL MAINTENANCE AND CLEANING 11.4 Maintenance And Routine Servicing WARNING Check and service boiler as necessary. Following service procedures must be performed Frequency of servicing will depend upon installation conditions by qualified service agent. Boiler owner shall not and usage, manufacturer recommends annually.
  • Page 66 11 - GENERAL MAINTENANCE AND CLEANING 11-1 Electrodes DANGER Before servicing, turn off electrical power to boiler at service switch. Close manual gas valve to turn gas supply OFF to boiler. Failure to comply will result in death or serious injury. 11.6 Draining the Boiler •...

  • Page 67: Ratings And Capacities

    Number (MBH) (1)(2) Maximum Minimum DMG-240 95.0 1000 Btu/hr (British Thermal Units Per Hour) Heating Capacity and AFUE (Annual Fuel Utilization Efficiency) are based on DOE (Department of Energy) test procedures. Net AHRI Ratings based on piping and pickup allowance of 1.15. Contact Technical Support before selecting boiler for installations having unusual piping and pickup requirements, such as intermittent system operation, extensive piping systems, etc.

  • Page 68: Trouble Shooting

    13 - TROUBLE SHOOTING 13.1 Troubleshooting This boiler is fitted with an electronic regulation and control unit. Control system is a microprocessor, Comfort Master©, which controls and protects the boiler. If a fault is detected anywhere in the boiler, boiler will lock out and display will show the fault code as follows: Red flashing display: •...
  • Page 69 13 - TROUBLE SHOOTING Error Code Table Error Description Probable Causes Checking/Solution Code Replace the sensor if necessary Purge the air in the Temperature difference Sensor fault heating system between the supply and Sensor not/poorly connected Check for water circulation (direction, pump, valves) return temperatures too No circulation Check that the sensors are operating correctly...

  • Page 70: Shutdowns And Lock-Outs

    13 - TROUBLE SHOOTING Error Code Table Error Description Probable Causes Checking/Solution Code Check whether the SU PCB has been correctly fitted in Communication error with Bad connection connector on PCU PCB SU PCB Communication error with Bad connection Check the wiring Replace SCU PCB SCU PCB Defective SCU PCB Bad connection...
  • Page 71 13 - TROUBLE SHOOTING Shutdown Code Table Shut- down Description Probable Causes Checking/Solution Code Parameter error on the PSU Su:0 Parameter error Reset df and dU Restore parameters Maximum supply Non-existent or insufficient Check the circulation (direction, pump, valves) Su:1 temperature exceeded circulation / sensor error Reasons for the heat demand...
  • Page 72 13 - TROUBLE SHOOTING Shutdown Code Table Shut- down Description Probable Causes Checking/Solution Code Su:20 Identification running No action required Communication error with Check whether SU PCB has been correctly fitted in the Su:21 Bad connection SU PCB connector on SU PCB Purge gas supply to remove air Check gas valve is fully opened No flame during...

  • Page 73: Error History

    13 - TROUBLE SHOOTING 13.3 Error History Boiler control is equipped with error memory which, records last 16 errors. In addition to storing error codes, the following data is also saved: • Number of times that the error occurred: (n:xx). •...

  • Page 74: Optional Sensors

    13 - TROUBLE SHOOTING 13.5 Optional Sensors 1 K Ω Outdoor Air Sensor, if used. A. Boiler automatically recognizes sensor when used. B. See Chart 1 for sensor data. Sensor part number BD710487302V C. Locate outdoor sensor to protect against wind and direct sunlight. Mounting instructions provided with sensor. D.

  • Page 75: Troubleshooting Chart 1

    13 - TROUBLE SHOOTING Troubleshooting Chart 1 E02 - Supply Sensor Short E03 - Supply Sensor Open E04 - Heat Exchanger Temp. E05 - Heat Exchanger Temp. E06 - Return Sensor Short E07 - Return Sensor Open E08 - Low Return Temp. E09 -High Return Temp.

  • Page 76: Troubleshooting Chart 2

    13 - TROUBLE SHOOTING Troubleshooting Chart 2 E16 - False Flame Signal Turn Off All Heat Calls Inspect Burner through sight glass. Is flame present? Initiate heat call. Check CO Replace Gas at high fire is 9.1-9.5% Valve Out of Range In Range Adjust Gas Mixture See Section 9.

  • Page 77: Troubleshooting Chart 3

    13 - TROUBLE SHOOTING Troubleshooting Chart 3 E12 - High Temperature Is High Limit Jumper Plug in Place? Is external Re-install plug High Limit Switch off? NO or N/A Check switches 4 and 5 in wire diagram. Both electrical connected and continuity? Reset Switch Does heat...

  • Page 78: Troubleshooting Chart 4

    13 - TROUBLE SHOOTING Troubleshooting Chart 4 E10, E11 - Temperature Difference Between Supply and Return Too Great E35 - Supply and Return Sensors Reversed Is return line warmer than supply line? Error Code is Check water pressure. Is water accurate.

  • Page 79: Troubleshooting Chart 5

    13 - TROUBLE SHOOTING Troubleshooting Chart 5 E14 - Burner Start Up Failures Is this a new boiler on first startup? LP installation? Is the gas shutoff valve closed? LP Conversion Kit installed? Check all wires including Open the gas shutoff igniter and gas valve are valve Install...

  • Page 80: Troubleshooting Chart 6

    13 - TROUBLE SHOOTING Troubleshooting Chart 6 E36 - Burner Flame Loss LP Installation? LP Conversion kit installed? Is gas shutoff valve fully open? Install LP Conversion Kit Check all wires including Open Gas shutoff valve. igniter and gas valve are connected and tight.

  • Page 81: Troubleshooting Chart 7

    13 - TROUBLE SHOOTING Troubleshooting Chart 7 E34 - Fan Fault Check all wires including blower valve are connected and tight Check venting for Connect all obstruction (both inlet and wires and exhaust) assure secure Replace Blower Clear Vent Assembly Obstruction Troubleshooting Chart 8 E39 - Shutdown Input In Locked Out Mode...

  • Page 82: Troubleshooting Chart 9

    13 - TROUBLE SHOOTING Troubleshooting Chart 9 E40 - HRU/URC Unit test error Is HRU terminal being used on the auxiliary SCU board (see section 8) ? Is wiring connection to HRU Is wiring connection from terminal secure? SCU board to main board secure? Fix Wiring Fix Wiring...

  • Page 83: Troubleshooting Chart 10

    13 - TROUBLE SHOOTING Troubleshooting Chart 10 Note: This error code refers to the onboard low water E42 - Low Water Pressure pressure switch, not any field installed external low water cutoff device. Check system water pressure with tridicator or other device. Is water pressure at least 15 psig? The error code is Check wire harness...

  • Page 84: Troubleshooting Chart 11

    13 - TROUBLE SHOOTING Troubleshooting Chart 11 E43 - No Water Temperature Difference During Operation Start Boiler. Is supply line warmer than return line? Onboard pump operating properly? Replace Pump Check wire plugs are Possible air in the securely connected to system.

  • Page 85: Temperature-Resistance Chart

    13 - TROUBLE SHOOTING Figure 13-1 Temperature-Resistance Chart for Supply and Return Temperature Sensors T (°C) T (°F) R (Ohm) 309396 171840 98932 58879 36129 22804 14773 12000 9804 6652 4607 3252 2337 1707 1266 P/N 240011656, Rev. E [07/30/2018]...

  • Page 86: Glossary

    14 - GLOSSARY • APPLIANCE - Device to convert gas into energy; term • DOMESTIC - Relating to household usage as opposed to includes any component, control, wiring, piping or tubing commercial usage. required to be part of the device. •...
  • Page 87 15 - GLOSSARY • PRESSURE TEST - Operation performed to verify gas tight integrity of gas piping following its installation or modification. • PURGE - To free gas conduit of air or gas, or mixture of gas and air. • PURGE TIME - Period of time intended to allow for dissipation of any unburned gas or residual products of combustion.
  • Page 88 IMPORTANT In accordance with Section 325 (f) (3) of the Energy Policy and Conservation Act, this boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases. This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the same function.

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