HTP EFTC-140F Service Manual
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HTP EFTC-140F Service Manual

Hot water combination boiler
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EFTC-140F Hot Water Combination Boiler
Advanced Heating
& Hot Water Systems
120 Braley Road, East Freetown, MA 02717
•
1-800-323-9651
•
www.htproducts.com
LP-528 REV. 8.01.14

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Summary of Contents for HTP EFTC-140F

  • Page 1 Service Manual EFTC-140F Hot Water Combination Boiler Advanced Heating & Hot Water Systems 120 Braley Road, East Freetown, MA 02717 • 1-800-323-9651 • www.htproducts.com LP-528 REV. 8.01.14...
  • Page 2 EFTC-140F Hot water combination boiler Service Manual Model EFTC-140F (Hot Water Combination Boiler) • Natural Gas ( NG ) – Factory Default • Liquid Propane Gas ( LP ) – Field-Convertible (Refer to the gas conversion manual.) Heat Exchanger bears the ASME “H” Stamp 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 not store 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 · Do not try to light any appliance. · Do not touch any electrical switch; do not use any phone in your building.
  • Page 3 LP-528 REV. 8.01.14...

  • Page 4: Table Of Contents

    Chapter 1 Product Characteristics Specifications Dimensions Components Description Flow chart Time chart Operation flow chart Wiring diagram Connector function Chapter 2 Components description Main Control Board Temperature sensors Burner Overheat Switch Water level detection sensor Detection sensor Jumped wire connection Air Pressure switch Condensate Blockage APS Flow sensor Ignition transformer Flame Detection Sensor Gas valve BLDC Fan Burner assembly Fire Tube Heat exchanger Condensate trap Internal DHW storage tank Internal CH/DHW circulation pumps DHW Mixing Valve Chapter 3 How to use control panel Function explanation Contol panel LCD Specification Control Panel Mode DHW Temperature Control DHW Temperature Control CH Supply water temperature control LP-528 REV.
  • Page 5 Outdoor temperature display Water flow rate (GPM or LPM) CH Return water temperature Fan Speed (RPM) Program Lock mode CH Supply water temperature DHW Outlet Water Temperature Exhaust Gas Temperature Internal storage tank water temperature Overheat temperature sensor View supply power time View Burner Operating Time (Unit: 1hr) View Burner Operating Time (X 1000 hr) View Ignition cycles (X 10 times) View Ignition cycles (X 10,000 times) Pump Condition Display Fault Code History Clear Error Code History System Reset Change DHW Flow Rate Measurement Unit Internal Storage tank Preheating Mode Change maximum outdoor temperature Change minimum outdoor temperature Fan, Max RPM Adjustment Fan, Min RPM Adjustment Reset Burner Operating Time Delete Igniting Cycles Boost Function CH anti-cycling time Burner ON temperature LP-528 REV. 8.01.14...
  • Page 6 Warm weather shut down Maximum CH supply temperature Minimum CH supply temperature Maximum DHW Set Temperature CH Capacity DHW Heating Capacity Internal CH primary pump post run time Internal CH pump overrun timer (ON) Internal CH pump overrun timer (OFF) Internal DHW Storage Tank Set Point Internal DHW Storage Tank Differential Delay Time (from DHW to CH Mode) Internal CH Pump Post Purge Timer Internal CH & DHW Pumps Test Mode Chapter 4 Troubleshooting Flame Detection Gas Detection APS/Burner Overheat Switch Storage DHW/Exhaust Overheat Error code Error Code 10 Error Code 11 Error Code 16 Error Code 20 Error Code 28 Error Code 29 Error Code 30 Error Code 32 Error Code 33 Error Code 35 LP-528 REV. 8.01.14...
  • Page 7 Error Code 36 Error Code 37 Error Code 38 Error Code 40 Error Code 41 Error Code 42 Error Code 43 Error Code 61 Error Code 66 Error Code 68 Error Code 72 Error Code 76 Error Code 80 Error Code 81 Error Code 85 Error Code 94 Chapter 5 Replacement instructions Blow Assembly Gas Valve Flow Sensor Electronic Mixing Valve APS (Air Pressure Switch) Inter Primary CH Circulation Pump Internal DHW Storage Tank Flame Detection Sensor Main Controller Ignition Transformer Chapter 6 Components diagram Repair Parts Diagram Memo LP-528 REV. 8.01.14...

  • Page 8: Chapter 1 Product Characteristics

    Chapter 1 Product Characteristics Specification ■ Model Name EFTC-140F 140,000 Btu/h Gas Input Rate 28,000 Btu/h AFUE 93.2% 35°F Rise 7.1 Gal Hot Water Capacity 45°F Rise 5.5 Gal 77°F Rise 3.2 Gal Installation Indoor / Floor stand type Flue System Sealed Combustion Direct Vent Vent Run 2″(50ft) , 3″(100ft) Schedule 40 PVC, CPVC, PP, SS NG(Orifice/Needle) 0.232″ (5.9 mm) Orifice Size LP(Orifice/Needle) 0.185″ (4.7 mm) 3.5″ WC to 14″ WC Gas Supply Pressure 3.5″ WC to 14″ WC Low Fire 2″/3" VENT NG: -0.0039″ WC / -0.002″ WC Manifold Pressure High Fire 2"/3″ VENT NG: -0.374″ WC / -0.216″ WC Main Supply...

  • Page 9: Dimensions

    Chapter 1 Product Characteristics ■ Dimensions Description Diameter Gas Connection Adapter 1/2″ NPT (1/2 x 3/4 Bell Coupling Provided to Upsize Gas Line) ‘CH supply’ Adapter 1″ ‘CH return’ Adapter 1″ ‘DHW outlet’ Adapter 3/4″ ‘DHW inlet’ Adapter 3/4″ Condensate Adapter 1/2″ Drain Adapter 1/2″ Exhaust Vent Connection 3″ Intake Pipe Connection 3″ LP-528 REV. 8.01.14...

  • Page 10: Components Description

    Chapter 1 Product Characteristics ■ Components Description K1-14CCB K1-19CCB Name of Component Name of Component Exhaust Outlet Collar Water Mixing valve Main PCB Bracket Water Fill Valve BLDC FAN DHW Outlet Connector Automatic Air Vent CH Return Connector Flame Detection Sensor CH Supply Connector Main PCB Main Heating Exchanger Assembly Exhaust Gas Pipe Confirmation Window Flame Manual Switch Gas Inlet Connector Power Port Ignition Trans CH Circulation Pump Igniter Air Pressure Sensor Gas Valve Tilt Switch Air Pressure Sensor Sub Heat Exchanger Assembly Air Intake Pipe Internal Circulation Pump Air Intake Collar Water Discharge Pipe & Connector Condensate Outlet Connector Condensate Collector...

  • Page 11: Flow Chart

    Chapter 1 Product Characteristics ■ Flow chart [ Space Heating Mode ] [ Domestic Hot Water Mode ] LP-528 REV. 8.01.14...

  • Page 12: Time Chart

    Chapter 1 Product Characteristics ■ Time chart ■ If normal ignition IGNITION GAS VALVE FLAME DETECTION 3s 1.5s 3s ■ If flame extinguishes IGNITION GAS VALVE FLAME DETECTION 120s (1st : 60s + 2nd 60s) ■ If abnormal ignition (Alarm after the 10 trial) IGNITION GAS VALVE FLAME DETECTION 3s 1.5s 3s 1.0s 10s 1.0s 3s LP-528 REV. 8.01.14...

  • Page 13: Operation Flow Chart

    Chapter 1 Product Characteristics ■ Operation flow chart LP-528 REV. 8.01.14...
  • Page 14 Chapter 1 Product Characteristics ■ Operation flow chart LP-528 REV. 8.01.14...

  • Page 15: Wiring Diagram

    Chapter 1 Product Characteristics ■ Wiring Diagram LP-528 REV. 8.01.14...
  • Page 16 Chapter 1 Product Characteristics ■ Wiring Diagram Mixing Valve LP-528 REV. 8.01.14...

  • Page 17: Connector Function

    Chapter 1 Product Characteristics ■ Connector function Connector Descriptions no. of location and SELV Pin nr. Board Silk type GROUND Power Supply Line HT (120VAC) Pump 1: DHW Pump HT (120V~) Ignitor HT (120V~) L(HT) Pump 2: Central Heating Pump HT (120V~) 65001WS-12 Gas Valve HT (120V~) Power Supply Neutral HT (120V~) 9-12 AC Power COM Line HT (120V~) RS485 + SELV (5VDC) RS485 - SELV (5VDC) RS-485 SMW250-05 RS485 + SELV (5VDC) RS485 - SELV (5VDC) Unuse SELV (26VDC) SELV (14VDC) LWD1140-06...
  • Page 18 Chapter 1 Product Characteristics ■ Connector function Connector Description no. of location and Pin Board SELV type Silk Flame Detect Sensor SELV (5VDC) OP.S Operation water temperature sensor SELV (5VDC) DH.S DHW temperature sensor SELV (5VDC) Returen water temperature sensor SELV (5VDC) LWD1140-14 BG.S Exhaust temperature sensor SELV (5VDC) ST.S Storage water temperature sensor SELV (5VDC) SP.S CH Over heat temperature sensor SELV (5VDC) SELV (14VDC) IWM Stepper motor position SELV (14VDC) SELV (14VDC) IWM Stepper motor coil X phase SELV (14VDC) CN14 IWM Stepper motor coil Y phase SELV (14VDC) SMW250-09 SELV (14VDC) IWM Stepper motor coil /X phase SELV (14VDC)

  • Page 19: Chapter 2 Components Description

    Chapter 2 Components description Description / Part # Main Control Board / 7855P-008 Check Point Function This part controls all components contained in the combination boiler. Failure Event Abnormal main controller operation. When the main controller has abnormal condition, components may not operate Effects properly. Error Code Er 38, Er 70 Diagonostic Check each connection and/or wires damage on the PCB. Color / Wire Number LP-528 REV. 8.01.14...

  • Page 20: Temperature Sensors

    Chapter 2 Components description CH Supply Temperature Sensor: 7855P-031 Storage Temperature Sensor: 7855P-057 Description / Part # Check Point DHW Temperature Sensor: 7855P-094 Exhaust Temperature Sensor: 7855P-092 The controller compares each sensor with setting temperature then goes to Function safety shut down when measured temperature is over the setting temperature. Failure Event Sensor malfunction or overheating condition detected.

  • Page 21: Burner Overheat Switch

    Chapter 2 Components description Description / Part # Burner Overheat Switch: 7855P-066 Check Point CN11 Burner Overheat limit switch prevents damage to burner plate caused by Function temperature exceding 392 º F Failure Event Detects overheating temperature if switch has an abnormal condition. Effects Boiler shuts down if burner plate temperature exceeds the setting temperature. Error Code Er 43 ① Check the connection around the overheat limit switch and use a multi meter to measure resistance. If resistance is 0 Ohm , replace the switch. Diagonostic ② Check the 'Dip Switch' setting on the 'Main PCB'. ③ Check gas orfice 'Nozzles' Size. Color / Wire Number ① Temperature switch_burner upper (392℉/200℃ , orange) : Connector ⑦,⑮ ① ② ③ ④ ⑤ ⑥ ⑦ ⑧ ⑯...

  • Page 22: Water Level Detection Sensor

    Chapter 2 Components description Water Level Detection Sensor: Description / Part # Check Point CN11 7855P-029 Function This sensor detects water level inside of heat exchanger to prevent dry fire. Failure Event Water is not detected at proper level . Effects Boiler operation is interrupted. Error Code Er 80 ① Visual inspection : wiring connection Diagonostic ② Check CH pressure gauge (minimum CH pressure is 15 PSI). Color / Wire Number ① Water level sensor (red/green) : Connector ②,⑩ ① ② ③ ④ ⑤ ⑥ ⑦ ⑧ ⑯ ⑨ ⑩ ⑪ ⑫ ⑬ ⑭ ⑮ CN11 LP-528 REV.

  • Page 23: Detection Sensor

    Chapter 2 Components description Gas Leak Detection Sensor: Check Point Description / Part # 7850P-093 (Main PCB) Function This sensor shutsdown the unit if a gas leak is detected Failure Event Gas leak detection sensor is not operating correctly Effects Risk of explosion and personal injury. Error Code Er 40 ① Follow instruction on first page of installation manual. Check for leakage Diagonostic around the gas valve and gas piping by using soapy water. ② Check the burner assembly Color / Wire Number LP-528 REV. 8.01.14...

  • Page 24: Jumped Wire Connection

    Chapter 2 Components description Jumped Wire Connection: 7850P- Check Point Description / Part # CN11 (Main PCB) Function This part is used to jump out circuit. Failure Event Jumper is disconected Effects The unit shutsdown Error Code Er 42 Diagonostic ① Make sure the jumper is properly connected Color / Wire Number Jumped Wire Connection (white): connector ⑥,⑭ ① ② ③ ④ ⑤ ⑥ ⑦ ⑧ ⑯ ⑨ ⑩ ⑪ ⑫ ⑬ ⑭ ⑮ CN11 LP-528 REV. 8.01.14...

  • Page 25: Air Pressure Switch

    Chapter 2 Components description A P S : A i r P r e s s u r e S w i t c h : Check Point Description / Part # CN11 7855P-017 (Main PCB) Function This APS monitors the flue for blockage ① Combustion noise occurs Failure Event ② Imperfect and lifting flame occurs ③ The unit will not ignite Effects Pressure due to exhaust vent blockage will affect the boiler operation Error Code Er 29 ① Check APS wiring connection...

  • Page 26: Condensate Blockage Aps

    Chapter 2 Components description C o n d e n s a t e B l o c k a g e A P S : Check Point Description / Part # CN11 7855P-017 (Main PCB) Function This switch monitors the condensate dischage line for blockage Failure Event ① The unit will not ignite Effects Pressure due to condensate line blockage will affect the boiler operation Error Code Er 20 ① Check Condensate Blockage APS wirring connection ② Check the hose for blockage or kinking.

  • Page 27: Flow Sensor

    Chapter 2 Components description Check Point Description / Part # DHW Flow Sensor: 7855P-083 (Main PCB) Function This sensor detects water flow (more than 0.5 GPM) through DHW loop Failure Event Water flow is not detected Effects Domestic hot water set point is not achieved Error Code ① Restart the appliance Diagonostic ② Visual inspection : check flow sensor wiring for proper connection ① Ground (blue) : Connector ⑥ Color / Wire Number ② Flow Signal (white): Connector ⑤ ③ DC 5V (red) : Connector ④ ① ② ③ ④ ⑤ ⑥ LP-528 REV. 8.01.14...

  • Page 28: Ignition Transformer

    Chapter 2 Components description Check Point Description / Part # Ignition Transfomer: 7855P-007 CN9 (Main PCB) Function Generates sparks energy to ignite the fuel Failure Event sparks energy is not generated Effects The unit does not ignite Error Code Er11 ① Check wiring for proper connection Diagonostic ② Check range of voltage Igniter (red) : connector ④ Color / Wire Number Igniter (red) : connector ⑩ ① ② ③ ④ ⑤ ⑥ ⑦ ⑧ ⑨ ⑩ ⑪ ⑫ LP-528 REV. 8.01.14...

  • Page 29: Flame Detection Sensor

    Chapter 2 Components description Check Point Description / Part # Flame Detection Sensor: 7855P-031 CN7 (Main PCB) Function Detects flame during combustion Failure Event Ignition fault Effects Abnormal product operation Error Code Er 11, Er 72 ① Check the discoloration of flame monitoring window Diagonostic ② Check the connection around the flame detection sensor Flame detection sensor (red) ① : connector ① Color / Wire Number Flame detection sensor (black) ② : connector ⑧ ① ② ① ② ③ ④ ⑤ ⑥ ⑦ ⑧ ⑨ ⑩ ⑪ ⑫ ⑬ ⑭ LP-528 REV. 8.01.14...

  • Page 30: Gas Valve

    Chapter 2 Components description Check Point Description / Part # Gas Valve: 7855P-034 CN9 (Main PCB) Negative gas valve controls the regulation of gas and air imixture in the Function combustion system ① Gas leakage occurs Failure Event ② Gas valve does not operate (Unable to open/close) ③ Gas flow is not modulated (Proportional gas valve) ① Spark is not generated. Effects ② Operation of product is stopped ③ Carbon monoxide exceeding the reference is discharged Error Code Er 11 ① Check wiring for proper connection Diagonostic ② Check the connection and mounting location ③ Check resistance using a multi-meter Color / Wire Number Gas valve (purple) : connector ⑥, ⑫ ① ②...

  • Page 31: Bldc Fan

    Chapter 2 Components description Check Point Description / Part # BLDC Fan: 7855P-025 CN4 (Main PCB) Function Supplies air and fuel to the burner ① Abnormal noise occurs at the fan Failure Event ② Abnormal fan speed(RPM) ③ Poor connection ① Abnormal combustion Effects ② Abnormal noise occurs ③ The unit does not operate Error Code Er 41, Er 61 ① Check vent blockage Diagonostic ② Check BLDC fan wiring for proper connection ③ Check voltage range using a multi meter [Blower] GND (blue) ⓒ: connector ②, 30VDC Color / Wire Number Power(white) ⓔ : connector ④, 30VDC Speed feedback signal(yellow) ⓓ : connector ⑥, 14VDC VDD (red) ⓑ : connector ③, 30VDC ① ② ③ ④ ⑤ ⑥ LP-528 REV. 8.01.14...

  • Page 32: Burner Assembly

    Chapter 2 Components description Check Point Description / Part # Burner Assembly: 7855P-064 N/A (Main PCB) This component provides the heat source by mixing and combusting air Function and gas. ① Unable to initialize/sustain combustion Failure Event ② Soot occurs on the surface of burner ③ Gas leakage occurs from burner ① Abnormal combustion Effects ② Unstable flame generation ③ Ignition failure Error Code Diagonostic Visual inspection : Unstable flame conditions during operation. Color / Wire Number LP-528 REV. 8.01.14...

  • Page 33: Fire Tube Heat Exchanger

    Chapter 2 Components description F i r e T u b e H e a t E x c h a n g e r : Check Point Description / Part # N/A 7855P-064 (Main PCB) Heats the water by Absorbing the high-temperature heat generated by the Function burner.

  • Page 34: Condensate Trap

    Chapter 2 Components description Check Point Description / Part # Condensate Trap: 7855P-053 N/A (Main PCB) This component reliably discharges the condensate generated by the Function combustion Failure Event Unneutralized condensate is discharged Product corrosion and environmental degradation are caused by the Effects condensate Error Code Er20 Diagonostic ① Check the hose for blockage or bending Color / Wire Number LP-528 REV. 8.01.14...

  • Page 35: Internal Dhw Storage Tank

    Chapter 2 Components description Internal DHW Storage Tank: Check Point Description / Part # 7855P-059 (Main PCB) Function Transfers energy into DHW to provide stable temperature Failure Event Leakage occurs at DHW storage tank. ① Operation of product is stopped Effects ② Domestic hot temperature fluctuation Error Code Er20 Diagonostic Replace DHW storage tank Color / Wire Number LP-528 REV. 8.01.14...

  • Page 36: Internal Ch/Dhw Circulation Pumps

    Chapter 2 Components description Internal CH/DHW Recirculation Check Point Description / Part # CN9 Pumps: 7855P-081 (Main PCB) Function Provides circulation through the heat exchanger and internal storage tank Failure Event Water flow is not detected. ① Unit does not opperate Effects ② Internal CH/DHW circulation pump is not operating Error Code ① Visual inspection : check wiring for proper connection Diagonostic ② Check supply voltage Internal DHW circulation pump (yellow/green) : Connector ③, ⑨ Color / Wire Number Internal CH primary circulation pump (white) : Connector ⑤, ⑪ ① ② ③ ④ ⑤ ⑥ ⑦ ⑧ ⑨ ⑩ ⑪ ⑫ LP-528 REV. 8.01.14...

  • Page 37: Dhw Mixing Valve

    Chapter 2 Components description Check Point Description / Part # DHW Mixing Valve: 7855P-043 CN14 (Main PCB) Function This component controls DHW outlet temperature by mixing cold and hot water Water flow rate is not detected and water leakage occurs around the mixing Failure Event valve. ① Ignition sequence does not start. Effects ② Operation of product is stopped once water leakage is detected. Error Code Er 66, Er 68 ① Restart the unit Diagonostic ② Check the connection around the mixing valve. [IWM (Inlet Water Modulation)] GND (brown) : connector ① DHM Position Sensor (orange) : connector ② DC 14V (white) : connector ③ Color / Wire Number DHM X phase (black) : connector ④ DHM Y phase (red) : connector ⑤ DC 14V (blue) : connector ⑥ DHM /X phase (green) : connector ⑦ DHM /Y phase (yellow) : connector ⑧...

  • Page 38: Chapter 3 How To Use Control Panel

    Chapter 3 How to use control panel ■ Function explanation [Initial power-up condition] When power is supplied, zero point of the mixing valve is checked for 6 seconds. After that, normal 800 steps function is in progress. At this time, if zero point is not confirmed, Er 66 occurs. After error is automatically re stored when zero point was confirmed, normal 800step function is in progress. [Central Heating mode] Setting the central heating target temperature can be done through the front display panel. The setpoint temperature is memorized even if power is lost. The T/T signal from a room thermostat will activate the central heating mode. DHW mode is always the priority. The central heating mode will shut off until DHW demand is satisfied. [DHW mode] DHW mode is activated by the flow sensor sensing flow of 0.5 GPM or above. When there is DHW demand, flow sensor monitor the frequency (range: 8Hz to12Hz), with 2 minutes. The storage tank will maintain a user defined setpoint. DHW temperature can be set 95~140℉(35℃~60℃). If there is DHW demand, burner starts and mixing valve operates automatically. [Freeze protection mode] Freeze protection mode operates with 2 stages as shown below: 1. Stage 1: CH supply and/or storage tank water temperature sensors detect temperature below 46℉(8℃), first stage of this mode is activated. With the first stage, while burner does not turn ON, internal DHW and CH circulation pumps operate for 600 seconds and stops for 30 seconds repeatedly until the temperature is reached to 50℉(10℃). 2. Stage2: After stage 1 operation, if CH supply and DHW storage tank temperatures are below 41℉(5℃), second stage of this mode is operational and the burner is activated. With the second stage, both CH and DHW storage tank circu lation pumps are run until CH supply and/or DHW storage tank temperature reaches 104℉(40℃). If the unit is powered off, the internal circulation pumps operate, but the burner remains off. Error code Er.85 is displayed when the temperature is below 34℉(1℃), and will automatically reset when temperature above 50℉(10℃). [Water level sensor Mode] This mode senses water amount inside of boiler and prevent shortage of water. It senses water level real time and if shortage is detected more than 4 sec, combustion stops. If water level is reached desired amount for more than 4 sec, boiler starts operating, also to supply with enough water, inner recirculation pump operates after 30sec, heating circulation pump operates 30 sec runs, 10sec stops. [Mixing valve operation] During a DHW demand, mixing valve modultaes to control the DHW outlet temperature by mixing the cold and hot water. When there is no DHW demand, mixing valve stands vy at 800 steps. To prevent the mixing valve mechanism from getting stuck, it moves 2,000 steps (fully closed) for 5 sec, then moves to default position (fully opened) and finally b ack to 800 step. [Storage Mode] Storage mode is used to keep the internal indiret storage tank heated to a user defined setting. This mode is very important to prevent any delay of domestic hot water demand.

  • Page 39: Contol Panel

    Chapter 3 How to use control panel [Gas leakage detector mode] : Gas leakage detector mode is designed to stop combustion by built in sensor in controller in case of gas leakage. In case of gas leakage, room temperature controller power is off and after one min, gas leakage is detective more than 10 min or 3 times in 10 min, the error is locked until manually on/off from the room controller. With either front display panel or room controller off, fan stops after post-purge and still detects gas leakage 5 seconds. [Front panel and room controller connect mode] : Room controller and front panel can be connected [Heating demand connect mode] : Outside heating demand can be connected [Mixing valve default mode] : If there is no DHW demand, mix valve stands by 800 steps, if still no operation of mixing valve is detected, to prevent mixing valve stuck, 2,000 steps (close way) for 5 sec and default (open way) and back to 800 step. [Mixing valve operation] : If there is DHW demand, mixing valve modulates to set DHW temperature and water outlet temperature. When demand is off, with the waiting mode, it goes back to 800 steps and after 2 minutes waiting mode, stays at 800 steps. If controller is off, it closes at max step. [Pump operating mode] : In case pump 1 and 2 is not detected operation, it automatically runs for 90 seconds. [Summer mode] ■ Control panel : Summer mode can be set with front panel, if used, no heating mode can be operated. Customized Temperature Control [Pre-heating mode] Advanced technology used for the flow sensor and heat capacity control makes domestic hot water highly efficient by : DHW pre-heating mode can be set with front panel, no heating mode can be operated. maintaining constant temperature during usage. [Heating burner operation delay mode] : To prevent from quick burner ON/OFF, even if the temperature is reached, after anti-frequency time, burner is on. The time set is between 0~20 and default is 1 minute. [Memory mode] : Desired condition and error can be set with front display panel. And the setting is memorized after power off or breakout. [Safety function] 1. Power supply After power is supplied for 5 sec, boiler monitors in real time if power and Hz are safe range. 1-1. Low power supply If power supply is below 93Vac(+-3V) for 10 sec, boiler stops combustion until power supply is 95Vac(+-3V). 1-2. Frequency error With power supplied, boiler chooses either 50Hz or 60Hz and if frequency reaches out of the range (±5Hz) for more than 10 sec, combustion stops until frequency is within ±5Hz [Combustion safety]...

  • Page 40: Lcd Specification

    Chapter 3 How to use control panel ■ LCD Specification ■ Control panel mode Status display mode LP-528 REV. 8.01.14...
  • Page 41 Chapter 3 How to use control panel ■ Control panel mode Installer Setting Mode. LP-528 REV. 8.01.14...
  • Page 42 Chapter 3 How to use control panel LP-528 REV. 8.01.14...

  • Page 43: Dhw Temperature Control

    Chapter 3 How to use control panel Domestic Hot Water temperature control ( Range:95 ~ 120℉) Press power button to turn on Press hot water the unit. temperature control Turn the dial to set desired DHW button to enter DHW temperature temperature. setting mode. The default tempera- ture is set to 125℉ Press ‘heating water temperature button’ for more than 5 secs to Press dial button to complete convert temperature unit ( ℉ or ℃ setting. Domestic Hot Water high temperature control (Range:121℉ ~ 140℉) Press power Press ‘hot water button to turn on temperature control the unit. button’ to enter ‘DHW temperature Press ‘hot water temperature setting mode. The default tempera- button’ for 5 secs to set high temperature. ture is set 125℉ Press dial button to complete setting. Turn the dial to set desired DHW temperature.

  • Page 44: Ch Supply Water Temperature Control

    Chapter 3 How to use control panel CH Supply water temperature control (Range: 86~ 180℉) Press power Press ‘Central button to turn on heating temperature the unit. control button’ to Turn the dial to set enter temperature desired heating setting mode. The water temperature. default temperature ℉ is set to 180 Press dial button to complete setting. View System Parameters (Status Display Mode) Outdoor Temperature display Press ‘current status’ for 5 secs Press power and ‘0:ot’ will button to turn on show up. the unit. Press dial button for 1 sec when ‘0:ot’ shows up. Default setting in common. Press dial button for 1 sec and Out- Press dial button for a sec again, to Press ‘current status’ button with...

  • Page 45: Water Flow Rate (Gpm Or Lpm)

    Chapter 3 How to use control panel Water flow rate (GPM or LPM) Water flow status will be displayed. After ‘0:ot’ has been displayed by (ex : 2.64) pressing ‘current status button’ for Press dial button for 1 sec when 5 secs, turn the dial until it shows ‘A:GA’ shows up. ‘A:GA’. Press ‘current status button’ during Press dial button for a sec again, to ‘A:GA’ mode to go back to the initial go back to the previous mode. status. CH Return Water temperature Current return water temperature status will be displayed. (ex : 100℉) After ‘0:ot’ has been displayed by pressing ‘current status button’ for Press dial button for 1 sec when 5 secs, turn the dial until it shows ‘b:lt’ shows up. ‘b:lt’. Press ‘current status button’ during Press dial button for a sec again, to ‘b:lt’ mode to go back to the initial go back to the previous mode. status. LP-528 REV. 8.01.14...

  • Page 46: Fan Speed (Rpm)

    Chapter 3 How to use control panel Fan speed (RPM) Fan RPM current status will be displayed. After ‘0:ot’ has been displayed by Check RPM by pressing ‘dial pressing ‘current status button’ for 5 button’ for 1 sec when ‘c:Fr’ shows up secs, turn the dial until it shows ‘c:Fr‘. Press ‘current status’ button with ‘c:Fr’ Press dial button for a sec again, to mode to go back to the initial status. go back to ‘c:Fr’ mode. Program lock mode NOTE: The Control System will not allow the changes if Lock Mode is activated. Lock Mode will have to be turned off before making further changes. Turn the dial until current status ‘off’ After ‘0:ot’ has been displayed by Press dial button for 1 sec when mode turns into ‘on’. pressing ‘current status button’ for 5 ‘d:Lc’ shows up. secs, turn the dial until it shows ‘d:Lc’. Press dial button for a sec again Press ‘current status button’ with after setting completion to go back ‘d:Lc’ mode to go back to the initial to the previous mode. status. LP-528 REV. 8.01.14...

  • Page 47: Ch Supply Water Temperature

    Chapter 3 How to use control panel CH Supply water temperature Current supply water temperature status will be displayed. (ex: 108℉) After ‘0:ot’ has been displayed by pressing ‘current status button’ for Press dial button for 1 sec when 5 secs, turn the dial until it shows ‘E:oP’ shows up ‘E:oP’. Press ‘current status button’ during Press dial button for a sec again, to ‘E:oP’ mode to go back to the initial go back to the previous mode. status. DHW outlet water temperature Current DHW temperature status will be displayed. (ex : 120℉) After ‘0:ot’ has been displayed by pressing ‘current status button’ for Press dial button for 1 sec when 5 secs, turn the dial until it shows ‘F:dH’ shows up ‘F:dH’. Press ‘current status button’ during Press dial button for a sec again, to ‘F:dH’ mode to go back to the initial go back to the previous mode. status. LP-528 REV. 8.01.14...

  • Page 48: Exhaust Gas Temperature

    Chapter 3 How to use control panel Exhaust gas temperature After ‘0:ot’ has been displayed by Current exhaust gas temperature Press dial button for 1 sec when pressing ‘current status button’ for 5 status will be displayed. (ex : 130℉) ‘H:Eh’ shows up. secs, turn the dial until it shows ‘H:Eh’. Press dial button for a sec again, to Press ‘current status button’ with go back to the previous mode. ‘H:Eh’ mode to go back to the initial status. Internal storage tank water temperature. Current hot water tank temperature After ‘0:ot’ has been displayed by Press dial button for 1 sec when ‘I:St’ status will be displayed. (ex : 130℉) pressing ‘current status button’ for 5 shows up. secs, turn the dial until it shows ‘I:St’. Press dial button for a sec again, to Press ‘current status button’ with ‘I:St’ go back to the previous mode. mode to go back to the initial status. LP-528 REV. 8.01.14...

  • Page 49: Overheat Temperature Sensor

    Chapter 3 How to use control panel Overheat Temperature Sensor Current hot overheating sensor tem- perature status will be displayed. After ‘0:ot’ has been displayed by (ex : 130℉) pressing ‘current status button’ for Press dial button for 1 sec when 5 secs, turn the dial until it shows ‘J:oH’ shows up ‘J:oH’. Press ‘current status button’ during Press dial button for a sec again, to ‘J:oH’ mode to go back to the initial go back to the previous mode. status. View supply power time (displayed value X 100 hours) After ‘0:ot’ has been displayed by Turn the dial until 1:PH shows up. pressing ‘current status button’ for Press dial button for 1 sec when 5 secs, turn the dial until it shows ‘I:rt’ shows up ‘I:rt’. Current power input time will be shown. (ex : 875×100hr) Press current status button for a sec Press dial button for a sec again, to after confirmation to go back to the go back to the previous mode. initial status. LP-528 REV. 8.01.14...

  • Page 50: View Burner Operating Time (Unit: 1Hr)

    Chapter 3 How to use control panel View Burner Operating Time (Unit: 1hr) Turn the dial until ‘2:rh’ shows up. After ‘0:ot’ has been displayed by Press dial button for a sec when ‘I:rt’ pressing ‘current status button’ for 5 shows up. secs, turn the dial until it shows ‘I:rt’. Press current status button for 1 sec after confirmation to go back to the Press dial button for a sec when 2:rh Current power input time will be initial status. shows up. shown. (ex : 375hr) View Burner Operating Time (displayed value X 1000 hours) Turn the dial until ‘3:rH’ shows up. After ‘0:ot’ has been displayed by Press dial button for a sec when ‘I:rt’ pressing ‘current status button’ for 5 shows up. secs, turn the dial until it shows ‘I:rt’. Press dial button for a sec when Current power input time will be Press current status button for 1 sec ‘3:rh’ shows up. shown. (ex : 75 ×1000hr=75,000hr) after confirmation to go back to the initial status. LP-528 REV. 8.01.14...

  • Page 51: View Ignition Cycles (X 10 Times)

    Chapter 3 How to use control panel View ignition cycles (displayed value X 10 times) Turn the dial until ‘4:lt’ shows up. After ‘0:ot’ being displayed by press- Press dial button for a sec when ‘I:rt’ ing ‘current status button’ for 5 secs, shows up. turn the dial until it shows ‘I:rt’. Press dial button for a sec when Current ignition attempts number Press current status button for 1 sec ‘4:lt’ shows up. will be shown. (ex : 175 ×10times=- after confirmation to go back to the 1750times) initial status. View ignition cycles (displayed value X 10,000 times) Turn the dial until ‘5:IH’ shows up. After ‘0:ot’ has been displayed by Press dial button for a sec when ‘I:rt’ pressing ‘current status button’ for 5 shows up. secs, turn the dial until it shows ‘I:rt’. Press dial button for a sec when Current ignition attempts number Press current status button for 1 sec ‘5:IH’ shows up. will be shown. (ex : 95 ×10000 after confirmation to go back to the times=950,000times) initial status. LP-528 REV. 8.01.14...

  • Page 52: Pump Condition Display

    Chapter 3 How to use control panel Pump Condition Display Pump condition current status will be displayed. After ‘0:ot’ has been displayed by Check RPM by pressing ‘volume pressing ‘current status button’ for 5 button’ for 1 sec when ‘P:ou’ secs, turn the dial until it shows ‘P:ou‘. shows up Press ‘current status’ button with ‘P:ou’ mode to go back to the initial status. LP-528 REV. 8.01.14...

  • Page 53: Fault Code History

    Chapter 3 How to use control panel Change System Parameters (INSTALLER MODE) Fault Code history 10 recent Fault Codes can be Press ‘current status button’ for 5 Press dial button for a sec to access viewed by turning the dial. secs while display is powered off to the codes. enter installer setting mode Press ‘current status button’ after confirmation to go back to the initial status. Clear Error Code history Press ‘current status button’ for 5 Turn the dial until ‘2:cE’ shows up. Press dial button for a sec when secs while display is powered off to ‘2:cE’ is displayed enter into installer setting mode Turn the dial to set ‘on’ status when Press dial button during ‘on’ status to Press ‘current status button’ for a initial ‘of’ shows up. save the setting. sec to go back to initial status after (Default : off mode) confirmation. LP-528 REV. 8.01.14...

  • Page 54: System Reset

    Chapter 3 How to use control panel System Reset Press ‘current status button’ for 5 Turn the dial until ‘3:In’ shows up. Press dial button for a sec when secs while display is powered off to ‘3:In’ is displayed. enter into installer setting mode. Turn the dial to set ‘on’ status when Press dial button during ‘on’ status to Press ‘current status button’ for a initial ‘off’ shows up. save the setting. sec to go back to initial status after (Default : off mode) confirmation. Change DHW flow rate measurement unit (GA_gallon or LI_litter) Press ‘current status button’ for 5 Turn the dial until ‘4:Fu’ shows up. Press dial button for a sec when secs while display is powered off to ‘4:Fu’ is displayed. enter into installer setting mode. Turn the dial to set ‘Li’ when initial Press dial button to save the setting Press ‘current status button’ for a ‘GA’ shows. (Convert Liter to Gallon) during ‘Li’ status. sec to go back to initial status after confirmation. LP-528 REV. 8.01.14...

  • Page 55: Internal Storage Tank Preheating Mode

    Chapter 3 How to use control panel Internal Storage Tank Pre-heating Mode (on or off) Press ‘current status button’ for 5 Turn the dial until ‘5:St’ shows up. Press dial button for a sec when secs while display is powered off to ‘5:St’ is displayed. enter into installer setting mode Turn the dial to set ‘off’ status when Press dial button during ‘off’ status to Press ‘current status button’ for a initial ‘on’ shows up.(Default : on) save the setting. sec to go back to initial status after confirmation. Change maximum outdoor temperature Press ‘current status button’ for 5 Turn the dial until ‘6:oH’ shows up. Press dial button for a sec when secs while display is powered off to ‘6:oH’ is displayed. enter into installer setting mode. Turn the dial to the desired setting Press dial button to save the Press ‘current status button’ for a when initial 68 setting is displayed. setting. sec to go back to initial status after confirmation. LP-528 REV. 8.01.14...

  • Page 56: Change Minimum Outdoor Temperature

    Chapter 3 How to use control panel Change minimum outdoor temperature Press ‘current status button’ for 5 Turn the dial until ‘7:oL’ shows up. Press dial button for a sec when secs while display is powered off to ‘7:oL’ is displayed. enter into installer setting mode. Turn the dial to the desired setting when initial 5 setting is displayed. Press dial button to save the Press ‘current status button’ for a setting. sec to go back to initial status after confirmation. Fan, Max RPM Adjustment. Press ‘current status button’ for 5 Turn the dial until ‘8:FH’ shows up. Press dial button for a sec when secs while display is powered off to ‘8:FH’ is displayed enter into installer setting mode Turn the dial to the desired setting Press dial button to save the setting. Press ‘current status button’ for a when initial 0 is displayed. sec to go back to initial status after (-30 ~ +30, Default : 0) confirmation. LP-528 REV. 8.01.14...

  • Page 57: Fan, Min Rpm Adjustment

    Chapter 3 How to use control panel Fan, Min RPM Adjustment. Press ‘current status button’ for 5 Turn the dial until ‘9:FL’ shows up. Press dial button for a sec when secs while display is powered off to ‘9:FL’ is displayed enter into installer setting mode. Turn the dial to the desired setting Press dial button to save the setting. Press ‘current status button’ for a when initial 0 is displayed. sec to go back to initial status after (-30 ~ +30, Default : 0) confirmation. Reset burner operation time Press ‘current status button’ for 5 Turn the dial until ‘10:dr’ shows up. Press dial button for a sec when secs while display is powered off to ‘10:dr’ is displayed enter into installer setting mode. Turn the dial to ‘on’ status when Press dial button to save the setting. Press ‘current status button’ for a initial ‘off’ shows up. (Default : off) sec to go back to initial status after confirmation. LP-528 REV. 8.01.14...

  • Page 58: Delete Igniting Cycles

    Chapter 3 How to use control panel Reset igniting cycles Press ‘current status button’ for 5 Turn the dial until ‘11:dl’ shows up. Press dial button for a sec when secs while display is powered off to ‘11:dl’ is displayed enter into installer setting mode. Turn the dial to ‘on’ status when Press dial button to save the setting. Press ‘current status button’ for a initial ‘off’ shows up.(Default : off) sec to go back to initial status after confirmation. Boost Function Press ‘current status button’ for 5 Turn the dial until ‘12:bt’ shows up. Press dial button for a sec when secs while display is powered off to ‘12:bt’ is displayed enter into installer setting mode. Press dial button to save the setting. Turn the dial to the desired setting Press ‘current status button’ for a when initial 0 is displayed. sec to go back to initial status after (Range:0~120 min, Default : 0 min) confirmation. LP-528 REV. 8.01.14...

  • Page 59: Ch Anti-Cycling Time

    Chapter 3 How to use control panel CH anti-cycling time Press ‘current status button’ for 5 Turn the dial until ‘13:Ft’ shows up. Press dial button for a sec when secs while display is powered off to ‘13:Ft’ is displayed. enter into installer setting mode. Press dial button to save the setting. Turn the dial to the desired setting Press ‘current status button’ for a when initial setting is displayed. sec to go back to initial status after (Range: 0~20 min, Default : 1 min) confirmation. Burner 'ON' differential temperature Press ‘current status button’ for 5 Turn the dial until ‘14:bo’ shows up. Press dial button for a sec when secs while display is powered off to ‘14:bo’ is displayed. enter into installer setting mode. Press dial button to save the Press ‘current status button’ for a Turn the dial to the desired setting setting. sec to go back to initial status after when initial setting is displayed. confirmation. (Range: 9 ℉ ~ 27℉, Default: 27 ℉) LP-528 REV. 8.01.14...

  • Page 60: Warm Weather Shutdown

    Chapter 3 How to use control panel Warm weather shutdown Press ‘current status button’ for 5 Turn the dial until ‘15:OF’ shows up. Press dial button for a sec when secs while display is powered off to ‘15:OF’ is displayed. enter into installer setting mode. Turn the dial to the desired setting Press dial button to save the setting. Press ‘current status button’ for a when initial setting is displayed. sec to go back to initial status after (50 ~ 110 ℉, Default : 110℉) confirmation. Maximun CH Supply tempature Press ‘current status button’ for 5 Turn the dial until ‘16:cH’ shows up. Press dial button for a sec when secs while display is powered off to ‘16:cH’ is displayed. enter into installer setting mode. Turn the dial to the desired setting when initial setting is displayed. Press dial button to save the setting. Press ‘current status button’ for a (Range: miniimum supply tempera- sec to go back to initial status after ture + 9 ℉ ~ 180 ℉) - Default: 180℉ confirmation. LP-528 REV. 8.01.14...

  • Page 61: Minimum Ch Supply Temperature

    Chapter 3 How to use control panel Minimun CH Supply tempature Press ‘current status button’ for 5 Turn the dial until ‘17:cL’ shows up. Press dial button for a sec when secs while display is powered off to ‘17:cL’ is displayed. enter into installer setting mode. Turn the dial to the desired setting when initial setting is displayed. Press ‘current status button’ for a Press dial button to save the (Range: 86 ℉ ~ maximum CH sup- sec to go back to initial status after setting. ply temperature - 9 ℉, Default: 86 ℉) confirmation. Maximum DHW set temperature Press ‘current status button’ for 5 Turn the dial until ‘18:dH’ shows up. Press dial button for a sec when secs while display is powered off to ‘18:dH’ is displayed. enter into installer setting mode. Turn the dial to the desired setting Press ‘current status button’ for a when initial setting is displayed. Press dial button to save the sec to go back to initial status after (Range: 120℉~140℉, setting. confirmation. Default : 140℉) LP-528 REV. 8.01.14...

  • Page 62: Ch Capacity

    Chapter 3 How to use control panel CH capacity Press ‘current status button’ for 5 Turn the dial until ‘19:cb’ shows up. Press dial button for a sec when secs while display is powered off to ‘19:cb’ is displayed. enter into installer setting mode. Turn the dial to the desired setting Press ‘current status button’ for a Press dial button to save the sec to go back to initial status after when initial setting is displayed. setting. (Range: 50~100%, Default : 100%) confirmation. DHW heating capacity Press ‘current status button’ for 5 Turn the dial until ‘20:db’ shows up. Press dial button for a sec when secs while display is powered off to ‘20:db’ is displayed. enter into installer setting mode. Turn the dial to the desired setting Press ‘current status button’ for a Press dial button to save the when initial setting is displayed. sec to go back to initial status after setting. (Range: 50~100%, Default : 100%) confirmation. LP-528 REV. 8.01.14...

  • Page 63: Internal Ch Primary Pump Post Run Time

    Chapter 3 How to use control panel Internal CH primary pump post run timer (T/T calling for heat) Press ‘current status button’ for 5 Turn the dial until ‘21:PP’ shows up. secs while display is powered off to Press dial button for a sec when ‘21:PP’ is displayed. enter into installer setting mode. Turn the dial to the desired setting Press dial button to save the Press ‘current status button’ for a when initial setting is displayed. setting. sec to go back to initial status after (Range: 1min ~ 60min, confirmation. Default: 40min) Internal CH pump overrun timer (On) Press ‘current status button’ for 5 Turn the dial until ‘22:Po’ shows up. Press dial button for a sec when secs while display is powered off to ‘22:Po’ is displayed. enter into installer setting mode. Turn the dial to the desired setting Press ‘current status button’ for a Press dial button to save the when initial setting is displayed. sec to go back to initial status after setting. (Range: 1min ~ 60min, confirmation. Default: 5min) LP-528 REV. 8.01.14...

  • Page 64: Internal Ch Pump Overrun Timer (Off)

    Chapter 3 How to use control panel Internal CH pump overrun timer (Off) Press ‘current status button’ for 5 Turn the dial until ‘23:PF’ shows up. Press dial button for a sec when secs while display is powered off to ‘23:PF’ is displayed. enter into installer setting mode. Turn the dial to the desired setting Press dial button to save the Press ‘current status button’ for a when initial setting is displayed. setting. sec to go back to initial status after (Range: 1min ~ 60min, confirmation. Default : 10min) Internal DHW storage tank set point Press ‘current status button’ for 5 Turn the dial until ‘24:SF’ shows up. Press dial button for a sec when secs while display is powered off to ‘24:SF’ is displayed. enter into installer setting mode. Turn the dial to the desired setting when initial setting is displayed. Press dial button to save the Press ‘current status button’ for a (Range: 140 ℉ ~ 167 ℉, Default: setting. sec to go back to initial status after 158 ℉) confirmation. LP-528 REV. 8.01.14...

  • Page 65: Internal Dhw Storage Tank Differential

    Chapter 3 How to use control panel Internal DHW storage tank differential Press ‘current status button’ for 5 Turn the dial until ‘25:So’ shows up. Press dial button for a sec when secs while display is powered off to ‘25:So’ is displayed. enter into installer setting mode. Turn the dial to the desired setting Press dial button to save the Press ‘current status button’ for a when initial setting is displayed. setting. sec to go back to initial status after (Range: 9℉ ~ 36 ℉, Default: 27℉) confirmation. Delay time when switching from DHW to CH mode Press ‘current status button’ for 5 Turn the dial until ‘26:dt’ shows up. Press dial button for a sec when secs while display is powered off to ‘26:dt’ is displayed. enter into installer setting mode. Turn the dial to the desired setting Press ‘current status button’ for a when initial setting is displayed. sec to go back to initial status after confirmation.. LP-528 REV. 8.01.14...

  • Page 66: Internal Ch Pump Post Purge Timer

    Chapter 3 How to use control panel Internal CH primary pump post purge timer (T/T satisfied) Press ‘current status button’ for 5 Turn the dial until ‘27:PE’ shows up. Press dial button for a sec when secs while display is powered off to ‘27:PE’ is displayed. enter into installer setting mode. Turn the dial to the desired setting Press dial button to save the Press ‘current status button’ for a when initial setting is displayed. setting. sec to go back to initial status after (Range: 1min ~ 60min, confirmation. Default : 10min) Internal CH and DHW pumps test mode Press ‘current status button’ for 5 Turn the dial until ‘29:AP’ shows up. Press dial button for a sec when secs while display is powered off to ‘29:AP’ is displayed. enter into installer setting mode. Turn the dial to the desired setting when initial setting is displayed. Press dial button to save the Press ‘current status button’ for a setting. sec to go back to initial status after confirmation. LP-528 REV. 8.01.14...

  • Page 67: Chapter 4 Troubleshooting

    Chapter 4 Troubleshooting 1. Flame Detection LP-528 REV. 8.01.14...

  • Page 68: Gas Detection

    Chapter 4 Troubleshooting 2. Gas Detection 3. APS/Burner overheat limit/Condensate Block switch APS /Burner overheat limit /Condensate Block IT OFF GV OFF ERROR E29 LP-528 REV. 8.01.14...

  • Page 69: Storage Dhw/Exhaust Overheat

    Chapter 4 Troubleshooting 4. ‘Storage’, ‘DHW’, ‘OP’, ‘CH Overheat’, ‘Exhaust Overheat’ Sensor LP-528 REV. 8.01.14...

  • Page 70: Error Code

    Chapter 4 Troubleshooting [Error code] LP-528 REV. 8.01.14...
  • Page 71 Chapter 4 Troubleshooting LP-528 REV. 8.01.14...
  • Page 72 Chapter 4 Troubleshooting LP-528 REV. 8.01.14...
  • Page 73 Chapter 4 Troubleshooting Error code Meaning Cause If flame loss issue repeats Flame loss 8 times while unit is operating, (manual reset) error code 10 will appear. Failure event If flame is not detected within 1minute after ignition trial, the unit restarts. If ignition trial is repeated eight times in a row, ignition sequence will stop. Error will not disappear until display panel is manually reset. Check point ① ▶ If the flame sensing ② Ensure gas valve viewing port is exces- wiring is properly connected. sively discolored, loss of fame will occur. ③ Check Gas Inlet ④ Please check Pressure Range: flame detector sensor’s NG: connecting line and 3.5” WC ~ 14” WC ensure correct position LP: as shown. 3.5” WC ~ 14”WC ⑤ Please check the blockage of flue (intake and exhaust pipes). ⑥ If all things are normal, please replace main controller. WARNING Failure to turn the power off to the appliance before repair could result in serious injury or death. LP-528 REV.
  • Page 74 Chapter 4 Troubleshooting Error code Meaning Cause During ignition trials, if unit failed Ignition failure to ignite 10 times continuously, (manual reset) error code 11 will appear. Failure event If the unit failed to detect flame during ignition sequence pre-purge time will exceed 10 sec, and error code Er 11 will appear. Check point ① Check separation distance ② Check ignition after removing the flame rod. transformer and (separation distance: 1/8”) electrical wires for proper connection. 1/8” ③ Check Gas Inlet ④ Please check Pressure Range: flame detector sensor’s NG: connecting line and 3.5” WC ~ 14” WC ensure correct position LP: as shown. 3.5” WC ~ 14”WC ■ From more than DC 2.5V after ignition safety, cut-off will appear ① When setting before ignition is less than DC 2.5V: Re- place flame sensor. ② When setting after ignition is more than DC 2.5V: Replace flame sensor. Flame detector sensor setting (Please check after closing front cover) ITEM Normal operating settings Before ignition...
  • Page 75 Chapter 4 Troubleshooting Error code Meaning Cause If temperature on the CH supply CH overheating temperature sensor (tagged OP temperature issue on connectors) exceeds 203 ◦ F, error Er 16 will appear (manual reset) Failure event In case that CH supply temperature is more than 203 ◦ F, water temperature overheating fault occurs and all output except for fan post-purge is stopped. Check point ① Check to see if the default DIP SWITCH settings have been changed from the factory settings – assure that default settings are set to correct overheating condition. ② Please check CH supply temperature sensor (wires are tagged OP). When the value measured with a multi-meter is 0Ω, replace the sensor. ③ Check internal CH pump is operational. Use a flat head screw driver to rotate a screw on the back side of the pump to ensure the pump internal shaft is not stuck. Check pump wiring to ensure proper connection. ④ If all things are normal, please replace main controller WARNING Failure to turn the power off to the appliance before repair could result in serious injury or death. LP-528 REV.
  • Page 76 Chapter 4 Troubleshooting Error code Meaning Cause Condensate air When condensate outlet blockages pressure switch is open occurs, error code Er 20 will appear (manual reset) Failure event If the condensate drain line is blocked, 'Er 20' will occur Check point ① Check Condensate discharging line ② Check APS line for proper connection LP-528 REV. 8.01.14...
  • Page 77 Chapter 4 Troubleshooting Error code Meaning Cause CH supply overheating If CH supply overheating sensor open or short sensor is shorted (manual reset) or disconnected, 'Er 28' is displayed. Failure event If connection of the CH supply over-heating sensor connected to heat exchanger is shorted or disconnected, 'Er 28' is displayed. Check point ① Check whether over-heating switch is shorted or disconnected. ② Check CH supply over-heating sensor condition. Connect multi meter with over-heating switch’s sock- et and measure the value. (If value shows 0Ω it’s a sensor’s malfunction so replace it) LP-528 REV. 8.01.14...
  • Page 78 Chapter 4 Troubleshooting Error code Meaning Cause APS open When exhaust vent blockages (manual reset) occurs, error code 29 will appear Failure event In case of vent blockage, the air pressure in the combustion system exceeds tthe APS setting and Er 29 is displayed. Check point ② Check APS hose. (check hose damages ) ① Check APS wiring to assure proper connection ③ Please check the blockage of flue (exhaust pipe). ④ If the above conditions are normal, please replace APS. ⑤ If all things are normal, please replace main controller. WARNING Failure to turn the power off to the appliance before repair could result in serious injury or death. LP-528 REV.
  • Page 79 Chapter 4 Troubleshooting Error code Meaning Cause Storage tank temperature When storage tank temperature sensor error sensor malfunctions or (automatic reset) gets disconnected, error code Er 30 will appear Failure event Storage tank temperature sensor malfunction. Check point ① Ensure the storage tank temperature sensor is properly connected. ② Check storage tank temperature sensor condition. When the resistance value measured with a multimeter is 0Ω, replace storage tank temperature sensor. ③ If all things are normal, please replace main controller. WARNING Failure to turn the power off to the appliance before repair could result in serious injury or death. LP-528 REV.
  • Page 80 Chapter 4 Troubleshooting Error code Meaning Cause When DHW outlet temperature DHW outlet sensor malfunctions or gets temperature sensor error disconnected, error code (automatic reset) Er 32 will appear. Failure event DHW outlet temperature sensor malfunction Check point ① Ensure the DHW outlet temperature sensor is properly connected. ② Check DHW outlet temperature sensor condition. When the resistance value meas- ured with a multimeter is 0Ω, replace DHW outlet temperature sensor. ③ If all things are normal, please replace main controller. WARNING Failure to turn the power off to the appliance before repair could result in serious injury or death. LP-528 REV.
  • Page 81 Chapter 4 Troubleshooting Error code Meaning Cause CH supply temperature When CH supply temperature sensor sensor error malfunctions or gets disconnected, (automatic reset) error code Er 33 will appear. Failure event CH supply temperature sensor wiring line disconnected or faulty. Check point ① Ensure the CH supply temperature sensor is properly connected. ② Check CH supply temperature sensor condition. When the resistance value measured with a multimeter is 0Ω, replace CH supply ③ If all things are normal, please replace main controller. WARNING Failure to turn the power off to the appliance before repair could result in serious injury or death. LP-528 REV. 8.01.14...
  • Page 82 Chapter 4 Troubleshooting Error code Meaning Cause Exhaust temperature When exhaust temperature sensor sensor error malfunctions or gets disconnected, (automatic reset) error code Er 35 will appear. Failure event Exhaust temperature sensor malfunction. Check point ① Ensure the exhaust temperature sensor is properly connected. ② Check exhaust temperature sensor condition. When the resistance value measured with a multimeter is 0Ω, replace exhaust temperature sensor. ③ If all things are normal, please replace main controller. WARNING Failure to turn the power off to the appliance before repair could result in serious injury or death. LP-528 REV. 8.01.14...
  • Page 83 Chapter 4 Troubleshooting Error code Meaning Cause When input voltage is lower than 90V (+/-3V) for 10 sec then error Er 36 Voltage error will occur. When Voltage is above (Automatic reset) 100V then error will automatically reset. Failure event Incoming voltage issue. Check point ① Ensure manual power switch is properly connected Check the supply voltage at the manual power switch is within 102V~132 Vac. if so, then it’s main controller’s malfunction and replace it. ② Check whether power voltage is within the safety scope 5 seconds after power is supplied. LP-528 REV. 8.01.14...
  • Page 84 Chapter 4 Troubleshooting Error code Meaning Cause If the electrical frequency is not in the range of 50/60 Hz +/-5Hz, all EEPROM error the outputs will malfunction (Manual reset) except for the fan post purge. Failure event Incoming frequency issue. Check point ①When operating power frequency is within 50/60 HZ ±5Hz error will automatically reset. LP-528 REV. 8.01.14...
  • Page 85 Chapter 4 Troubleshooting Error code Meaning Cause When EEPROM malfunctions, EEPROM error error 39 occurs and all of the outputs (Manual reset) will stop except fan post-purge. Failure event When EEPROM malfunctions, error occurs and all of the outputs will stop except fan post-purge. Check point ① Replace the main controller. WARNING Failure to turn the power off to the appliance before repair could result in serious injury or death. LP-528 REV. 8.01.14...
  • Page 86 Chapter 4 Troubleshooting Error code Meaning Cause When gas leakage is detected Gas leakage during operation, error (Manual reset) code Er 40 will appear. Failure event When gas leak is detected for more than 10 min continuously or 3 times in a hour, error code will appear. Check point ① Follow instruction on first page of installation manual. Check leakage by using soapy water on all related gas pipe connection and gas valve to determine source of leak. Once determined repair leak and reassemble. Check condition of O-rings and gaskets and replace them if damaged. ② If leaks are not present on the gas piping or valve . Start unit and monitor for leaks around blower assembly and connection to determine source of leaks. ③ If all things are normal, please replace main controller. WARNING Failure to turn the power off to the appliance before repair could result in serious injury or death. LP-528 REV.
  • Page 87 Chapter 4 Troubleshooting Error code Meaning Cause When standard fan speed is Excess fan speed detected exceeded during combustion, (Manual reset) error code 41 will appear. Failure event Excess fan speed. Check point ① Check whether error code disappears after turning OFF and ON the power. ② Check vent blockage. ③ Check whether BLDC fan is operating normally. ④ If all things are normal, please replace main controller. WARNING Failure to turn the power off to the appliance before repair could result in serious injury or death. LP-528 REV. 8.01.14...
  • Page 88 Chapter 4 Troubleshooting Error code Error code Meaning Meaning Cause Cause Jumped Wire Disconnected Vibration occurs hot water and Tilt Error Er 42 will appear if wire Tilt switch (Manual reset) switch senses it and error code 42 is disconnected. (Automatic restore) appears. Failure event Failure event It occurs when sensing serious shaking during operation then cut off gas valve power in circuit and manual Jumped Wire Disconnected restore error occurs. Check point Check point ① Check whether error code disappears after turning OFF and ON the power. ① Check whether error code disappears after turning OFF and ON the ① Check position of boiler and correctly installed condition. ① Ensure the jumper wire is properly connected on the control board. power.
  • Page 89 Chapter 4 Troubleshooting Error code Meaning Cause If burner plate temperature is Burner Plate overheating higher than the switch protection switch open high limit setting (392◦F), (Manual reset) error code 43 will appear. Failure event When burner overheating switch's temperature exceeds 392 F, error code will appear. Check point ① Check Burner Plate for distortion or burn marks . If plate shows signs of overheating replace entire burner plate assembly. ② Check burner overheat switch connections. Ensure all wire leads are secure. After removing the burner overheat switch from the burner plate, measured resistance using multi meter.If the resistance value is 0Ω, replace the switch. ③ If all things are normal, please replace main controller. WARNING Failure to turn the power off to the appliance before repair could result in serious injury or death. LP-528 REV.
  • Page 90 Chapter 4 Troubleshooting Error code Meaning Cause Blower operation error Blower is disconnected or (automatic reset) malfunctioning Failure event Blower operation error. Check point ① Check vent blockage. ② Check whether BLDC fan is operating normally. Although fan operation is normal, replace the fan in case the speed is higher than the reference value. ③ If all things are normal, please replace main controller. WARNING Failure to turn the power off to the appliance before repair could result in serious injury or death. LP-528 REV. 8.01.14...
  • Page 91 Chapter 4 Troubleshooting Error code Meaning Cause Mixing valve error (Manual reset) Mixing valve is unable to detect its zero point (fully opened) Failure event Mixing valve unable to detect its zero reference point. Check point ① Mixing Valve recognizes zero point after turning off and on the power. Check indication of error after basically turning off and on the power. If mixing valve doesn’t operate normally, replace the part. ② If all things are normal, please replace main controller. WARNING Failure to turn the power off to the appliance before repair could result in serious injury or death. LP-528 REV. 8.01.14...
  • Page 92 Chapter 4 Troubleshooting Error code Meaning Cause Mixing valve is controlled by more Mixing valve operation error than 500 steps and blocked when zero (automatic reset) point is recognized for 10 secs. Failure event Mixing valve operation error Check point ① Mixing Valve recognizes zero point after turning off and on the power. Check indication of error after basically turning off and on the power. If mixing valve doesn’t operate normally, replace the part. ②If all things are normal, please replace main controller. WARNING Failure to turn the power off to the appliance before repair could result in serious injury or death. LP-528 REV. 8.01.14...
  • Page 93 Chapter 4 Troubleshooting Error code Meaning Cause Flame detector error When flame is detected before ignition (Automatic reset) error code 72 appears. Failure event Flame detector error Check point ① Ensure the appliance cover is secure. Flame detection sensor can detect external light source and cause an error code. Please check flame detector sensor’s connecting line and ensure correct position as shown. ■ From more than DC 2.5V after ignition safety cut-off will appear ① When setting before ignition is less than DC 2.5V : Replace flame sensor ② When setting after ignition is more than DC 2.5V : Replace flame sensor Flame detector sensor setting (Please check after closing front cover) ③ If all things are normal, please replace main controller. WARNING Failure to turn the power off to the appliance before repair could result in serious injury or death. LP-528 REV.
  • Page 94 Chapter 4 Troubleshooting Error code Meaning Cause Connection error between LCD display When communication with display panel and main controller panel is not stabilished for 10 minutes, (automatic reset) 'Er 76' is displayed. Failure event Connection error between LCD display panel and main controller. Check point ① Ensure proper connection between display panel and main controller. ② If all things are normal, please replace main controller. WARNING Failure to turn the power off to the appliance before repair could result in serious injury or death. LP-528 REV. 8.01.14...
  • Page 95 Chapter 4 Troubleshooting Error code Meaning Cause If adequate water level is not detected Low water level error in the Boiler Heat Exchanger, error (automatic reset) Er 80 will occur. Failure event Low water level error Check point ① If CH pressure is lower than 15 PSI, check automatic Water feed valves to as- sure they are operating properly . Check to ensure automatic air vent operates properly. Either there is no sufficient wa- ter or there is air trapped in the system. ② Check freezing condition of the water replenishment line. Visually check leakage around the internal CH piping ③ Ensure internal CH and DHW pumps are then check boiler operational. Use a flat head screw driver to rotate near piping for a screw on the back side of the pump to ensure leaks . the pump internal shaft is not stuck. Check pump wiring to ensure proper connection. ④ If all things are normal, please replace main controller. WARNING Failure to turn the power off to the appliance before repair could result in serious injury or death. LP-528 REV.
  • Page 96 Chapter 4 Troubleshooting Error code Meaning Cause When low water level Low water level circuit error circuit malfunctions, (automatic reset) error code Er 81 appears Failure event Low water level circuit error Check point ① Ensure the low water level sensor is properly connected. ② If all things are normal, please replace main controller. WARNING Failure to turn the power off to the appliance before repair could result in serious injury or death. LP-528 REV. 8.01.14...
  • Page 97 Chapter 4 Troubleshooting Error code Meaning Cause When system detects water Freeze Protection temperature below 33◦F, error code (automatic restore) 85 appears; The unit runs to increase the temperature to prevent freezing. Failure event When system detects water temperature below 33◦F, error code 85 appears Check point ① Check whether operation of boiler is normal after turning display panel off/on. ② Check internal CH and DHW pumps are operational. Use a flat head screw driver to rotate a screw on the back side of the pump to ensure the pump internal shaft is not stuck. Check pumps wiring to ensure proper connection. ③ ▶ Ensure storage tank and CH supply temperature sensor are properly connected. OP sensor Storage tank temperature sensor LP-528 REV. 8.01.14...
  • Page 98 Chapter 4 Troubleshooting Error code Meaning Cause When exhaust temperature Exhaust temperature exceeds190◦F, error code 94 overheating issue will appear. error will automatically (automatic reset) reset when exhaust temperature is below 180◦F. Failure event Exhaust temperature overheating issue Check point ① Ensure exhaust temperature sensor is properly connected. Check main controller connection. ② Check Exhaust Temperature sensor condition when the resistance value meas- ured with a multimeter is 0Ω, replace exhaust temperature sensor. LP-528 REV. 8.01.14...
  • Page 99 Chapter 5 Replacement Instructions Main components Replacement Instructions 1. Blow Assembly 1. Switch main gas valve to close’s 7. Separate exhaust pipe from gas mixer. 2. Switch manual power switch to 120V OFF. 3. Switch water valve to close. 4. Separate wire connector attached with gas mixer. 8. Loosen three screws from the fan and gas mixer. 5. Separate nut connected with venturi. 9. Replace fan with the new part after separating gas 6. Loosen four screws from fan and separate from burner. mixer and fan. 10. Attach Fan and gas mixer and tighten with three screws. 11. Attach fan on the burner and put gas mixer into exhaust pipe. 12. Fix fan by tightening the four screws in the condition placed FAN on the burner upper case. 13. Connect venturi and gas pipe and assemble a nut. 14. Connect wire connector on the fan. 15. Switch water valve to open. 16. Switch manual power switch to open 17. Switch main gas valve to open. 18. Test operation WARNING Failure to turn the power and gas off to the appliance and ensure the unit is cool before repair could result in serious injury or death.
  • Page 100 Chapter 5 Replacement Instructions Main components Replacement Instructions 2. Gas Valve 1. Switch main gas valve to close’s 7. Loosen four screws to separate adapter connected to 2. Switch manual power switch to 120V OFF. gas valve upper. 3. Switch water valve to close. 4. Separate wire connector attached with gas valve. 8. Loosen four screws to separate adapter connected to gas valve bottom. 5. Loosen and separate upper gas valves pipe nuts. 9. Replace gas valve with new component after separating a adapter. 10. Tighten each four screws to assemble adapter on the gas valve upper/bottom. 11. Tighten two screws after fixing adapter on right side of boiler. 6. Loosen two screws to separate adapter connected to 12. Connect gas valve and gas pipe and assemble a nut. gas valve on the right side of boiler. 13. Connect wire connector on the gas valve. 14. Switch water valve to open. 15. Switch manual power switch to open 16. Switch main gas valve to open. 17. Test whether it operate normally WARNING Failure to turn the power and gas off to the appliance and ensure the unit is cool before repair could result in serious injury or death.
  • Page 101 Chapter 5 Replacement Instructions Main components Replacement Instructions 3. Flow Sensor 4. Mixing Valve 1. Switch main gas valve to close’s. 1. Switch main gas valve to close’s 2. Switch manual power switch to 120V OFF. 2. Switch manual power switch to 120V OFF. 3. Switch water valve to close. 3. Switch water valve to close. 4. Separate sensor connected to flow sensor. 4. Separate wire connector connected to mixing valve. 5. Separate two clips fixing the flow sensor. 5. Separate two clips fixing the mixing valve. 6. Replace flow sensor with new component. 7. Assemble flow sensor and cold water inlet pipe and fix flow sensor with two clips. 8. Attach temperature sensor on the flow sensor. 9. Switch water valve to open. 10. Switch manual power switch to open. 11. Switch main gas valve to open. 12. Test whether it operate normally. 6. Replace mixing valve with new component. 7. Assemble flow sensor and pipe and fix mixing valve with two clips. 8. Connect wire connector on the mixing valve. WARNING 9. Switch water valve to open. Failure to turn the power and gas off to the 10. Switch manual power switch to open.
  • Page 102 Chapter 5 Replacement Instructions Main components Replacement Instructions 5. APS (Air Pressure Switch) 6. Circulation Pump (CH) 1. Switch main gas valve to close’s 1. Switch main gas valve to close’s 2. Switch manual power switch to 120V OFF. 2. Switch manual power switch to 120V OFF. 3. Switch water valve to close. 3. Switch water valve to close. 4. Separate wire connector from air pressure switch 4. Open water drain valve to drain water in boiler. 5. Separate wire connector connected to circulation pump(for heating) 5. Separate hose from air pressure switch. 6. Loosen two screws for separating pipe connected with circulation pump(for heating). 6. Loosen bracket’s two screws and separate air pressure switch. 7. Replace circulation pump(for heating) with new component after separating circulation pump. 7. Replace air pressure sensor with new component. 8. Assemble circulation pump(for heating) and pipe and fix 8. Fix air pressure switch on the bracket and tighten two it with two nuts. screws. 9. Connect wire connector. 9. Connect hose on the air pressure switch. 10. Close the water drain valve. WARNING 10. Connect wire connector on the air pressure switch. 11. Switch water valve to open. 11. Switch water valve to open. 12. Switch manual power switch to open Failure to turn the power and gas off to the 12. Switch manual power switch to open 13. Switch main gas valve to open.
  • Page 103 Chapter 5 Replacement Instructions Main components Replacement Instructions 7. Circulation Pump (Inner circulation) 8. Flame Detection Sensor 1. Switch main gas valve to close’s 1. Switch main gas valve to close’s 2. Switch manual power switch to 120V OFF. 2. Switch manual power switch to 120V OFF. 3. Switch water valve to close. 3. Switch water valve to close. 4. Open water drain valve to drain water in boiler. 4. Separate wire connector connected to flame detection sensor. 5. Separate wire connector connected to circulation pump(for internal circulation). 5. Flame detection sensor is rotated 45 degrees clockwise. 6. Loosen two screws for separating pipe connected with circulation pump(for internal circulation). 6. Pull forward the flame detection sensor. 7. Fix new flame detection sensor. 7. Replace circulation pump(for internal circulation) with 8. Connect wire connector on the flame detection sensor. new component after separating circulation pump. 9. Switch water valve to open. 8. Assemble circulation pump(for internal circulation) and 10. Switch manual power switch to open pipe and fix it with two nuts. 11. Switch main gas valve to open. 9. Connect wire connector. 12. Test whether it operate normally. 10. Close the water drain valve. 11. Switch water valve to open. NOTE 12. Switch manual power switch to open 1. Check part is properly secured. WARNING 13. Switch main gas valve to open.
  • Page 104 Chapter 5 Replacement Instructions Main components Replacement Instructions 9. Main Controller 1. Switch main gas valve to close’s 8. After fixing the new main controller to bracket, tighten 2. Switch manual power switch to 120V OFF. two screws both side of main controller. 3. Switch water valve to close. 4. Separate wire connector connected to main controller. 9. Assemble wire connectors on main controller. 10. Switch water valve to open. 5. Loosen two screws both side of PCB cover. 11. Switch manual power switch to open 12. Switch main gas valve to open. WARNING 13. Test operation Failure to turn the power off to the appliance and ensure the unit is cool before repair could NOTE result in serious injury or death. When assemble connector, check wiring color and spot to avoid mistake.
  • Page 105 Chapter 5 Replacement Instructions Main components Replacement Instructions 10. Ignition Transformer 1. Switch main gas valve to close’s 7. Separate ignition transformer from the bracket. 2. Switch manual power switch to 120V OFF. 3. Switch water valve to close. 4. Separate two ports connected to ignition transformer upper. 5. Separate two ports connected to ignition rod. 8. Assemble ignition transformer on the bracket after replacing with new component. 9. Assemble ignition transformer at the original position. 10. Assemble ports 11. Switch water valve to open. 12. Switch manual power switch to open 13. Switch main gas valve to open. 14. Test whether it operate normally NOTE 1. Check part is properly secured. WARNING 2. Check normal operation. Failure to turn the power and gas off to the appliance and ensure the unit is cool before repair could result in serious injury or death.
  • Page 106 Chapter 7 Repair Part Diagram 1. Cabinet Replacement Parts LP-528 REV. 8.01.14...
  • Page 107 Chapter 7 Repair Part Diagram LP-528 REV. 8.01.14...
  • Page 108 Chapter 6 Repair Parts Diagram 2. Combustion System Replacement Parts LP-528 REV. 8.01.14...
  • Page 109 Chapter 7 Repair Part Diagram LP-528 REV. 8.01.14...
  • Page 110 Memo LP-528 REV. 8.01.14...
  • Page 111 Memo LP-528 REV. 8.01.14...
  • Page 112 Memo LP-528 REV. 8.01.14...

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