prestige Condensing Water Boiler SERVICE TECHNICIAN’S TROUBLE SHOOTING GUIDE Date revised: 5/11/09 2008-36 TSG-PRESTIGE
Table of Contents INTRODUCTION Page 1-2 SERVICING TIPS AND INSTRUCTIONS Page 3-4 CONTROL MODULE DISPLAY - GENERAL Page 5-9 PRESTIGE CONTROL MODULE DISPLAY Page 10-11 SOFT LOCKOUT ERROR CODE Page 12-16 HARD LOCKOUT ERROR CODE Page 17-24 COMBUSTION TEST / SETTINGS Page 25-26 INTERNAL WIRING / ELECTRICAL Page 27-29 REPLACEMENT PARTS Page 30-40 TORQUE SPECIFICATIONS Page 41 i
Introduction Definitions WARNING Indicates a potentially hazardous situation which, if ignored, can result in death, serious injury or substantial property damage. CAUTION Indicates a potentially hazardous situation which, if ignored, can result in minor injury, property damage. NOTICE Indicates special instructions on installation, operation or maintenance, which are important to the equipment/product, but not related to personal injury hazards.
Introduction Introduction This guide is to be used in conjunction with the Triangle Tube PRESTIGE Boiler Installation and Maintenance Manual. Good Troubleshooting Practices Before leaving for the job site: Check your parts and tools • • Test equipment and tools you will need: Electrical meter that tests both voltage (AC/DC), continuity (ØW), resistance ( Temperature gauge or metering device Manometer Calibrated Combustion Analyzer Standard tools of the trade (wrenches, screwdrivers...
Servicing Tips and Instructions WARNING Label all wires and wire connections prior to disconnecting when servicing any boiler controls. Wiring errors can cause improper and dangerous operation. Always disconnect the power supply to the boiler before servicing. Failure to comply could result in severe personal injury, death or substantial property damage.
Servicing Tips and Instructions 8. Reconnect the external power supply to the boiler and perform the verification of operation steps as outline in the Prestige Installation Manual. WARNING After completing any servicing of the boiler verify proper operation of the boiler. Steps to verify proper operation are outlined in the Start-Up Procedures in the PRESTIGE Boiler Installation and Maintenance Manual. Failure to comply could result in severe personal injury, death or substantial property damage.
Control Module Display - General Standby Mode TO TEMPORARILY PLACE THE BURNER INTO LOW FIRE TEST MODE: press the MODE button until “StbY” is displayed. Then press and hold both MODE and “-” buttons simultaneously until the first digit flashes “L”. StbY After the boiler is turned on, the control panel will be in the STANDBY mode. This is the standard mode for the PRESTIGE. The control automatically returns to this mode after 20 minutes if no keys have been pressed on the display.
Control Module Display - General Standby Mode Display Display 0 180 1 180 2 180 3 180 4 180 5 180 6 180 7 180 8 180 9 180 b 18 Boiler function STANDBY, no demand Fan prepurge or post purge cycle Ignition sequence Burner ON for space heating (CH) Burner ON for domestic hot water (DHW) Pre-check for air flow prior to prepurge cycle Burner OFF due to reaching temperature setpoint Space Heating (CH) post pump cycle Domestic hot water (DHW) post pump cycle Burner blocked: Supply temperature too high (202 F) .
Control Module Display - General Key: Parameter Mode P ARA STEP STEP To access PARAMETER mode when the system is in STANDBY mode, press the MODE button once. STEP STEP Key: Display MODE P ARA Display Description of parameters 1. . 140 2. 01 3. 01 4.1 8 6 Domestic Hot Water Setting (See Note 1) DHW Application Selection (See Note 2) CH Application Selection (See Note 3) CH Maximum Boiler Operating Setpoint Note 1: This parameter is factory set to 140ºF.
Control Module Display - General Accessing Boiler Information NOTICE Information mode Key: Display Key: ARA PDisplay P ARA I NFO I NFO MODE MODE MODE MODE I NFO J J1212 .34 .34 .56 .56 Pressing MODE once Pressing MODE once Pressing MODE twice Pressing MODE twice The ignition counters and burner hours are split into three two digit numbers. For example: Write the numbers down from left to right to arrive at 123,456 CH ignitions. To switch from STANDBY mode to Information mode, press MODE twice.
Control Module Display - General In the INFO Mode a temperature reading of -22 typically indicates an “open” circuit. A temperature reading of 240 typically indicates a short-circuit.
Prestige Control Module Display Boiler control display is blank - Check for 120 volts at terminals L and N of the 120V terminal strip • - Check the internal fuse F1 by locating the control module and removing the black housing. The internal fuse F1 is located in the right corner of the control module near the 120V high voltage electrical connector on the control as shown in Fig. 1, page 4. See Servicing Tips and Instructions, page 3, for accessing the internal fuses of the control module.
Prestige Control Module Display • If all the above steps fail to resolve the problem, replace the control module. Boiler display shows a number of 1 to 8 for the first digit on the left followed by 2 or 3 digits (boiler temperature) - The boiler is in normal operating mode. Reference the boiler installation manual for detailed explanation of the boiler operation. Boiler Display shows FUSE - Check and ensure the transformer is properly connected to the MCBA module.
Soft Lockout Error Code The boiler will display Soft Lockouts with a flashing “9”, then “b” as the first digit on the left of the display followed by a steady two digit code. The boiler will automatically reset a Soft Lockout once the condition has been corrected and returned to standard operating condition.
Soft Lockout Error Code Code Error Condition Correcting Error Condition b- 24 High Temperature Limit, Boiler Supply and Return If the primary boiler return water temperature exceeds the boiler supply temperature, the burner will shut down until the boiler return temperature drops below the boiler supply temperature. The boiler circulator will continue operating. b- 25 High Temperature Limit, Boiler Supply • The following items should be checked:.
Soft Lockout Error Code Code Error Condition b- 25 High Temperature Limit, Boiler Supply (continued) Correcting Error Condition - Check and verify 120V at the 120V terminal strip along terminals 1 and 2 inside the boiler enclosure. Check circulator wire harness from the boiler to the circulator if necessary. • b- 26 LWCO Device Verify and ensure the external DHW circulator is operating properly. - Check and verify 120V at the circulator wiring in the circulator junction box.
Soft Lockout Error Code Code Error Condition Correcting Error Condition b- 30 High Temperature Limit, Boiler Supply and Return Temperature Differential is greater than 72ºF If the primary boiler water temperature differential between the supply and the return is too high (greater than 72ºF), the burner will shut down for a 180 seconds (MCBA 54) or 150 second (MCBA 14) period. The circulator will continue circulating until the start of the next cycle.
Soft Lockout Error Code Code Error Condition b- 38 Indirect Water Heater Temperature Sensor Correcting Error Condition The control module detects the indirect water heater temperature sensor as “open” which is typically an improper or missing connection of the sensor. - Review parameter setting for DHW operating signal selection. Reference Prestige Control Supplement for proper selection.
Hard Lockout Error Code The boiler will display a Hard Lockout with an E as the first digit on the left of display followed by a two-digit code. The boiler must be manually reset by pressing the RESET button on the display once the condition has been corrected. A Hard Lockout will occur when boiler conditions, that are considered critical in terms of safety, are not met or exceeded.
Code E- 02 Correcting Error Condition Error Condition Failed Ignition Error (continued) • On LP applications the incoming gas regulator should be installed as follows: - Size the regulator for the appropriate flow. - The regulator diaphrm should be installed horizontally - The piping before and after the regulator should be straight rigid pipe for a minimum of 10 pipe diameters. - It’s best practice to avoid flexible pipe between boiler and the outlet of the regulator.
Hard Lockout Error Code Code E- 05 Correcting Error Condition Error Condition Internal Failure This error may occur due to a short in either the ignition cable or display panel. • Check flat ribbon cable to display for short. • Check for moisture at display and repair cause of moisture, dry and/or replace display. • Inspect ignition cable replace if necessary. • Reset the boiler control module and retry ignition sequence and boiler operation.
Hard Lockout Error Code Code Error Condition E- 14 Low Voltage Internal Short or Voltage Backfeed (continued) Correcting Error Condition - Remove all field wiring from the boiler’s and reset the boiler control module. - Initiate a call for heat external to the boiler and check for voltage on field wiring to terminals 7 and 8 (CH heating) and terminals 11 and 12 (DHW heating). • Check for the line voltage being supplied to the boiler for polarity and for 120 VAC.
Hard Lockout Error Code Code E- 18 High Temperature Limit, Supply Temperature (continued) E- 19 High Temperature Limit, Return Temperature E- 24 Correcting Error Condition Error Condition Low Voltage Internal Short or Voltage Backfeed the display temperature (INFO Mode display, “1” is the first digit followed by the temperature.) - Replace the supply temperature sensor if the temperature comparison is largely varied by more than 10ºF.
Hard Lockout Error Code Code Error Condition Correcting Error Condition E- 25 High Temperature Limit, Supply Temperature Rate of Increase This error will occur if the boiler supply water temperature rate of increase is deemed too rapid. The control module will display a soft lockout of b_25 and initiate a recycle sequence. After 5 cycles the boiler will go into a hard lockout. E- 28 Blower Assembly • This problem will occur if the flow rate and demand load on the boiler are too low.
Hard Lockout Error Code Code E- 29 Correcting Error Condition Error Condition Blower Assembly The control module is detecting the blower in operation when it should not be. • E- 31 Boiler Supply Temperature Sensor The control module detects a short or jumped out condition of the boiler supply (outlet) temperature sensor.
Hard Lockout Error Code Code Error Condition Correcting Error Condition E- 52 Flue Temperature Sensor The control module detects the flue temperature exceeding the 250ºF limitation of the boiler. • This is an indication the heat exchanger flue ways may need cleaning. Reference the Maintenance section of the installation manual for procedures on cleaning the flue side of the heat exchanger. • Isolate the boiler from the boiler system piping and drain the boiler heat exchanger.
Combustion Test / Settings WARNING The installation and startup of the PRESTIGE should be performed by a qualified installer / service technician. The startup procedures should include a complete combustion test. The complete combustion test must also be performed after any adjustments to the factory settings on the burner. Failure to comply with these requirements can result in severe personal injury, death or substantial property damage.
Combustion Test / Settings WARNING To perform the following procedure it is essential the service technician reads and follows the procedures closely. After any adjustments are completed it is essential to perform a combustion check before proceeding with further steps. Failure to comply with these procedures can result in personal injury, death or substantial property damage. If the O2 level measured during the combustion test is below 2.3% for natural or 2.
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Internal Wiring / Electrical NTC Sensor Resistance Curve 200 180 NTC (kOhm) 160 140 120 100 80 60 40 20 0 -40 -20 0 20 40 60 80 100 120 Temperature (ºC) 5/16” V2: 32 Ω V2: 18 Ω 3/16” (Tip) Fig. 5: Gas Valve Solenoid Coil Resistance - Prestige Solo 60, 110, 175, 250 and Excellence 110 Ensure tip is aligned on the centerline of the rod Fig.
Replacement Parts 7 6 5 9 2 5 3 1 8 Fig.
Replacement Parts 7 8 6 5 10 3 1A 2 1 1B 9 Fig.
Replacement Parts 3 1 2 Fig.
Replacement Parts 3 2 4 8 1 9 5 4 7 6 Fig.
Replacement Parts Fig.
Replacement Parts 3 2 9 4 1 6 10 5 4 8 7 Fig.
Replacement Parts 3 2 4 5 9 1 6 4 8 10 Fig.
Replacement Parts 2 3 11 9 14 12 10 15 1 5 8 13 Fig.
Replacement Parts Fig.
Replacement Parts 7 4 3 10 8 12 6 9 5 2 13 1 Fig.
Replacement Parts Fig.
Torques Specifications The following lists the torques specifications for various screws: 41
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