95M-200 GAS-FIRED DIRECT VENT MODULATING HOT WATER BOILER Control Manual And Troubleshooting Guide P/N# 240006104, Rev.
1- TABLE OF CONTENTS 1- Table Of Contents....................................................................................................... 2 2 - Important Safety Information..................................................................................... 3 3 - Operating Information................................................................................................ 4 4 - Modulating Control Features........................................................................................
2 - IMPORTANT SAFETY INFORMATION General Installation shall conform to requirements of authority having jurisdiction or in absence of such requirements: Boiler installation shall be completed by qualified agency. • United States ! WARNING • National Fuel Gas Code, ANSI Z223.1/NFPA 54. Fire, explosion, asphyxiation and electrical shock hazard. Improper installation could result in death or serious injury. Read this manual and understand all requirements before beginning installation.
3 - OPERATING INFORMATION 3. DHW heating: Target temperature is determined by Boiler is controlled by microprocessor electronic control that senses: adding Parameter 1 to Parameter 33 (default 150°F and 30°F). Do not change Parameter 1 from factory default setting of 150°F unless application is specially engineered for other temperature. DHW heating default setting is 180°F.
3 - OPERATING INFORMATION Control module provides freeze-up protection when boiler water temperature drops below 45° F: DHW heating. DHW Operation (option) • Below 45° F, boiler circulator operates constantly. • Below 37° F, boiler operates at low fire. • Boiler and circulator turn off if boiler water temperature rises above 50° F. This boiler control feature does not eliminate possibility of freezing.
4 - MODULATING CONTROL FEATURES Boiler Control Design IMPORTANT: • Integrated modulating boiler control is designed for central heating (CH) hot water boilers with modulating fan and gas-air control. • Modulation is based upon data relayed to control by temperature sensors. • Burner uses direct spark igniter (DSI). • Modulating boiler control is intended for use in combination with user interface display unit for both information and operation.
5 - BOILER STARTUP 4. Control module turns on DHW circulator when indirect NOTICE water heater operating control closes. Control module shuts off boiler circulator (stops space heating) during calls for DHW heating. Instructions in this manual are based on factory default parameter settings. Startup Verify Operation – Space Heating 1.
5 - BOILER STARTUP 6. Lower DHW aquastat to stop call for heat. • [1180] Post-purge. When room thermostat is satisfied (call for heat ended), burner turns off. Blower continues for 15-second post-purge, then turns off. If another call for heat occurs, boiler remains off for ten seconds before starting again, and display shows [6180]. • [1150] Post-purge. When room thermostat is satisfied (call for heat ended), burner turns off. Blower continues for 15 second post-purge, then turns off.
6 - CHECKOUT PROCEDURES AND ADJUSTMENTS Verify Sequence Of Operation Test Other Field Installed Safety Controls (if used) Detailed sequence of operation containing faults can be found in Sections 7, “Detailed Sequence of Operation.” Refer to this section and Section 8, “Service Hints,” for more information. If boiler is equipped with any additional safety controls, test for operation as outlined by control manufacturer. Burner should be operating and go off when controls are tested.
6 - CHECKOUT PROCEDURES AND ADJUSTMENTS 8. Drill ½” hole in plastic CPVC vent pipe or exhaust 8. Boiler must be in high fire mode for this operation. See tee, just large enough to allow access for combustion analyzer sample probe. “User Interface Quick Reference” section 10, for more information on placing boiler in high fire mode. 9. Turn thermostat to closed position so appliance is Calculate BTUH Input Rate as follows: activated. Btuh input rate = 10.
6 - CHECKOUT PROCEDURES AND ADJUSTMENTS Pressure Guidelines Fan Speed Minimum RPM Maximum RPM Fuel Natural Gas LP Natural Gas LP Gas Line Inlet N/A N/A At least 4” WC At least 10” WC Pressure Differential Pres0.3” WC 2.0” WC sure Note: Differential pressure values listed for comparison only. These values will change with vent length and altitude of installation.
7 - DETAILED SEQUENCE OF OPERATION POWER ON.
8 - SERVICE HINTS Troubleshooting Tools ! WARNING Tools needed for troubleshooting your boiler: Fire, Explosion, Shock Hazard. Revision, modification, substitution or elimination of factory equipped, supplied or specified components could result in death or serious injury.
9 - TROUBLESHOOTING ! DANGER Checking the Differential Air Pressure Electric shock hazard! Following procedures may expose you to dangerous line voltage. Use caution to avoid touching live electrical contacts. All service must be performed by a trained, experienced service technician. Failure to follow these instructions WILL result in death or serious injury ! WARNING Fire, Explosion. Shut off gas at a location external to appliance should overheating occur or gas supply fail to shut off.
9 - TROUBLESHOOTING ! DANGER Electric shock hazard! Disconnect power before servicing. All service must be performed by a trained, experienced service technician. Never jumper (bypass) any device except for momentary testing as outlined on the following pages of this manual. Failure to follow these instructions WILL result in death or serious injury Control Module Fuses Check control module fuses before replacing control module or any major components (blower, etc.
9 - TROUBLESHOOTING Boiler Not Firing And: Check For: Step Corrective Actions: 1 NO - Check external line switch and fuse or breaker. 2 Determine if red light on line voltage monitor is flashing indication fault. If there is fault verify input voltage dial is properly set in accordance with steps in installation manual. If fault does not clear after ten minutes replace line monitor. 120 vac on both sides of fuse F1? 1 NO - Turn off power to boiler and replace fuse if necessary.
9 - TROUBLESHOOTING SOFT LOCKOUT (Display flashes “9” and then “b” in first position; last two digits on steady (code)) Code 08 18 19 Reason For Soft Lockout 0.14” Pressure switch contacts open Corrective Actions (pressing RESET should restart boiler immediately): 1 Check pressure switch for proper operation. Replace pressure switch if moisture has entered switch. Check venting for blockage. Clear if present.
9 - TROUBLESHOOTING 29 30 61 65 Blower turning when it should be off. 1 Check boiler wiring against wiring diagram. Replace line voltage and low voltage wiring harnesses if necessary. Replace control module if wire replacement doesn’t resolve. 1 Flow rate too low. Check system for: Verify boiler and system are full of water. Inspect and verify system piping and components. Verify piping agrees with boiler manual recommendations. Make sure system pressure drop is not too high.
9 - TROUBLESHOOTING HARD LOCKOUT (Display flashes first digit “E” and last two digits (code)) Code 00 02 Reason For Hard Lockout Corrective Actions (pressing RESET should restart boiler immediately): 1 Burner may be operating too hot due to incorrect combustion. Inspect flame during operation following procedure in this manual. If flame is acceptable at both high and low fire, go to step 2. If flame is not acceptable: For propane boilers, verify propane orifice is correct and properly installed.
9 - TROUBLESHOOTING HARD LOCKOUT (Display flashes first digit “E” and last two digits (code)) Code Reason For Hard Lockout Corrective Actions (pressing RESET should restart boiler immediately): WARNING: Electrical shock hazard. Turn off power to boiler when working with wiring or replacing any boiler component. 09 11 12 13 17 18 19 28 Internal control failure. Casting temperature switch opened. Internal control failure. 1 Reset control and retry. If problem persists, replace control module.
10 - USER INTERFACE QUICK REFERENCE STANDBY MODE - KEY FUNCTIONS AND DISPLAY When boiler is powered on, the display will always show a single character (which represents the boiler’s current operating sequence) followed by the measured outlet water temperature during self-test. then displays Sequence and Measured or Target Outlet Temperature.
10 - USER INTERFACE QUICK REFERENCE STANDBY MODE - BOILER SEQUENCE DISPLAY After display shows Stby for a brief period, first character shows boiler status, followed by boiler outlet water temp. If the burner is being held off due to a soft lockout, the display alternates between showing “9” followed by boiler outlet water temp. and “b” followed by the two-digit codes below. Soft lockout means the boiler will start again automatically if the condition is corrected or timed out.
10 - USER INTERFACE QUICK REFERENCE PARAMETER MODE Press [MODE] button 1 time from Standby Mode. Display shows Para until a key is pressed Para then displays Parameter and Current Status.
10 - USER INTERFACE QUICK REFERENCE INFORMATION MODE Press [MODE] button 2 times from Standby Mode. Display shows Info until a key is pressed Info Press and Hold Key(s) in BLACK (1) Duration Result [MODE] [STEP] [STORE] [+] [-] Tap (1) (2) (3) (4) (5) (6) Digits Digits Digits Digits Digits Digits after after after after after after flashing flashing flashing flashing flashing flashing dot dot dot dot dot dot show show show show show show Then displays Parameter, Flashing Dot, and Current Status.
10 - USER INTERFACE QUICK REFERENCE HARD LOCKOUT MODE Boiler in hard lockout (requires manual RESET) Display flashes first digit E Code E Reason for hard lockout and last two digits (lockout code) (see below) Code xx Reason for hard lockout 00 Flame detected on start-up 18 Supply water temperature higher than 200°F 02 Ignition failed after 5 retries 19 Return water temperature higher than 190°F 03 Gas valve disconnected 25 Outlet temperature increased too fast 04 Power lost after lockout
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11 - INSTALLATION AND CHECKOUT CERTIFICATE Boiler Model: Boiler Serial Number: Date of Installation: Measured BTUH Input: Boiler Location: Altitude of Location: Honeywell AM Kit Installed? (Yes/No): Service Dates: System Type (Give Brief Description): Installation Instructions Have Been Followed Checkout Procedure/Adjustments Performed Maintenance/Service Issues Reviewed With Owner or Maintenance Person Installation Manual Affixed Adjacent To or On Boiler Installer/Technician’s Company: Installer
