E- Series Boiler Troubleshooting Manual WARNING There are a number of live tests that are required when fault finding this product. Extreme care should be used at all times to avoid contact with energized components inside the product. You MUST be a qualified service person before proceeding with these test instructions. Before checking resistance readings, turn off power source to unit and then isolate each item to be checked from the circuit by unplugging it.
Table of Contents Code Numbers Page # Boiler Description …………………………………………………………………………………………………………………………. 4 Error indication (Short reference) ………………………………………………………………………………………………... 5 BL 01 …………………………………………………………………………………………………………………………………………….. 6 BL 05 …………………………………………………………………………………………………………………………………………….. 7 BL 11 …………………………………………………………………………………………………………………………………………….. 8 BL 12 …………………………………………………………………………………………………………………………………………….. 9 BL 60 ……………………………………………………………………………………………………………………………………………..
E 32 ….…………..……………………………………………………………………………………………………………………………… 36 E 36 ....…..……………………………………………………………………………………………………………………………………… 37 E 37 …..…………….………………………………………………………..……………………………………………………………….... 38 E 41 …………………………………………………………..…………………………………………………………………………..……… 39 E 42 …………………………………………………………………………………………………………………………………………..….. 40 E 44 ………………………………………………………………………………………………………………………………………………. 41 E 68 ……………………………………………………………………………………………………………………………………………….
Parts of the Boiler Bi-metal high 4 008082013GW
Block and Errors - Error indication (short reference) A detected error is indicated on the display by means of a blocking or error messages. A distinction should be made between these two messages due to the fact that a blocking code can be of a temporary nature, however, error messages are fixed “lockouts” or hard lockouts. The control will try its utmost to prevent a lockout and will temporary switch off the unit by blocking it, below is a list of some messages the unit will display.
WARNING: Turn off power supply before installing jumper. Rectify error by determining which external contact is open. If external contacts are not being used place jumper across terminals 24 & 25 The 120 volt external pump is for E and QP model boilers ͢ If multiple boiler safeties are to be wired in series check with your local inspector or the local or State codes to see if this is allowed in your area before proceeding. NEVER wire boiler safeties in parallel.
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BL 11 Maximum average ΔT of T1 supply sensor and T2 return sensor for central heating is repeatedly exceeded. Operation is normally possible for the hot water supply during the block. The pump continues to operate at minimum capacity during the block. Rectify Issue, Check following 1. 2. 3. 4. 5. Check flow through the heating system. Possible causes: radiator shut off valves closed, blocked water filter. Verify proper installation of the boiler plumbing, connections and all components.
BL 12 Maximum average ΔT of supply sensor and return sensor for hot water is repeatedly exceeded. Operation is normally possible for the central heating installation during the block. The pump continues to operate at minimum capacity during Rectify Issue, Check following 1. 2. 3. 4. Check flow through the boiler and DHW tank. Possible causes: radiator shut off valves closed, blocked water filter, restriction in DHW tank to high.
NOTE; in order to reset all parameters in your boiler back to factory defaults follow the “Activating Factory Settings” (Green button function) instructions found in your owner’s manual. CAUTION: All parameters you adjusted will now have to be reprogrammed if the bL60 code clears up. If after resetting the boiler the bL60 still appears, you will need to replace the sub-PC board and reprogram the MCBA. The sub PC board must be from a conversation kit for the same gas type as your boiler.
A temperature difference has been detected A temperature difference has been detected between the supply T1and sensor andsensor the return between the supply return whileT2 sensor while the burner is not in After operation. the burner is not in operation. the After the average has disappeared, the blocking average ΔTΔT has disappeared, the block will code will go away. disappear. Check the supply T1 sensor and the return T2 sensor for the proper resistance valve. Replace if found to be defective.
Inspect vent system and all air passages ways for blockage 212˚F is the default temperature setting for parameter 84. Verify to see if the temperature setting for this parameter is set higher than the default. If so, inspect vent system for blockage. CAUTION: ensure all vent components are properly seated when reinstalled. T5 sensor is registering too high of a temperature. This error can only occur if the optional T5 sensor is was purchased and installed on the boiler.
Explanation: The bL81 can be triggered if the flue gas plug has gotten wet and then dried out. (MCBA sees resistance when wet and then sees no resistance when dry) This tricks the MCBA into thinking that a flue gas sensor was installed and then removed in which the bL 81 is triggered. Moisture can come from a clog, broken or dry condensate trap. Moisture can be from a leaking concentric vent pipe or from driving rain during extreme weather.
Flue sensor Explanation: The bL81 can be triggered if the flue gas plug has gotten wet and then dried out. (MCBA sees resistance when wet and then sees no resistance when dry) This tricks the MCBA into thinking that a flue gas sensor was installed and then removed in which the bL 81 is triggered. Moisture can come from a clog, broken or dry condensate trap. Moisture can be from a leaking concentric vent pipe or from driving rain during extreme weather.
This can occur when PARA 84 has been changed to 20 and the field installed jumper is loose or removed. 212˚F is the default temperature setting for parameter 84. Verify to see if the temperature setting for this parameter is set higher than the default. If so, inspect vent system for blockage.
Check the installation for the presence of air. If there is a secondary pump installed and it is not hydraulically separated, it could cause a loss of pressure difference. AIR: if boiler, inner boiler piping, or Low Loss Header has a large air bubble in it the pressure sensor will not see the pressure spike that the pump generates when it starts. The pressure spike is what tells the MCBA that the pump has started. The air bubble will absorb that spike. Bleed all air from the system.
The frequency of the power supply deviates more than + or - 1.5 Hz. If using a back-up generator ensure it is properly grounded and providing a clean steady voltage and sign wave of 59.3 to 60.8 Hz.
WARNING: Turn off power and water supply to the boiler before removing or installing any parts. Boiler has not been burning but an ionization flow (flame) has been detected. Check whether the ionization cable and/or the electrode are responsible for a short circuit. Remove the plugs from the ionization cable connected to the control unit and to the electrode. Now using a ohm meter take a measurement between the ionization connection and the ground.
E 01 24 volt short circuit Remove all 24 volt connectors, such as: fan, pump, any three port valve and the 24 volt plug to the connecting block. Check for a short circuit in the disconnected components. Next; switch on power to the control board with all the 24 volt components disconnected. Reconnect the components one at a time, if code E 01 appears when you plug up a component, that component has a short circuit. Rectify any short circuits or replace defective component causing short circuit.
WARNING: Turn off power and water supply to the boiler before removing or installing any parts. If checking gas pressures you MUST be qualified gas technician to service the gas system on this appliance. Ignition Failure Issue Flame Failure Issue Ionization flow, ionization cable or 02 setting Due to insufficient ionization the burner has shut down after ignition The minimum ionization current should be 4 micro amps (Check INFO step 48, the O2 should be a minimum of 4.4% for NG or 4.8% for LP.
WARNING: Turn off power and water supply to the boiler before removing or installing any parts. If checking gas pressures you MUST be qualified gas technician to service the gas system on this appliance. Control unit error - Connector not plugged into the gas valve or defect in the wiring harness to the gas valve. Check for 24 volts DC at gas valve. In some cases an E03 is caused from a loose connection on wires to the gas valve. This faulty connection may be in the Molex plug (X5) on the MCBA.
WARNING: Turn off power and water supply to the boiler before removing or installing any parts. If checking gas pressures you MUST be qualified gas technician to service the gas system on this appliance. The boiler automatically indicates this message if during an error read-out the electrical to if The boiler automatically indicates thispower message the boiler shut read-out off. Afterthe theelectrical power is power once again during aniserror to switched on, theoff.
WARNING: Turn off power and water supply to the boiler before removing or installing any parts. If checking gas pressures you MUST be qualified gas technician to service the gas system on this appliance. If error persist after reset Software error control unit, replace control unit. Remove the E-Prom from the defective control unit and place it onto the new control. The controller will automatically load the program into the new control unit.
WARNING: Turn off power and water supply to the boiler before removing or installing any parts. If checking gas pressures you MUST be qualified gas technician to service the gas system on this appliance. Replace the control unit. Remove the E-Prom from the defective control unit and place onto the new control. The controller will automatically load the program into the new control unit.
WARNING: Turn off power and water supply to the boiler before removing or installing any parts. If checking gas pressures you MUST be qualified gas technician to service the gas system on this appliance. Check E-Prom to ensure it has no damaged pins and it is properly connected.
WARNING: Turn off power and water supply to the boiler before removing or installing any parts. VERY RARE THAT AIR IS AT FAULT. If air is present it will be indicated by a gurgling noise. Normally when an airlock is present a BL85 will be indicated Clean the pump and/or filter when necessary.
WARNING: Turn off power and water supply to the boiler before removing or installing any parts. If checking gas pressures you MUST be qualified gas technician to service the gas system on this appliance. Replace the control unit. Remove the E-Prom from the defective control unit and place onto the new control. The controller will automatically load the program into the new control unit.
WARNING: Turn off power and water supply to the boiler before removing or installing any parts. - - T3 flow sensor ground connection T3 flow sensor failure or controller failure To determine flow temperatures for T3 use the chart to the left for proper resistance values for a set temperature. When no discrepancies are found on the sensors it may be a leakage of current coming in from an end switch or pump relay box connected to terms 22 and 23.
WARNING: Turn off power and water supply to the boiler before removing or installing any parts. Signal maximum flow water temperature exceeded (T1 ˃ 212⁰F). Actual flow flow Check actual temperature temperatureshould be verified before T1 is determined.
WARNING: Turn off power and water supply to the boiler before removing or installing any parts Signal maximum return water temperature exceeded (T2 ˃ 212⁰F).
WARNING: Turn off power and water supply to the boiler before removing or installing any parts. T1 and T2 (swapped). T2 temperature is measured to be higher than T1. Check resistance value of T1 and T2 (See resistance chart under error 19 for resistance values. Replace T! and/or T2 if found to be defective.
WARNING: Turn off power and water supply to the boiler before removing or installing any parts. If checking gas pressures you MUST be qualified gas technician to service the gas system on this appliance. Replace MCBA board, main board.
WARNING: Turn off power supply to the boiler before removing or installing any parts. No feedback signal from fan motor. Check the wiring harness to the fan motor and control unit. Check power supply to motor during combustion process, should be 24 volts DC. Fan motor wiring harness constant 24 volts DC.
WARNING: Turn off power to the boiler before removing or installing any parts There is a negative pressure on vent system (Pressure difference). Check to see if fan motor is spinning. Vent system and air intake must be installed according to the installation instructions. The E29 is triggered immediately after fan check code 5 during the starting sequence. If during fan check 5 the fan remains spinning more than 150 rpms an E29 will occur. Causes: Wind driving into a concentric terminal.
WARNING: Turn off power and water supply to the boiler before removing or installing any parts. Internal shut down of supply sensor T1. T1 sensor short circuit is indicated by low ohm reading. Replace defective sensor, see resistance values in chart on E 18 above.
WARNING: Turn off power and water supply to the boiler before removing or installing any parts. Shut down of return sensor T2, T2 sensor short circuit is indicated by low ohm reading. Replace defective sensor. Refer to resistance chart on E 19 above.
WARNING: Turn off power and water supply to the boiler before removing or installing any parts. Contact for supply sensor T1 open, indicated by infinite ohm reading.
WARNING: Turn off power and water supply to the boiler before removing or installing any parts. Contact for the return sensor T2 open, indicated by infinite ohm reading. Remove the plug from the flow sensor as a result of which error 32 occurs.
WARNING: Turn off power and water supply to the boiler before removing or installing any parts. If checking gas pressures you MUST be qualified gas technician to service the gas system on this appliance. Replace the control unit. Remove the E-Prom from the defective control unit and place onto the new control. The controller will automatically load the program into the new control unit.
WARNING: Turn off power and water supply to the boiler before removing or installing any parts. If checking gas pressures you MUST be qualified gas technician to service the gas system on this appliance. Replace the control unit. Remove the E-Prom from the defective control unit and place onto the new control. The controller will automatically load the program into the new control unit.
WARNING: Turn off power and water supply to the boiler before removing or installing any parts. If checking gas pressures you MUST be qualified gas technician to service the gas system on this appliance.
WARNING: Turn off power and water supply to the boiler before removing or installing any parts. If checking gas pressures you MUST be qualified gas technician to service the gas system on this appliance. No parameters present. Meaning the E-Prom has no program or is blank. Replace E-Prom or display (Model dependent). If this error is displayed, there is no software on the MCBA or display/EPROM. A RINNAI conversion kit specific for the boiler model and fuel type must be installed.
WARNING: Turn off power and water supply to the boiler before removing or installing any parts. If checking gas pressures you MUST be qualified gas technician to service the gas system on this appliance. No software present. Q-Series ribbon cable problem or defective key pad. Replace the control unit. Remove the E-Prom from the defective control unit and place onto the new control. The controller will automatically load the program into the new control unit.
WARNING: Turn off power and water supply to the boiler before removing or installing any parts T5 sensor is reading too high of a flue gas temperature. (Adjust parameter 84 – default 212 ⁰F) See location of T5 sensor below. If red cap is installed, T5 sensor is not being used. Moisture on the flue gas sensor wires or terminals could cause a false temperature reading.
WARNING: Turn off power and water supply to the boiler before removing or installing any parts. If checking gas pressures you MUST be qualified gas technician to service the gas system on this appliance.
WARNING: Turn off power to the boiler before removing or installing the fuse. Check fuse mounted on PC board to see if it blown. In addition, check transformer output and wiring harness for transformer to ensure it is plugged in properly. This is the low voltage fuse that is located directly next to the PCB board transformer. The OEM fuse has colored stripes; the spare fuse located on control cover is a clear glass. Please verify the amp rating (4 amp) on the metal rim of the fuse before installing it.
WARNING: Turn off power and water supply to the boiler before removing or installing any parts. If checking gas pressures you MUST be qualified gas technician to service the gas system on this appliance.
WARNING: Turn off power and water supply to the boiler before removing or installing any parts. If checking gas pressures you MUST be qualified gas technician to service the gas system on this appliance.
Checking the O2 Setting 49 008082013GW
Boiler Controls Burner off while there is a demand for central heat of DHW. Burner off when room thermostat is demanding or burner off when DHW is calling.
Explanation of the function buttons This LED should never be left on. Pressing R or the reset button for more than 5 seconds will activate a 17 minute de-aeration cycle.
Starting up: Filling and de-aerating the boiler and installation Requirements of the water system 52 008082013GW
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Filling the heating system Note: You must have either a hot water or heat demand to activate de-aeration Check the water pressure regularly and top off the installation when necessary. The working pressure of the installation should be between 16 and 18 PSI when the system is cold. Adjust your auto-feed to 16 – 18 PSI.
Altering adjustments 55 008082013GW
See additional definitions below PARA 36 E Combi. setting definitions 00 = activation by temperature drop for DHW (no plate warming) 10 = activation by temperature drop for DHW (plus plate warming) 20 = flow switch activation only DHW. (No plate warming/ no temp actuation) In either setting above - 00 or 10 the Flow switch is still in the circuit and if it sticks "closed" it can keep the boiler locked in DHW and code 6 with appear on the screen. Unplug flow switch as it is not needed.
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Activating factory settings (Green button function) 58 008082013GW
Isolating the boiler 59 008082013GW
Reset service interval counter 60 008082013GW
