Munchkin Gas-Fired Hot Water Boiler manual Part 14 Troubleshooting

GAS-FIRED BOILER Boiler Manual

PART 14: TROUBLESHOOTING (CONTINUED)

Table 14-2: 925 Control Board FAULT Codes

Code	Description		Remedy
		1.	Check circulation pump operation
		2.	Assure that there is adequate flow through the boiler by accessing the status menu and assuring that there is less than a 50°F rise from the
			return thermister to the supply thermister.
		3.	Check thermister reading on supply thermister. Replace switch if faulty.
F00	High Limit Exceeded.	4.	If this is a new installation, disconnect the two light grey wires from the zone control, and twist the wires together. Depress the S4 reset
„			button. If the fault clears, the problem is outside the boiler
		5.	If this is an existing installation with glycol in it, check the condition of the water pressure switch. It may be necessary to jump out the water
			pressure switch (temporarily only, as a trouble shooting aid) The 24 VAC signal, may have grounded through the glycol if the water pressure
			switch is leaking.
		1.	Push the red reset button on the switch.
		2.	Check the flue temperature during operation using a combustion analyzer.
F01	Vent Temperature Limit Exceeded.	3.	Replace the vent limit switch if faulty.
„		4.	Verify the combustion drain if clear and draining properly.
		5.	Visually inspect the target wall to see if it is intact. If not intact replace target wall.
	Interrupted or Shorted	1.	Check the electrical connection to the thermister on the outlet manifold. Verify 5 VDC by checking in Molex connector. Verify thermister
F02			values by referencing chart in this manual.
	Supply (Outlet) Thermister.
„		2.	Replace thermister if necessary.
	Interrupted or Shorted	1.	Check the electrical connection to the thermister on the inlet manifold. Verify 5 VDC by checking in Molex connector. Verify thermister
F03			values by referencing chart in this manual.
	Return (Inlet) Thermister.
„		2.	Replace thermister if necessary.
	Supply (Outlet)	1.	Check circulation pump operation.
F05		2.	Assure that there is adequate flow through the boiler by accessing the status menu and assuring that there is less than a 50°F rise from the
	Temperature exceeds 230°F.
„			return thermister to the supply thermister.
F06		1.	Check circulation pump operation.
	Return (Inlet) Temperature	2.	Assure that there is adequate flow through the boiler by accessing the status menu and assuring that there is less than a 50°F rise from the
„	Exceeded 230°F.		return thermister to the supply thermister.
		3.	Check direction of flow on boiler circulator. (See Piping Details in this manual.)
		1.	Watch the igniter through the observation window provided.
	No flame detected – The boiler will	2.	If there is no spark, check the spark electrode for the proper ¼” gap. Use 2 quarters together as a gauge to hold ignitor against to check
	make three attempts at ignition		gap distance.
F09	before the control goes into this	3.	Remove any corrosion from the spark electrode and flame rectifier probe.
„	lockout condition. *See spark	4.	If there is a spark but no flame, check the gas supply to the boiler.
	electrode detail.	5.	If there is a flame, check the flame sensor.
		6.	Check any flue blockage or condensate blocks.
		1.	Monitor the gas pressure to the unit while in operation.
		2.	Assure that the flame is stable when lit.
	Loss of Flame Signal – The boiler	3.	Check to see if the green light on the display module is out while the boiler is running.
F10	will relight 4 times before the control	4.	If the green light doesn’t come on or goes off during operation check the flame signal on the status menu.
„	goes into this lockout condition.	5.	If the signal reads less than 1 microampere, clean the flame rectifier probe.
		6.	If the flame rectifier probe continues to read low, replace it.
		7.	Check the stability of the flame rectification signal. If the signal is unstable, you may need to replace the burner gasket.
		1.	Turn the gas off to the unit at the service valve.
		2.	If the flame signal is still present replace the igniter.
	False Flame Signal – The boiler will	3.	If the flame signal is not present after turning off the gas supply, check the gas valve electrical connection.
F11	lock out if it senses a flame signal	4.	If there is no power to the gas valve, remove the valve and check for obstruction in the valve seat or replace the gas valve.
„	when there should be none present.	5.	Turn the gas on at the service valve after corrective action is taken.
		6.	Check for condensate back up. Condensate back up can damage the refractory wall, and if the wall falls against the rectifier probe, it may
			conduct the signal to ground, giving a false reading.
	Combustion Fan Speed Low – The	1.	Check the combustion air fan wiring.
	boiler will lock out if it senses that	1a.	Check the quality of the 24 VAC signal by measuring from any connected safety to ground. A low voltage situation may cause a “false”
F13	the fan speed is less than 70% of		error code
	expected rate for more than 60	2.	Replace the combustion air fan.
„
	seconds.	3.	Replace the control board.
	Combustion Fan Speed High – The	1.	Check the combustion air fan wiring.
	boiler will lock out if the fan speed is
F14		2.	Replace the combustion air fan.
	more than 130% of expected rate for	3.	Replace the control board.
„
	more than 60 seconds.
		1.	Make sure the connector is correctly connected to the gas valve.
		2.	Check the electrical wiring from the valve to the control board.
		2a.	Voltage readings will be from 18-22 VDC on the outlet of the gas valve plug from any pin to ground, the connector must remain in contact
F18	Gas Valve Error		with the pins.
„		2b.	On the 399M only, check the 24 VAC relay block.
		3.	Replace the low voltage wiring harness assembly.
		4.	Replace control board.
„	Supply voltage frequency out of range. (92-132 VAC 60 Hz)
F19
„	Watchdog	Call factory for further assistance. Watchdog
F30
„	Parameter Memory	Call factory for further assistance. Parameter memory error, reprogramming needed
F31
„	Parameter Memory Write Error	Call factory for further assistance. Parameter memory write error
F32
„	Programming Error	Call factory for further assistance. Parameter memory error, reprogramming needed
F33
„	Parameters Programmed	Press S4 reset
PP
„	Internal processor error, due to incoming voltage problems. (92-132 VAC 60 Hz). May also occur if neutral wire has been broken or damaged.
Nc
„	Internal error
F

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