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Troubleshooting Chart
37
Section VII. Troubleshooting
General:
N
OTE:
T
hese instructions are intended for the use
o
f qualified personnel trained and experienced in the
installation and servicing of this type of heating equip-
ment and its related system components. Some
states may require installation and service personnel
to be licensed. Persons not qualified should not
attempt to repair this equipment according to these
instructions.
WARNING: Never leave a jumper wire connected
to keep a heater running. A jumper wire should be
used as a test device only, as it is not a cure for a
defective control.
CAUTION: Never allow the main burner to operate
more than five seconds with the filter system shut off.
Serious damage to the heater will result. Anytime the
heater bangs or knocks, it indicates a water void or
lack of water flow. Shut off heater immediately if this
occurs.
Wiring:
As a preliminary check, make sure that all wire
connections are clean and tight and that all wiring
conforms to the wiring diagrams See Figures 35
and 36.
Automatic Reset Time
The heater will automatically reset when an error
condition is corrected and resume operation as
detailed in the table below. The heater can be manu-
ally reset using the keypad by cycling the mode but-
ton through “STANDBY” and back to the original
operating mode (“SPA” or “POOL”).
Error Codes (See chart on page 44)
“LO” Error Code
The V
ersion 13 ignition control features revised
logic for the “LO” error code. The “LO” error code indi-
cates that the contacts on one or more of the switches
in the limit string are open. The limit string contains the
temperature limit switches (2), the vent pressure
switch, and the water pressure switch. If the limit string
opens the error code “LO” will be displayed. There are
two types of “LO” error (note there is no differentiation
between the types on the display):
1. “Soft” lockout
When an “LO” error is displayed without a call for
heat the control will accept keypad inputs to change the
mode, adjust the temperature set points, enter bypass
operation, or change from °F to °C. The heater will not
operate until the error code is cleared. When the error
code is cleared the heater will remain in the selected
mode and retain any new temperature set points. If
power is interrupted the heater will retain the selected
mode and set points. If there is a call for heat “soft”
lockout will end and the control will enter “hard” lockout.
2. “Hard” lockout (Safety lockout)
When an “LO” error is displayed and a call for heat
is present the control will enter “hard” lockout (safety
lockout). The control will only accept keypad inputs to
change the mode (to place the heater into “STANDBY”
or to reset the control). The heater will not operate until
the error code is cleared or the call for heat is removed.
When the error code is cleared the heater will remain in
the selected mode. If power is interrupted the heater
will retain the selected mode in memory.
During a pre-install prior to pool/pump startup the
heater will display the “LO” error code because the
water pressure switch contacts will be open. This will be
a “soft” lockout if the heater remains in “STANDBY”
mode or if there is no call for heat in “SPA” or “POOL”
modes. If the temperature of the heater is below the
factory set points of 65° F, changing the mode from
“STANDBY” to “SPA” or “POOL” will generate a call for
heat and the control will go into a “hard” lockout. The
error code “LO” will be displayed and the control will
only accept keypad inputs for mode change until the
error code is cleared.
Supply Wiring
If the heater is connected to the line side of the cir-
cuit it will be powered at all times. In this situation, when
the pump shuts down the heater will display a fault
code of “LO”. If there is a call for heat and the pump
then re-starts there will be a 2-minute delay for the
heater to fire. After the pump has been running for at
least 2 minutes there is no delay for heater operation.
Wiring the heater to the load side of the timer or con-
troller will not result in a 2-minute delay if the pump primes
quickly enough to activate the heater’
s water pressure
switch. If the pump is slow to prime the heater may dis-
play an “LO” fault code and will take 2 minutes to auto-
matically restart. If the pump has primed, this wait can be
avoided by manually clearing the error code via the key-
pad by changing the mode through the “STANDBY” set-
ting and returning to the initial setting (“SPA” or “POOL”).
When a heater is wired to the line side of the power cir
-
cuit (continuous power) the blower will not operate when
the pump is cycled via a time clock or other switch method.
Internal Wiring
If the heater display is blank after the electrical has
been installed check the ribbon cable from the display
board leading to the ignition control board.
This cable is
not polarized and can be inserted upside down if it was
removed when electrical was done. Invert the cable on
the connector pin and see if the display is now on. The
display may read ‘CE’. If it does, remove power from
the heater for 1 minute and then re-connect the power
.
36
Code Fault Diagnosis Step Remedy
1. Check for Low & High Voltage Output
from Fuse Board
Disconnect plug from P5 connector from Fuse Board. Measure for 24vac between
pins of receptacle on Fuse Board. Reconnect plug. Disconnect plug form P6 of Fuse
Board. Measure for 120vac between pin 3 and 6 of receptacle on Fuse Board.
Reconnect plug. If OK, proceed to section titled "Low voltage circuit fault". Otherwise,
proceed to step 2.
2. Ensure field power supply to heater is
turned on.
Measure for field supply voltage across terminals of TB1 terminal block on Fuse
Board. If OK, proceed to step 3.
3. Check for faulty Fuse Board wiring.
Inspect Fuse Board wiring. Ensure all plugs are securely fastened to Fuse Board. If
OK, proceed to step 4.
4. Verify that FC1and FC2 Fuses on
Fuse board are not open.
Remove FC1 and FC2 fuses from fuseholder. Measure continuity across fuse. If
fuses are open, proceed to section titled "Open FC1 and/or FC2 Fuses". If fuses are
OK, reinstall them and proceed to step 5.
5. Verify that 240vac Voltage Selector
Plug is not installed with a 120vac field
power supply.
Check that proper Voltage Selector Plug is installed in Fuse Board. If OK, proceed to
step 6.
6. Check for defective Transformer.
Disconnect plug from P4 connector from Fuse Board. Measure for 24VAC between
pins 1 & 2 of plug of Transformer and for 120VAC between pins 4 & 6. If 24VAC or
120VAC is not present, replace Transformer. Otherwise, proceed to step 7.
7. Fuse Board is defective Replace Fuse Board.
1. Check for Low Voltage Output from
Fuse Board
Disconnect plug from P5 connector from Fuse Board. Measure for 24vac across
pins. Reconnect plug. If OK, proceed to step 2. Otherwise proceed to step 5.
2. Check for faulty Control Module
wiring.
Inspect Control Module wiring. Ensure all plugs are securely fastened to Control
Module. If OK, proceed to step 3.
3. Verify low voltage input to Control
Module.
Verify 24vac across R and C terminals on Control Module. If not OK, replace
harness. If OK, proceed to step 4.
4. Verify that F1 Fuse on Control Module
is not open.
Remove F1 fuse from fuseholder. Measure continuity across fuse. If OK, replace
Control Module. If fuse is open, proceed to section titled " Open FC3 or F1 Fuse".
5. Verify that FC3 on Fuse Board is not
open.
Remove FC3 fuse from fuseholder. Measure continuity across fuse. If fuse is open,
proceed to section titled "Open FC3 and/or F1 Fuses". If OK, reinstall fuse and
proceed to step 6.
6. Check for defective Transformer.
Disconnect plug from P4 connector from Fuse Board. Measure for 24VAC between
pins 1 & 2 of plug from transformer. If 24VAC is not present, replace Transformer.
Otherwise, proceed to step 7.
7. Fuse Board is defective Replace Fuse Board.
1. Verify that 120vac Voltage Selector
Plug is not installed in with a 240vac
field power supply.
Check that proper Voltage Selector Plug is installed. If OK, proceed to step 2.
If 120VAC plug is installed and field supply voltage is 240VAC, FC1 and FC2 fuses
will have opened. Install the correct Voltage Selector Plug and new FC1 and FC2
fuses.
2. Check for faulty Transformer wiring.
Inspect Transformer wiring. Ensure insulation on wiring is not worn. If OK, proceed to
step 3.
3. Defective Transformer Replace Transformer
1. Check for faulty Gas Valve wiring.
Inspect Gas Valve wiring. Ensure insulation on wiring is not worn. If OK, proceed to
step 2.
2. Verify that Gas Valve is not defective
Measure for resistance across Gas Valve terminals and between each terminal and
ground. If short exists, replace Gas Valve. If OK, proceed to step 3.
3. Check for faulty Control Module
wiring.
Inspect Control Module wiring. Ensure insulation on wiring is not worn. If OK, proceed
to step 4.
4. Control Module is defective. Replace Control Module.
1. Check for faulty Igniter wiring.
Inspect Igniter wiring. Ensure insulation on wiring is not worn. If OK, proceed to step
2.
2. Check for faulty Blower wiring.
Inspect Blower wiring. Ensure insulation on wiring is not worn. If OK, proceed to step
3.
3. Check for defective Igniter.
Disconnect Igniter plug from Control Module. Measure resistance across Igniter. If
shorted, replace igniter. IF OK proceed to step 4.
4. Check for defective blower.
Disconnect blower plug from Control Module. Measure resistance across blower
windings. Winding resistance across lead should be in the following range: Black-to-
White: 10 to 14 ohms, Red-to-White: 18 to 22 ohms. If measured values vary
substantially from these values, blower is defective. Replace. Otherwise, proceed to
step 5.
5. Control Module is defective. Replace Control Module.
None Open FC4 Fuse.
None
Open FC1 and/or
FC2 Fuses.
None
Open FC3 and/or
F1 Fuses.
None
Heater will not
power-up.
None
Low voltage circuit
fault.
I
DL Heater Diagnostic Guide