Heater Troubleshooting Guides - F.W. Webb Company · A. Low water flow through heater. heater should be 5.5” to 10.0” WC for Natural Gas or B. Gas pressure on heater manifold

LRZE………………………………………………………………………LRZM……………………………………………………………………..LXi ………………………………………………………………………..LITE 2 LD ………………………………………………………………..LITE 2 LJ ………………………………………………………………..LITE 2 LG ……………………………………………………………….LX or LT STANDARD BURNERS ……………………………………LX or LT LOW NOx BURNERS ……………………………………….HiE2 ………………………………………………………………………SERIES 1 & 2 SPARK IGNITION …………………………………….SERIES 1 & 2 MILLIVOLT …………………………………………….HOT SHOT (100 K) ..…………………………………………………..DP OIL FIRED ………………………………………………………….

2, 34, 56, 78, 910, 1112, 1314, 1516, 1718, 19202122, 2324

Heater Troubleshooting Guides

Table Of Contents

1

F

STEP 2 – Check Transformer

24 VAC between Red (2) wire and Yellow (1) wire on Transformer?

YES

NO Replace Transformer

STEP 1 – Check in coming power (make certain filter pump motor is ON).

240 or 120 VAC between Black (A) wire and Red (B) wire?

YES

NO Make certain filter pump is on. Correct wiring.

STEP 3 – Check Fuse

24 VAC between Red (3) wire on PIB and Yellow (1) wire on Transformer?

NO Locate and correct short circuit, replace Fuse.

YES

STEP 4 – Check power to Water Press. Sw.

24 VAC between Purple (4) wire on PIB and Yellow (1) wire on Transformer?

NO Recheck voltage at Red (3) wire. If voltage is 24 VAC replace PIB.

STEP 5 – Check thru Water Press. Sw.

24 VAC between Gray (5) wire on PIB and Yellow (1) wire on Transformer?

NO

Do a Back Pressure Test. If pressure is higher than 2 PSI, replace Water Pressure Switch. If less, clean filter, baskets or repair pressure problem.

YES

STEP 6 – Check thru Vent Temp Limit

24 VAC between Orange (6) wire after Vent Temp Limit and Yellow (1) wire on Transformer?

NO Correct blockage in vent. Replace Vent Temp Limit

YES

STEP 7 – Check thru Fusible Link

24 VAC between Blue (7) wire on PIB and Yellow (1) wire on Transformer?

NO Check wires to Fusible Link, replace Fusible Link. Correct excessive heat problem in cabinet. Possible rollout.

YES

STEP 8 – Check power to High Limits

24 VAC between Black (8) wire on PIB and Yellow (1) wire on Transformer?

NO Recheck power at Blue (7) wire. If 24 VAC at Blue but not Black, replace PIB.

STEP 9 – Check thru High Limits

24 VAC between Black (9) wire on PIB and Yellow (1) wire on Transformer?

NO Replace both High Limits. Do a Temp. Rise Test. Correct flow problem.

YES

Make certain control is calling for heat.

24 VAC between Black/Yellow (10) wire on PIB at J3 and Yellow (1) wire on Transformer?

NO

STEP 10 – Check power to Ignition Control YES

Recheck power at Black (9) wire. If 24 VAC at Black, but not Black/Yellow (10), replace PIB.

24 VAC between Black/Yellow (11) at W terminal of Ignition Control and Yellow (1) wire of Transformer?

NO

STEP 11 – Check power at Ignition Control

YES

Correct problem with Black/Yellow wire or its connectors.

YES

YES

STEP 13 – Go to back page

Is Igniter (12) glowing?

NO STEP 12 – Check Hot Surface Igniter (Igniter)

Turn heater OFF. Disconnect Igniter at C & D. Turn heater ON. Check voltage in the connector ends of C & D going to the Ignition Control (not to the Igniter). If your meter is a true RMS meter the voltage should read 105 to 130 VAC. If your meter is not a true RMS meter the voltage should read 64 to 130 VAC. If the voltage is within range replace the Igniter. If the voltage is low recheck incoming power. If the voltage is above 130 VAC replace both the Igniter and Ignition Control.

YES

LRZE TROUBLESHOOTING

Make certain Universal Control is calling for heat (red LED on).

Power Interface Board (PIB)

J15

J16

J17

J 6

24 VAC COMP/

IGN PUMP FAN/

LOUVER

L1

W

VAL

GND

IGN/

FS

24

VAC

FC IGN/

120

L2

Ignition Control

IGN/

240

Purple

Gray

Orange

Blue

Black

Black

Yellow

Black/Yellow

Red

Brown

Yellow

Red

Black/Yellow

Black

Black

White

White

Red

Bla

ck

Whi

te

Brown

Yellow

3

Transformer

Fuse 250 V – 2 amp

Gas Valve

Hot Surface Igniter

Flame Sensor

Burner

Pressure Switch

Fusible Link 305 °F

High Limits

Universal Control

5

7 8

9

10

A B

C

D 14

Red/White

Black/White

J 3

J12

4

120 or 240 VAC Power Supply

J 9 H2O

11

13

Brown

12

Water Temperature Sensor

Valve Monitor Circuit

15

Diagnostic LED

1

2

Red

150 ºF (red dot)

130 ºF

Black

Vent Temp Limit 464 °F

Red Marking

Blue 6

After the Igniter begins to glow, wait approximately 40 seconds. Did the burners ignite?

NOSTEP 13 – Check for Ignition

Check voltage between Brown (13) wire at Gas Valve and Yellow (1) wire of transformer. Is there 24 VAC?NO

Check voltage at VAL of Ignition Control. If 24 VAC, replace brown wire. If no voltage replace Ignition Control.

Do Burners stay on past 7 seconds? NOSTEP 14 – Check Burners operation

YES

Heater is not recognizing the flame (flame rectification). Any of the following can prevent flame rectification:• Low gas pressure.• Plugged burner orifice.• Poorly connected or missing ground wire. • Corroded or dirty Flame Sense Rod.• Ignition Control not receiving flame sense signal.Or there is insufficient current when the gas valve is powered. Current loss can be caused by any of the following:• Excessive corrosion on wire terminals.• Frayed or over heated wires.• Pitting of contact points of the Water Pressure Switch or corrosion on connectors of the High Limits.To determine whether the problem is lack of rectification or loss of current, check voltage at the Black/Yellow (11) wire at the Ignition Control. Keep the meter probe at this location and watch the reading. If, after the gas valve receives power, the voltage slowly drops until the gas valve shuts off, then returns to normal, the problem is due to loss of current.

YES

YES

Check supply gas pressure (see chart below). Did burners ignite?

YES NO

Check manifold pressure (see chart below). If supply was correct but there is no pressure on manifold replace the Gas Valve. If pressure is high check for plugged or wrong orifices. If pressure exists but is low correct supply problem.

LRZE TROUBLESHOOTING

STEP 15 – Check Burners operationDo Burners stay on past 5 minutes?

YES NO

24 VAC between Brown (15) and Yellow (1) wires?

DISPLAY FAULT CAUSE

Display showsNO FLOW

FAULT-HIGH LIMIT

FAULT-FUSELINK/FIELD

FAULT-CHECK IGN CONTROL

1. Pump is not running.

2. Low pump pressure.

3. Pressure switch fault.

1. Water temperature in heaterexceeds the internal limit.

2. Limit switch fault.

1. Fusible link fault.

1. Air flow restricted at intake ordischarge.

2. Oscillating pump pressure.

3. Low gas supply pressure.

4. No flame at burners.

FAULT-SHORTED H20 SENSORORFAULT-OPEN WATER SENSOR

1. Faulty wiring or connection.

2. Faulty sensor.

5. Check Ignition Control LED.

REMEDY1. This is normal display when the pump is OFF. No service

required.2. Clean filter or clear blockage, check position of valves

in plumbing system.3. Adjust or replace pressure switch.

1. Verify function of high limit switches. Perform Temperature Rise Test (see chart below). Identify and correct cause of overheating.

2. Identify and correct loose connections or replace switches.

1. Identify and correct loose connections or replace Fusible Link.

1. Check for proper clearances around heater and for adequate room ventilation if enclosed. Inspect for blockage or restrictionat discharge of flue.

2. Clean filter or identify and repair cause of pump oscillation.

3. Identify and repair incorrect supply pipe size or pipe line blockage.

4. Identify and correct loose wiring connections, or problemwith Igniter. Flame Sensor, Gas Valve or Ignition Control.

5. If the LED is on continuously, replace the ignition control. If the LED is blinking, check for causes of the unrecognized flame.

1. Inspect Sensor wiring. Ensure Sensor is connected intoPower Interface Board (PIB).

2. Inspect Sensor wires. Replace Temperature Sensor.

Blue

Yellow

Heater is operating.

Fault Codes

Recheck gas pressure, burner orifices and air supply (see manual for more details).

Temperature Rise Chart

Go back to Step 13.

YES NO

Replace PIB.

Does flame look blue or yellow?

Gas PressureChart

Set gas valve knob to the Pilot position. Set thermostat

rocker switch to OFF. Set meter to VDC above one.

Does pilot light? 1. Verify gas is on. 2. Check for air in gas line. 3. Check for clogged pilot tube or orifice.

Does pilot stay on when gas valve knob is released?

1. Check P/G output. 2. Check for shorted wires. 3. Check pilot coil (yellow wires).

STEP 1 – Try to light pilot

STEP 2 – Check pilot operation

STEP 3 – Check pilot output

Is there 500+ mV between PP and PP-TH terminals?

1. Check for low Pilot Generator output. 2. Check for partial shorts or loose wires. 3. Replace Pilot Generator.

For the following tests leave the Red probe on the PP terminal.

Move the Black probe to each test position.

STEP 4 – Check Fusible Link

Is there 500+ mV through Fusible Link?

Replace Fusible Link. Check for Roll out, Soot, Down drafting,

Low Gas Pressure, etc.

STEP 6 – Check Fireman’s Switch

Is there 500+ mV through Fireman’s Switch?

STEP 7 – Check High Limits

Is there 500+ mV through at White wire of Pressure Switch?

Check that a control system (if installed) is calling for heat or Fireman’s Switch

loop is closed.

Check wire harness to High Limits for damage, if OK replace both High Limit. Check for damage to by pass disc,

headers, or exchanger.

Do a Temperature Rise Test.

Is there 500+ mV @ Black Wire of Pressure Switch?

Make certain filter pump is ON. Perform Back Pressure Test. If 2.5 PSI or more, replace switch. If less, check pump, filter, etc. for pressure problem.

Set rocker switch to ON. Set thermostat to maximum.

Is there 200+ mV @ Black wire of Temp. Board on terminal TH/PP?

Is there 200+ mV @ TH terminal of the Gas Valve?

500+ mV do the tests below .

Move rocker switch to OFF. Rotate Gas Valve Knob to ON. Move rocker switch to ON. Does heater fire?

Check #1 burner and orifice. Check gas pressure. If all OK replace Gas Valve.

NO

YES

NO

YES

NO

YES

NO

YES

NO

YES

NO

YES

STEP 8 – Check Pressure Switch

NO

YES

NO

YES

STEP 9 – Check Thermostat

YES

NO

NO STEP 10 – Check Gas Valve

Pressure Switch

Thermistor

Pilot Generator

Fusible Link 305 °F

Gas Valve

Fireman’s Switch Connection

AquaLink RS

TH

Hi-Limit 150º F

(red dot) Hi-Limit 130º F

Temperature Control

Thermostat

Jandy

MIN MAX

Rocker Switch

PP-TH PP

1

2

3

5

6 7 8

YES

9

Wires to control or fireman’s switch. Minimum wire size: 14 AWG, 105º C Maximum length: 10 to 15 feet.

Zero volts - Replace rocker switch.

LRZM TROUBLESHOOTING

SEN SEN POT POT

TH/PP +

(PP) Valve (TH)

Temperature Board

10

RED

WHITE

WHITE

WHITE

WHITE WHITE WHITE

BLACK

ORANGE

To dissipate excess current, the LED will flash approximately every 7 seconds when the heater is enabled but the thermostat setting has been satisfied. If the LED does not flash, try reversing the Generator leads at the Gas Valve.

Coil wires

Perform Thermistor Test (see back pg.)

Disconnect pot wires (orange) and jump pot terminals. If voltage drops to 200+ mV, replace Temp. Control.

Replace Temp. Board

After correcting problem return to Step 9 and proceed.

Vent Temp Limit 464 °F

Red Marking

STEP 5 – Check Vent Temp Limit

Is there 500+ mV through Vent Temp Limit?

Check for blockage in the vent. Replace Vent Temp Limit.

NO

YES

4

Total Millivolt (mV) Loss TestAfter the heater is completely operational and firing, do a Total Millivolt Loss Test by place one meter probe on PP-TH and the other probe on TH of the Gas Valve. The meter will now read the total millivolts lost in the entire circuit. Maximum allowable loss for the LRZM is 80 mV. If the loss is greater than 80 mV, test each wire and component by placing one probe at one end and the other probe at the other end of each item. Ideally all wires should have a zero reading and each component, except the Rocker Switch and Temperature Board should have no more than a 5 mV loss. The Rocker Switch can have up to 10 mV and the Temperature Board up to 50 mV. Any item which shows higher than allowable loss should be cleaned, repaired or replaced.

Temperature Rise Chart Thermistor (Water Temperature Sensor) Chart

50 (10)60 (15)70 (21)80 (26)90 (32)

100 (38)

WATER TEMP INHEADER ºF (ºC)

APPROX. RESISTANCE IN 1,000’SOF OHMS (kOhms)

19.915.311.9

9.37.35.8

Gas Pressure Chart

Supply Pressure

Natural Gas

LP Gas

Manifold PressureNatural GasLP Gas

Minimum5.5 Inches WC(1.4 kPa)

10.0 Inches WC(2.5 kPa)Nominal4.0 Inches WC (1.0 kPa)

9.0 Inches WC (2.2 kPa)

Maximum10.0 Inches WC(2.5 kPa)

14.0 Inches WC(3.5 kPa)

Symptom Cause Remedy

Pump not operating.

Pilot outage.

Flame roll-out at startup.

Spillage at draft hood.

Lazy flame with yellow tip.

Not enough heat

Heater pounding or knocking.

Heater condensing

Pressure relief valve opens.

Pilot is lit but main burners will not come on.

Heater short cycles

A. No powerB. Pump defectiveC. Incorrect wiring

A. Inlet gas pressure low

B. Inlet gas pressure too high causingan unstable blowing pilot.

C. Weak or defective thermocouple.D. Damaged pilot or thermocoupleE. Dirty pilotF. Plugged or undersized pilot orifice.

A. Check burner orifices for blockage (spider webs)

B. Blocked flueC. Pilot out of position (delayed ignition)D. Blocked heat exchanger.E. Fiber board out of place.F. Altered vent cap.G. Low gas pressure

A. Cold chimneyB. Vent pipe pitches down to chimneyC. Blocked chimney.D. Altered draft hood.E. Prefabricated chimney with incorrect cap.

A. Inadequate water flow through heater.

A. Low water temperature.

A. Restriction in water flow system at or downstream of heater

A. Gas valve not at “ON” position.B. Hi-Limit switches failed.C. Pressure switch failed or out of adjustment.D. Fusible Link failed.E. Gas valve failed.F. Broken wire in thermostat circuit or

defective thermostat.G. Heater wired incorrectly.

A. Low water flow through heater.B. Failed High-limit switch.

A. Check circuit breaker and power.B. Replace.C. Recheck wiring.

A. Consult gas utility company. Inlet gas pressure to heater should be 5.5” to 10.0” WC for Natural Gas or 10.0” to 14” for Propane Gas.

B. Pressure should be regulated within limits shown above.

C. Replace thermocouple.D. Replace.E. Blow dust or lint out of pilot.F. Clean or replace pilot orifice.

A. Remove and clean each orifice.

B. Remove blockage.C. Correct pilot position.D. Clean or correct as necessary.E. Clean or correct fiber board as necessary.F. Install factory provided vent cap.G. Check and correct gas pressure.

A. Allow heater to operate five (5) minutes to create draft action.B. Reinstall vent cap to pitch up from heater to chimney.C. Remove blockage.D. Install factory provided draft hood.E. Install UL listed vent cap.

A. Check for blocked louvers or openings to heater.

A. Gas meter too small. Gas line from meter to heater too small.B. Gas pressure on heater manifold should be adjusted to 4.0” WC Natural

Gas, 9.0” WC Propane.C. Replace with heater of higher input rating.D. Check and correct water flow.

A. Check Temperature Rise (see chart above). If temperature rise is above the maximum check for damaged or incorrectly set bypass.

A. Flue product moisture will condense at the start-up until the water temperature reaches normal operating conditions.

A. Check for proper operation of all valves, bypass valve and any equipment between pool and heater outlet.

A. Turn knob to “ON” position.B. Investigate reason for overheating and replace Hi-limit switches.C. Adjust pressure switch or replace as necessary.D. Investigate reason for flame rollout and replace Fusible link as necessary.E. Check and replace Gas Valve as necessary.F. Check continuity through thermostat circuit with wires disconnected.

G. Check heater wiring against wiring diagram.

A. Increase size of pump or increase piping size as necessary.B. Check Hi-limit switches and replace as necessary.

A. Low primary air.

A. Inadequate gas supplyB. Low manifold gas pressure.

C. Heater size inadequate.D. Low Temperature Rise.

LRZM TROUBLESHOOTING

5

STEP 2 – Check Transformer

24 VAC between Red (2) wire

and Yellow (1) wire on Transformer?

YES

NO

If wired 240 VAC check voltage

between Black (E)

wire and Blue (F) wire. If wired

120 VAC check voltage between

Black (E) and White (D) wires. If

the correct voltage is present,

replace Transformer, if not check

Conversion Board position.

STEP 1 – Check Power at Dist. Brd. (make certain filter pump motor is ON).

240 or 120 VAC between Black (C) wire

and Red (B) wire on Power Dist. Brd.?

YES

NOMake certain filter pump is on.

Correct wiring.

STEP 3 – Check Fuse

24 VAC between Red (3) wire on PIB


NOLocate and correct short circuit,

replace Fuse.

YES

STEP 4 – Check power to Water Press. Sw.

24 VAC between Purple (4) wire on PIB


NO Recheck voltage at Red (3)

wire, if voltage is 24 VAC

replace PIB.

STEP 5 – Check Water Pressure Switch

24 VAC between Gray (5) wire on PIB

and Yellow (1) wire on Transformer?NO

Do a Back Pressure Test, if

pressure is higher than 2 PSI,

replace Water Pressure Switch,

if less clean filter, baskets or

repair pressure problem.

YES

STEP 6 – Check power to Fusible Link

24 VAC between Orange (6) wire on PIB


NO Recheck voltage at Gray (5)

wire, if voltage is 24 VAC

replace PIB.

YES

STEP 7 – Check Fusible Link

24 VAC between Blue (7) wire on PIB


Check Fusible Link Air Box and ,

Vent Temp Limit individually.

Replace failed part.

Correct excessive heat problem

in vent or air box.

YES

STEP 8 – Check power to High Limits

24 VAC between Black (8) wire on PIB


Recheck power at Blue (7)

wire. If 24 VAC at Blue

but not Black, replace PIB.

STEP 9 – Check High Limits

24 VAC between Black (9) wire on PIB


NO Replace both High Limits.

Do a Temp. Rise Test.

YES

24 VAC between Black/Yellow (10)

wire on PIB and Yellow (1) wire on

Transformer?

NO

STEP 10 – Check power to Ignition Control

YES

Recheck power at Black (9)

wire. If 24 VAC at Black, but

not Black/Yellow (10),

replace PIB.

YES

24 VAC between Black/Yellow (11) at

W terminal of Ignition Control and

Yellow of Transformer?

NO

STEP 11 – Check power at Ignition Control

YES

Correct problem with

Black/Yellow wire or its

connectors.

YES

Note: If Blower is ON, go to Step 13 on back page.

Is Blower ON?NO

STEP 12 – Check Blower

YESCheck voltage between F2 terminal of Ignition

Control and ground (A). Is voltage 105 VAC or

higher?

STEP 13 – Go to back page

NO YES

Correct incoming

power problem.

Check voltage between F1 terminal

of Ignition Control and ground (A).

Is voltage 105 VAC or higher? If no,

replace Ignition Control, if yes

check voltage between Black(L)

wire to Blower on PDB and ground

(A). If voltage is 105 VAC or higher

replace Blower, if lower check

wires, replace PDB

YES

LXi Troubleshooting Guide — Serial Number G11LB0001 or newer

After Blower comes on wait at least 15 seconds (Pre-Purge).

Is Igniter glowing?

NO

STEP 15 – Check Hot Surface IgniterCheck voltage between K and J of the Ignition Control. If 105 to 130 VAC, check wires and

connectors to the Igniter, if OK, replace Igniter. If voltage is less than 105 VAC check

incoming voltage between L1 and L2, if voltage is 105 to 130 VAC replace Ignition Control.

After the HSI begins to glow, wait

approximately 40 seconds. Did the burners ignite?

NOSTEP 16 – Check for Ignition

YES

Check voltage on Brown (13) wire at terminal VAL of the Ignition Control. Is there 24 VAC at VAL?

NO

Replace Ignition

Control.

YES

Check supply gas pressure. If

OK, replace Gas Valve.

Do Burners stay on beyond 7

seconds?

NO

STEP 17 – Check Burners operation

YES

Heater is not recognizing the flame (flame rectification). Any of the following can prevent flame rectification:

• Low gas pressure.

• Poorly connected or missing ground wire.

• Corroded or dirty Flame Sense Rod.

• Ignition Control not sending flame sense signal.

Or there is insufficient current when the gas valve is powered. Current loss can be caused by any of the following:

• Excessive corrosion on wire terminals.

• Frayed or over heated wires.

• Pitting of contact points, usually at the Water Pressure Switch or High Limits.

To determine whether the problem is lack of rectification or loss of current, check voltage at the Black/Yellow (11)

wire at the Ignition Control. Keep the meter probe at this location and watch the reading. If, after the gas valve

receives power, the voltage slowly drops until the gas valve shuts off, then returns to normal, the problem is due to

loss of current.

YES

Heater is operating.

Blower is ON – See Note below.

24 VAC between Orange (NO) wire at the Air Pressure Switch


STEP 13 – Check Air Pressure Switch Make certain Blower is on and combustion chamber is sealed. Check air tubes for kinks

or holes. Make certain front air tube is connected to the positive (+) side and back/lower

air tube is connected to negative (-) side of the Air Pressure Switch. If all are OK replace

the Air Pressure Switch.

YES

24 VAC between Orange (12) wire at the Ignition Control and

Yellow (1) wire on Transformer?

NO

STEP 14 – Check Power to PSW

Check wire connections. Replace Orange wire.

YES

Note: If the blower runs continuously, unplug F1/F2 connector from the Ignition Control, if the blower goes off replace the Ignition

Control. If the blower stays on, check for shorted wires between the Ignition Control and PDB or from the PDB and the Blower.

Service Codes

TEMPERATURE RISE

MODEL 250

Serial # A & B

Serial # C & Newer

MODEL 300

Serial # A & B

Serial # C & Newer

MODEL 400

Serial # A & B

Serial # C & Newer

MIN. MAX.

7 °F 10 °F

8 °F 12 °F

MIN. MAX.

8 °F 11 °F

11 °F 18 °F

MIN. MAX.

13 °F 17 °F

14 °F 21 °F

GAS PRESSUREInches of Water Column

Manifold

Supply

Natural LP

2.5 9.0

5.5 to 10.5 11 to 14

LXi Troubleshooting Guide — Serial Number G11LB0001 or newer

1) Check incoming Power Supply.2) Check Transformer Wiring.3) Replace Transformer.

STEP 1

24 VAC atTransformer

YES

YES

NO

NO24 VAC at RedWire of Fuse

Link?

Fuse is blown. Look for short oroverload of controls. Do notjumper or bypass. Fuse protectstransformer.

24 VAC atWhite Wire of

Fuse Link?

STEP 2

STEP 3

24 VAC atboth Fireman

Switch terminal’s

YES

NO

STEP 3a

STEP 4YES

24 VAC atWhite Wire of

Pressure Switch?

STEP 5

YES

24 VAC atBlack Wire of

Pressure Switch?

NO

NO

NO

Too much heat in control area.Look for down drafting, Roll-out,Soot, or Low Gas Pressure.Replace Fuse Link.

Check that a control system (ifinstalled) is calling for heat orthe Fireman’s Switch is closed.

1) Check each limit individually.4a & 4b2) Check if damage to disc,heads, or exchanger.3) Take Temperature Rise.

Perform back pressure test.If 2 PSI or more, replaceswitch. If less, check pump,filter, etc., for water flowproblems.

YES

STEP 6

STEP 9

STEP 8

STEP 7

YES

NO

NO

Do a Thermistor Test.Is thermistor withinrange? See chart onback page.

24 VAC atBlack/Yellow wire

at the IND ofIgnition Control?

Is temperature Board calling for heat?YES

NO

YES

ReplaceThermistor

Replace Temp.Board.

24 VAC at the Blackwire at TH of theIgnition Control

YES

Replace Ignition Control.Check wire connectors.

NO24 VAC at VALof the IgnitionControl?

Remember, the VAL terminal will only havepower for 7 seconds after the Ignitor hasheated for 35 seconds. If there is never 24VAC at the VAL, even after the Ignitor hasheated and shut down, replace the IgnitionControl.

YES

Does heaterfire?

NOOK

Replace GasValve.

Verify Ignitor wiring.Are all gas valvesopen? Is gaspressure correct?

Remove the connector at F1 & F2of the Ignition Control. Perform acontinuity test between F1 & F2terminals on the Ignition Control.Is there continuity?

NOYES

Wait for 15second delay.

Does Ignitorheat up?

1. Is Ignition Control wired for proper voltage?2. Is Ignitor properly connected?3. Do Ignitor Test. Is Ignitor within range?

YES

Replace Ignition Control. Replace Ignitor.

NOYES

NO

IGN 240IGN 120L1

L2

IGN/FSTHINDVALGND

FENWAL DIGITALIGNITION CONTROL

6

F1F2

24 VACFC

Fireman’sSwitch

ConnectionFusible

Link

Hot Surface Ignitor

RedRed

Gas Valve

Thermistor

MVMV

AquaLink RS

Transformer 240 VAC240 VAC

WhiteWhite

WhiteWhite

PressureSwitch

BlackBlack

YellowYellow

BlackBlack

Temperature Control

BrownBrown

Flame Proving Rod

White/BlackWhite/Black

White/RedWhite/Red

Hi-Limit 150° F (red dot)

Hi-Limit 135° F

RedRed

Yellow

/Gree

n

Yellow

/Gree

n

1

23

3a

4b

4 5

8

Fuse

YellowYellow

YellowYellow

Yel

low

Yel

low

RedRed

7

WhiteWhite

WhiteWhite4a

TanTan

TanTan

Yellow/BlackYellow/Black

LITE 2 LD-DIRECT IGNITION TROUBLESHOOTING w/Digital Ignition Control

8

MODEL MAXIMUM

125175250325400

3642423839

125175250325400

2836383838

MINIMUM

Temperature Rise

2733332830

2224242830

Lite, Lite 2, Series 1 & Series 2with 2” header connections

Series 1 with 1½” header connections

Btus

Resistanceat 20 K

or aboveDCV

2000K

200K

20K2K

hFE

2

20

200

1000200

750

PNPNPN

OFF

200m

DCA

20m

200m

10A

200

ACV

200μ

2000μ

Temp Resistance Temp Resistance

50° F 19.898 K Ohms 78° F 9.735 K Ohms

51° F 19.435 K Ohms 79° F 9.483 K Ohms

52° F 18.871 K Ohms 80° F 9.284 K Ohms

53° F 18.382 K Ohms 81° F 9.079 K Ohms

54° F 17.902 K Ohms 82° F 8.864 K Ohms

55° F 17.473 K Ohms 83° F 8.655 K Ohms

56° F 16.988 K Ohms 84° F 8.450 K Ohms

57° F 16.549 K Ohms 85° F 8.253 K Ohms

58° F 16.150 K Ohms 86° F 8.057 K Ohms

59° F 15.710 K Ohms 87° F 7.871 K Ohms

60° F 15.314 K Ohms 88° F 7.687 K Ohms

61° F 14.923 K Ohms 89° F 7.509 K Ohms

62° F 14.547 K Ohms 90° F 7.335 K Ohms

63° F 14.193 K Ohms 91° F 7.166 K Ohms

64° F 13.823 K Ohms 92° F 7.001 K Ohms

65° F 13.477 K Ohms 93° F 6.840 K Ohms

66° F 13.138 K Ohms 94° F 6.685 K Ohms

67° F 12.813 K Ohms 95° F 6.531 K Ohms

68° F 12.492 K Ohms 96° F 6.384 K Ohms

69° F 12.186 K Ohms 97° F 6.238 K Ohms

70° F 11.893 K Ohms 98° F 6.099 K Ohms

71° F 11.593 K Ohms 99° F 5.963 K Ohms

72° F 11.309 K Ohms 100° F 5.829 K Ohms

73° F 11.032 K Ohms 101° F 5.700 K Ohms

74° F 10.765 K Ohms 102° F 5.572 K Ohms

75° F 10.502 K Ohms 103° F 5.449 K Ohms

76° F 10.250 K Ohms 104° F 5.327 K Ohms

77° F 10.000 K Ohms

Safety Circuit TestLeave black probe on Transformerterminal with yellow wire.Move red probe to each component

Hot Surface Ignitor TestIgnitor must be disconnected fromthe Ignition Control and cool to the touch.Resistance through the Hot Surface Ignitorshould be 40 to 75 Ohms.

Temperature Rise Test Chart

Thermistor TestRemove thermistor leads from temperature board. Set meter totest resistance above 20 K Ohms. Using chart at the right,compare the actual water temperature to the resistance readingto determine if the thermistor is OK.

Thermistor Test Chart

240 VACTransformer

Yellow Wire

Fusible Link

DCV

2000K

200K

20K2K

hFE

2

20

2001000

200750

PNPNPN

OFF

200m

DCA

20m

200m

10A

200

ACV

200μ

2000μ

ACV above 30 V

Test Hot Surface Ignitor at Ambient Temperature- range 40 to 75 Ohms-

DCV

2000K

200K

20K2K

hFE

2

20

2001000

200750

PNPNPN

OFF

200m

DCA

20m

200m

10A

200

ACV

200μ

2000μ

Set meter to test resistance.

9

LITE 2 LJ TROUBLESHOOTING

24 VAC at far end of fuse?

Too much heat in control area.Look for down drafting, Roll-out,Soot,or Low Gas Pressure.Replace Fusible Link.

STEP 8 - Check Gas Valve

Does Ignitor heat up?

Replace PowerControl Board.

ReplaceIgnitor.

1) Check incoming power. (A & B)2) Turn off incoming power. Checkpositioning of Conversion Block.3) Replace Transformer.

1) Check for short circuits.2) Replace fuse.

STEP 4 - Check Fusible Link

Check wires for lose connections.Replace Ignition board.

24 VAC on white wireat Fusible Link? (4b)

STEP 1 - Check Transformer - Set meter to ACV above 240

Does heater fire? Replace GasValve.

Make certain all gas valvesare open, the correct fuelis provided to the heater, gaspressure and volume arecorrect.

STEP 3 - Check Fireman’s Switch Circuit

For the next tests insert and leave the common probein with the blue(2) wire.

24 VAC at 3a? Power Control is not sending power.Replace Power Control Board.

24 VAC at 3b?Fireman’s switch circuit is open.Make sure the external control iscalling for heat.

24 VAC on red wireat Fusible Link? (4a)

YES

NO

YES

NO

YES

NO

NO

NO

YES

YES

NO

YES

NO

YES

STEP 5 - Check High Limits One or both of the limits are open.(5b & 5c)1)Check for damage to bypass disc, heads,or exchanger.2)Jandy recommends replacing both limits.3)Do Temperature Rise Test.

STEP 6 - Check Pressure Switch

24 VAC at white wireof Pressure Switch? (5a)

YES

NO

24 VAC at black wireof Pressure Switch? (6)

Perform Back Pressure Test. If 2.5 PSI ormore, replace Pressure Switch. If less,check pump, filter, etc., for water flowproblems.YES

NO

STEP 7 - Check Hot Surface IgnitorNO Turn power off, disconnect Ignitor at 7a

and 7b. Perform Ignitor Test.Is resistance between 25 and 300 Ohms?

YES

Remove each fuse (7c & 7d).Check each for continuity.If either is blown, check for shortedwires, then replace fuse.If neither fuse is blown replace theignition control.

NO

After 10 seconds of Ignitorheat up, is there 24 VAC atbrown wire to gas valve?

NO

YES

For Thermostat troubleshooting refer to the installation manual.

YES

NO OK

For Ignitor Test, remove common probe from blue(2) wire.

For Gas Valve test reinsert the common probe in with the blue(2) wire.

1) Check incoming power. (A & B)2) Turn off incoming power. Checkpositioning of Conversion Block.3) Replace Transformer.

24 VAC betweenBlue 1 & Blue 2 wires?

YES

STEP 2 - Check Fuse (insert common probe in with blue 1 wire,touch other probe to far end of fuse)

12 VAC betweenBlue 2 & White 3 wires?

HOT SURFACE IGNITOR

INLET TEMPSENSORPOWER

ONFLAME

GAS

SAFETY

PUMP

BLOWER

FIREMANSWITCH

2 AM

P N

OR

MAL

EXT POWER

FUSIBLE LINKFUSIBLE LINK

135135ºº FFHIGH LIMITHIGH LIMIT

150150ºº FFHIGH LIMITHIGH LIMIT(RED DOT)(RED DOT)

PRESSUREPRESSURESWITCHSWITCH

BLACKBLACK

REDREDWHITEWHITE

WHITEWHITE

WHITEWHITE

FLAME SENSORFLAME SENSOR

HOT SURFACE IGNITORHOT SURFACE IGNITOR

MVMV

GASVALVE

THERMISTORTHERMISTOR

BLACKBLACK

115 or 230 VAC

YELLOWYELLOW

BROWNBROWN

FIREMAN’SFIREMAN’SSWITCHSWITCH

MODE

POOL-OFF-SPA UP DOWN PUMP

NORMAL

84 °F

POOL

REDRED

REDRED

FUSE

FUSEWHITESWHITES

WHITESWHITES

2 AMP, 2 AMP, 11¼”¼” LONG LONG FUSEFUSE

REDRED

REDRED

GREENGREEN

GREENGREEN

1

2

4a

A B

3a

4b

5a

5b

5c 6 3b

7a

7b

7c

7d

8

2 AMP, 2 AMP, 3/4” long3/4” long

1

23

POWER CONTROL BOARDPOWER CONTROL BOARD

TRAN

SFO

RM

ER

VO

LTA

GES

BE

TWEE

N B

LUE

(1) &

BLU

E(2)

–24

VAC

BE

TWEE

N B

LUE

(!) &

WH

ITE(

3) –

12 V

AC

- - -

10

MODEL MAXIMUM

125175250325400

3642423839

125175250325400

2836383838

MINIMUM

Temperature Rise

2733332830

2224242830

Lite, Lite 2, Series 1 & Series 2with 2” header connections

Series 1 with 1½” header connections

Btus

DCV

2000K

200K

20K2K

hFE

2

20

2001000

200750

PNPNPN

OFF

200m

DCA

20m

200m

10A

200

ACV

200μ

2000μ

Set meter to test resistance.


50° F 19.898 K Ohms 78° F 9.735 K Ohms

51° F 19.435 K Ohms 79° F 9.483 K Ohms

52° F 18.871 K Ohms 80° F 9.284 K Ohms

53° F 18.382 K Ohms 81° F 9.079 K Ohms

54° F 17.902 K Ohms 82° F 8.864 K Ohms

55° F 17.473 K Ohms 83° F 8.655 K Ohms

56° F 16.988 K Ohms 84° F 8.450 K Ohms

57° F 16.549 K Ohms 85° F 8.253 K Ohms

58° F 16.150 K Ohms 86° F 8.057 K Ohms

59° F 15.710 K Ohms 87° F 7.871 K Ohms

60° F 15.314 K Ohms 88° F 7.687 K Ohms

61° F 14.923 K Ohms 89° F 7.509 K Ohms

62° F 14.547 K Ohms 90° F 7.335 K Ohms

63° F 14.193 K Ohms 91° F 7.166 K Ohms

64° F 13.823 K Ohms 92° F 7.001 K Ohms

65° F 13.477 K Ohms 93° F 6.840 K Ohms

66° F 13.138 K Ohms 94° F 6.685 K Ohms

67° F 12.813 K Ohms 95° F 6.531 K Ohms

68° F 12.492 K Ohms 96° F 6.384 K Ohms

69° F 12.186 K Ohms 97° F 6.238 K Ohms

70° F 11.893 K Ohms 98° F 6.099 K Ohms

71° F 11.593 K Ohms 99° F 5.963 K Ohms

72° F 11.309 K Ohms 100° F 5.829 K Ohms

73° F 11.032 K Ohms 101° F 5.700 K Ohms

74° F 10.765 K Ohms 102° F 5.572 K Ohms

75° F 10.502 K Ohms 103° F 5.449 K Ohms

76° F 10.250 K Ohms 104° F 5.327 K Ohms

77° F 10.000 K Ohms

Temperature Rise Test Chart

Thermistor TestRemove thermistor leads from ignition board. Set meter to testresistance above 20 K Ohms. Using chart at the right, comparethe actual water temperature to the resistance reading to determineif the thermistor is OK.


HEATER SERVICE CODESFL0: Open switch in safety circuit.FL1: Temperature Sensor is open or shorted.FL2: Failed Ignition.FL3: Flame detected when no flame should exist.FL4: Hot Surface Ignitor problem.FL5: Brown-out condition exist.FL6: Signal to energize gas valve is not beingsent by controller.FL7: Fireman switch circuit is open.

Hot Surface Ignitor TestIgnitor must be disconnected from the Ignition Controland should be cool to the touch.Depending on the temperature of the ignitor, the resis-tance between the two leads of a good ignitor will be 25to 300 Ohms, typically 60 to 80 Ohms.

Resistance at 20 K

or aboveDCV

2000K

200K

20K2K

hFE

2

20

200

1000

200

750

PNPNPN

OFF

200m

DCA

20m

200m

10A

200

ACV

200μ

2000μ

11

Try to light the pilot.Does pilot light?

Does pilot stay onwhen gas valve

knob is released?

500+ mV @ PPand PP-TH

terminals? (1)

1. Verify gas is on.2. Check for air in gas line.3. Is pilot tube clogged?

If voltage is found at one and notthe other, replace Fuse Link.Check for Roll out, Soot, Downdrafting, Low Gas Pressure, etc.

No

1. Check P/G output .2. Check for shorted wires.3. Check broken wires.

1. Check for low Pilot Generatoroutput.

2. Check for partial shortsor loose wires.

3. Replace Pilot Generator.

500+ mV @and both terminals

of Fuse Link?

500+ mV @both terminals ofFireman’s Switch

Check that a control system(if installed) is calling for heator Fireman’s Switch is closed.

500+ mV @Black Wire of

Pressure Switch?

Perform Back Pressure Test. If2 PSI or more, replace switch.If less, check pump, filter, etc.for pressure problem.

500+ mV @White wire ofPressure Switch?

1. Check each High Limit individually. (3a & b)2. Check if damage to disc, heads, exchanger.3. Take Temperature Rise. (Water Flow?)

Set gas valve knob to pilot position.Set thermostat toggle to OFF.

Set rocker switch to ON

Is there 200+ mV@ Black wire ofPressure Switch?

Yes

Is there 200+ mV@ TH terminal ofthe Gas Valve?

NoIs there 500+ mV@ TH/PP onTemp. Board?

Yes

Move rocker switch to OFF.Rotate Gas Valve Knob toON. Move rocker switchto ON. Does heater fire?

Is there 500+ mV@ Valve (TH) onTemp. Board?

No

Yes

Yes

Is there 500+ mV@ TH terminal ofGas Valve?

Yes

ReplaceGas Valve

No

Yes

Yes

Yes

Yes

Yes

Yes

No

NoCheck and/or replaceblack wire from Valve(TH) terminal of Temp.Board and TH terminalof Gas Valve.

No

Perform Thermistor Test.

Replace Temp. Board

Disconnect Pot wires and jump potterminals. If voltage drops to 200+ mV,replace Temp. Control (P/N R0058200).

Check rockerswitch

Yes

No

Yes

No

No

No

No

No

No

1

2

3

4

5

5

6a6b

6a

7

LITE (LG - MILLIVOLT) TROUBLESHOOTING

Pilot

PPPP--THTH

THTH

PPPP

PRESSUREPRESSURESWITCHSWITCH

THERMISTORTHERMISTOR

PilotPilot

PILOTPILOTGENERATORGENERATOR

FUSIBLEFUSIBLELINKLINK

HIGH LIMITHIGH LIMIT150° F (RED DOT)150° F (RED DOT)

GAS VALVEGAS VALVE

TEMPERATURE CONTROLTEMPERATURE CONTROL

OrangeOrangeBlackBlackFIREMAN’SFIREMAN’S

SWITCH SWITCH BLOCKBLOCK

WhiteWhiteWhiteWhite

WhiteWhite

WhiteWhite

Red to PPRed to PP

WhiteWhite

Black t

o TH

Black t

o TH

BlackBlack

Yellow to

PP

Yellow to

PPAquaLink RS

SENSENPOTPOT

TH/PP+

(PP)Valve(TH)

White to PPWhite to PP--THTH

Note: Ten feet (10’) maximum Note: Ten feet (10’) maximum distance from heater to control.distance from heater to control.

HIGH LIMITHIGH LIMIT135° F135° F

3a, b

4 5

6a

7

2

1

3

6b

12

Black fromPressure Switch

Black to Gas Valve (TH)

Yellow to Gas Valve (PP)(This is the common wire to

provide power to the T-Stat Board)

Thermistor10 K Ohms

Orange

SENSENPOTPOT

TH/PP+

(PP)Valve(TH)

Black

Temperature Control

T-Stat Board


50° F 19.898 K Ohms 78° F 9.735 K Ohms

51° F 19.435 K Ohms 79° F 9.483 K Ohms

52° F 18.871 K Ohms 80° F 9.284 K Ohms

53° F 18.382 K Ohms 81° F 9.079 K Ohms

54° F 17.902 K Ohms 82° F 8.864 K Ohms

55° F 17.473 K Ohms 83° F 8.655 K Ohms

56° F 16.988 K Ohms 84° F 8.450 K Ohms

57° F 16.549 K Ohms 85° F 8.253 K Ohms

58° F 16.150 K Ohms 86° F 8.057 K Ohms

59° F 15.710 K Ohms 87° F 7.871 K Ohms

60° F 15.314 K Ohms 88° F 7.687 K Ohms

61° F 14.923 K Ohms 89° F 7.509 K Ohms

62° F 14.547 K Ohms 90° F 7.335 K Ohms

63° F 14.193 K Ohms 91° F 7.166 K Ohms

64° F 13.823 K Ohms 92° F 7.001 K Ohms

65° F 13.477 K Ohms 93° F 6.840 K Ohms

66° F 13.138 K Ohms 94° F 6.685 K Ohms

67° F 12.813 K Ohms 95° F 6.531 K Ohms

68° F 12.492 K Ohms 96° F 6.384 K Ohms

69° F 12.186 K Ohms 97° F 6.238 K Ohms

70° F 11.893 K Ohms 98° F 6.099 K Ohms

71° F 11.593 K Ohms 99° F 5.963 K Ohms

72° F 11.309 K Ohms 100° F 5.829 K Ohms

73° F 11.032 K Ohms 101° F 5.700 K Ohms

74° F 10.765 K Ohms 102° F 5.572 K Ohms

75° F 10.502 K Ohms 103° F 5.449 K Ohms

76° F 10.250 K Ohms 104° F 5.327 K Ohms

77° F 10.000 K Ohms

Thermistor TestRemove thermistor leads from temperature board. Setmeter to test resistance above 20 K Ohms. Using chartbelow, compare the actual water temperature to theresistance reading.

No

Perform Thermistor Test, see below.

Replace Temp. Board

Disconnect Pot wires and jumppot terminals. If voltage drops to200+ mV, replace Temp. Control(P/N R0058200).

Is there 200+ mV @ Blackwire of Pressure Switch?

Yes

Is there 200+ mV @ THterminal of the Gas Valve?

No Is there 500+ mV @TH/PP on Temp. Board?

Check rocker switchNo

Yes

Move rocker switch to OFF.Rotate Gas Valve Knob toON. Move rocker switch toON. Does heater fire?

Is there 500+ mV @Valve (TH) on Temp. Board?

No

Yes

Yes

Is there 500+ mV @TH terminal of Gas Valve? No

Check and/or replace black wire fromValve (TH) terminal of Temp. Boardand TH terminal of Gas Valve.

Yes

Replace Gas Valve

No

Set Gas Valve Knob to PILOT position. Move heater rocker switchto ON. Set thermostat to maximum.

Temperature Control Testing

Total Millivolt Loss TestSet meter to 2 VDC. Place one probe on PP-TH and the otherprobe on TH. The meter will display the total millivolt loss throughthe safety loop.• Series One or older - 20 Millivolts loss or less.• Series 2 - 30 Millivolts loss or less.• Laars Lite LLG or LG - 80 Millivolts loss or less

Pilot

To Temperature Board

Fusible LinkWhite

PP-THTerminal

TH Terminal

Gas Valve

DCV

2000K200K

20K2K

hFE

2

20

2001000

200750

PNPNPN

OFF

200m

DCA

20m

200m10A

200

ACV

200μ

2000μ

2 VDC

13

LX OR LT TROUBLESHOOTING w/Digital Ignition Control

STEP 1 - Check Transformer24 VAC atred wire onTransformer?

NO

YES

For 24 VAC tests, common probe (black) can be left on yellow wire of transformer or any chassis ground.

12 VAC atwhite/yellow wireof Transformer?

Check incoming power. (115 / 230 VAC)Make certain correct conversion block is installed.Replace transformer.

Check incoming power. (115 / 230 VAC)Make certain correct conversion block isinstalled. Replace transformer.

NO

STEP 2 - Check Fuse24 VAC at red wire oftransformer terminal bar?

Check for short circuits in safetyloop. Replace fuse

YES

NO

STEP 3 - Check Safety LoopNote: If fan is on skip to Step 4 at top of page 2.

YES

24 VAC at first wire (black)of safety loop terminal bar?

Recheck transformer and fuseReplace thermostat.

YES

NO

24 VAC at second wire (white)of safety loop terminal bar?

24 VAC at white wire onPressure Switch?NO

YESNO

Water pressure related problem.Clean filter, baskets, etc..Do back pressure test.Replace Pressure Switch.

Is Fireman’ Switch Blockopen? Make certainexternal control systemis calling for heat.

YES

24 VAC at third wire (white)of safety loop terminal bar?

NO Thermostat is not calling forheat. Check thermistor,temperature setting. Replace thermostat.

24 VAC at fourth wire (white)of safety loop terminal bar?

NOHigh Limit Switch(es) openReplace both limits.Perform TemperatureRise Test.

YES

24 VAC at sixth wire(white) of safety loopterminal bar?

NO Fusible Link or Exhaust TempLimit open 24 VAC on both sidesof Fusible Link?

YES

24 VAC at fifth wire (white)of safety loop terminal bar?

NOYES

YESReset Exhaust TempLimit. Check for lockin flue and/or vent.

Replace Fusible Link.Check for down draft, soot,and/or low gas pressure.

NO

24 VAC at seventh wire (purple)of safety loop terminal bar?

YES

NO

YES

24 VAC at eighth wire (yellow/black)of safety loop terminal bar?

NO Air Pressure Switchopen. Is fan on?

NO YES

YES

24 VAC at yellow/blackwire of ignition controlterminal bar?

24 VAC atyellow/black wire ofAir Pressure Switch?

NO

ReplaceThermostat.

YES NO YES

24 VAC onyellow/blackat TH ofIgnition Control?

Check vacuumtube for kinksand or holes.Replace AirPressure Sw.NO

Check wireconnections

YES


YESNext Page

Check wire connections.Replace thermostat.


Is Fan on?NO

YES

Proceed tostep 5.

IGN/ 120 L1 L2

IND VAL GNDIGN/ 240 IGN/

FS

F2

F1

FC24V

FenwalIgnition Control

75

4a

TH

FanFan

Fireman’sSwitch

PressureSwitch

Hi Limit150° F

Hi Limit135° F

FuseLink

Exhaust LimitTemp Switch

Fan Pressure Switch

Hot Surface Igniter

Flame ProvingRod

Low Pressure Hi Lim Sw Ext Sw 1

Air Flo Sw

AGS

10 K Ohms Thermistor

Temp Sensor

MVMV

Low Pressure

C

Call for heat relay

YELLOW/BLACKYELLOW/BLACK


GREENGREEN

YELLOWYELLOW

GREENGREEN

BROWNBROWNPURPLEPURPLE

REDRED

GR

AY

GR

AY

REDRED

BLACKBLACK

WHITEWHITE WHITEWHITE

WHITEWHITE

YELLOWYELLOW

BROWNBROWN

PURPLEPURPLE

Burner

BLACKBLACK

TransformerTransformerFuse

GroundGround

12 VAC12 VAC

24 VAC24 VAC

Thermostat(LX = GUI or LT = T-Stat)

IGNITION CONTROLTERMINAL BAR

#1959

SAFETY LOOPTERMINAL BAR

#1961

TRANSFORMERTERMINAL BAR

#1958

GAS VALVETERMINAL BAR

#1960

1

2

3

4

7a

WH/YELWH/YEL

REDRED

Gas ValveB

LA

CK

BLA

CK

6 WHITEWHITE

TANTANTANTAN

6aNO

Power Distr.Block

14

MODEL

LX or LT28

40

24

36

MINIMUM

TEMP. DIFF.

250

400

MAXIMUM

Is Fan on?

YES

NO

Replace Ignition Control

Remove connector at F1 & F2 4a of IgnitionControl. Perform continuity test between F1 & F2terminals of Ignition Control.Is there continuity?

NO

NO

YES

Check Fan wiring.Replace Fan.

STEP 4 - Check Fan

Remove connector atF1 & F2 of Ignition Control.Does Fan go off?

YESNO

Turn heater to off, wait atleast 45 seconds for post-purge to finish. Performcontinuity test between F1 &F2 terminals of the IgnitionControl. Is there continuity?

Replace IgnitionControl

Perform these stepsif fan never goes off.

Turn power off to heater,check for shorted wires,especially grey and blackwires at F1 & F2.

YES

Plug connector atF1 & F2 back in.

24 VAC at purple wire of theIgnition Control Terminal bar

NO

YES


24 VAC at purple wire interminal TH of the Ignition? 5

NO

Check wire and connections.

Is Hot Surface Ignitor glowing? 6NO

Turn power off. Disconnect Ignitorat 6a. Perform resistance test. Isresistance between 40 and 75Ohms?

YES

NO YES

Reconnect ignitor wires.Carefully check wiring. Turnpower on. If ignitor does notglow after pre-purge, replaceIgnition Control.

If resistance test shows Ignitor isopen, replace the Ignitor.If resistance test shows the Ignitor isshorted, locate and correct short,before replacing Ignitor. Note if theIgnitor is shorted it might damage theIgnition Control.

YES

YES

After 35 seconds of ignitor heatup, is there 24 VAC at VALterminal of the Ignition Control? Replace Ignition Control.

NO

24 VAC at brown wire inIgnition Control Terminal bar?

YES

NO


24 VAC at brown wire in GasValve Terminal bar?

YES

NO

Replace Thermostat.

24 VAC at brown wire at Gas Valve? 7a Check wire and connections.NO

YES

STEP 6- Check Ignitor

STEP 5 - Start Ignition Sequence

STEP 7- Check Gas Valve

Does the heater fire?NO

Make certain all gas valves are open. The correct fuel is providedto the heater, gas pressure and volume are correct.

Replace the Gas ValveOK

SERVICE CODESLOW PRESSURE - Water pressure relatedproblem or blown fuse. Clean filter and allbaskets. Do a back pressure test.Check Fuse. If the fuse is blown, check forshort circuits in the control wiring.HI LIM SW. Low water flow problem. Highlimit(s) open.Replace limit(s), do a Temperature Rise Test.EXT. SW. 1 - Fusible Link or Exhaust Temp.Limit Switch open. Too much heat in thecabinet (Fusible Link) or flue (Exhaust Temp.Limit Switch).Fusible Link open; check for sooted heatexchanger, low gas pressure, down draftcondition and or water flow problem. Do aGas Pressure Test and Temperature Rise Test.Exhaust Temp Limit Switch check forblockage of vent.AIR FLOW SW - Insufficient vacuum toclose the air pressure switch. Make certain thefan is running. Check the air hose from the fanto the Air Pressure Switch for holes and kinks.If the fan never switches to high speed replacethe Ignition Control.AGS - Automatic Gas Shutdown simplymeans the Ignition Control did not senseflame rectification. Make certain all gas cocksare open, and there is sufficient gas pressureand volume (gas line sized properly). If theheater fires and then the flame goes outquickly, it indicates the rectification signal isnot returning to the Ignition Control. Checkfor poor or missing ground wire.Temp Sensor - Water temperature sensoropen or shorted. The sensor is a 10 K Ohmsthermistor. A sensor failure may indicate poorwater chemistry. Carefully test the water,concentrating on Total Alkalinity and pH.

TEMPERATURE RISE

15

LX OR LT low NOX TROUBLESHOOTING

STEP 1 - Check Transformer

24 VAC atred wire onTransformer?

NO

YES

For 24 VAC tests, common probe (black) can be left on yellow wire of transformer or any chassis ground.

12 VAC atwhite/yellow wireof Transformer?



NO

STEP 2 - Check Fuse24 VAC at red wire oftransformer terminal bar?

Check for short circuits insafety loop. Replace fuse

YES

NO

STEP 3 - Check Safety LoopNote: If fan is on skip to Step 4 at top of page 2.

YES

24 VAC at first wire (black)of safety loop terminal bar?

Recheck transformer and fuseReplace thermostat.

YES

NO

24 VAC at second wire (white)of safety loop terminal bar?

24 VAC at white wire onPressure Switch?

NO

YESNO

Water pressure related problem.Clean filter, baskets, etc..Do back pressure test.Replace Pressure Switch.

Fireman’ SwitchBlock open. Makecertain externalcontrol system iscalling for heat.

YES

24 VAC at third wire (white)of safety loop terminal bar?

NO Thermostat is not calling for heat.Check thermistor, temperaturesetting. Replace thermostat.

24 VAC at fourth wire (white)of safety loop terminal bar?

NO High Limit Switch(es) openReplace both limits. PerformTemperature Rise Test.

YES

24 VAC at sixth wire(white) of safety loopterminal bar?

NO Fusible Link or Exhaust Temp Limitopen24 VAC on both sides ofFusible Link?

YES

24 VAC at fifth wire (white)of safety loop terminal bar?

NO

YES

YES

Reset Exhaust TempLimit.Check for blockin flue and/or vent.

Replace Fusible Link.Check for down draft, soot,and/or low gas pressure.

NO

24 VAC at seventh wire (purple)of safety loop terminal bar?

YES

NO

YES

24 VAC at eighth wire (yellow/black)of safety loop terminal bar?

NO Air Pressure Switchopen. Is fan on?

NO YES

YES

24 VAC at yellow/black wire ofignition control terminal bar?

24 VAC atyellow/black wire ofAir Pressure Switch?NO

ReplaceThermostat.

YESNO YES

24 VAC onyellow/blackat TH ofIgnition Control?

Check vacuumtube for kinks andor holes.Replace AirPressure Switch.

NO

Check wire connections

YES


YES NextPage



Fireman’sSwitch

Water PressureSwitch

Hi Limit150° F

Hi Limit135° F

FusibleLink

Exhaust LimitTemp Switch

Air Pressure Switch

TransformerTransformer

Hot Surface Igniter

Flame ProvingRod

Fuse

Low Pressure Hi Lim Sw Ext Sw 1

Air Flo Sw

AGS

10 K Ohms Thermistor

Temp Sensor

MVMV

GroundGround

Low PressureThermostat

(LX = GUI or LT = T-Stat)

IGN

240

L1 TH VAL

GND

FS

F2F1

24 V

AC

C

NO

12 VAC12 VAC

24 VAC24 VAC

Call for heat relay

FCIG

N 12

0

PS

Burner

Gas Valve

FanFan

1Power Distr.Block

115/230Power

2

IGNITION CONTROLTERMINAL BAR

SAFETY LOOPTERMINAL BAR

TRANSFORMERTERMINAL BAR

3

4

6a

GAS VALVETERMINAL BAR

6

75

4a

7a

GREENGREENBROWNBROWN

PURPLEPURPLE

BLACK


REDRED

GREENGREEN

YELLOWYELLOWWH/YELWH/YEL

REDRED


BLACKBLACK

WHITEWHITE

WHITEWHITE

WHITEWHITE

YELLOWYELLOW

BROWNBROWN

BLACKBLACKWHITEWHITE

PURPLEPURPLE

GR

AY

GR

AY

BL

AC

KB

LA

CK

16

MODEL

LX or LT 2840

2436

MINIMUM

TEMP. DIFF.

250400

MAXIMUM

Is Fan on?

YES

NO

Replace Ignition Control

Remove connector at F1 & F2 4a of IgnitionControl. Perform continuity test between F1 & F2terminals of Ignition Control.Is there continuity?

NO

NO

YES

Check Fan wiring.Replace Fan.

STEP 4 - Check Fan

Remove connector atF1 & F2 of Ignition Control.Does Fan go off?

YESNO

Turn heater to off, wait atleast 45 seconds for post-purge to finish. Performcontinuity test between F1 &F2 terminals of the IgnitionControl. Is there continuity?

Replace IgnitionControl

Perform thesesteps if fannever goes off.

Turn power off to heater,check for shorted wires,especially grey and blackwires at F1 & F2.

YES

Plug connector atF1 & F2 back in.

24 VAC at purple wire of theIgnition Control Terminal bar

NO

YES


24 VAC at purple wire interminal PS of the Ignition? 5

NOCheck wire and connections.

Is Hot Surface Ignitor glowing? 6NO

Turn power off. DisconnectIgnitor at 6a. Perform resistancetest. Is resistance between 40and 75 Ohms?

YES

NO YES

Reconnect ignitor wires.Carefully check wiring.Turn power on. If ignitordoes not glow after pre-purge, replace IgnitionControl.

If resistance test shows Ignitor isopen, replace the Ignitor.If resistance test shows the Ignitor isshorted, locate and correct short,before replacing Ignitor. Note if theIgnitor is shorted it might damage theIgnition Control.

YES

YES

After 35 seconds of Ignitor heatup, is there 24 VAC at VALterminal of the Ignition Control? Replace Ignition Control.

NO

24 VAC at brown wire inIgnition Control Terminal bar?

YES

NO


24 VAC at brown wire in GasValve Terminal bar?

YES

NO

Replace Thermostat.

24 VAC at brown wire at Gas Valve? 7a Check wire and connections.NO

YES

STEP 6- Check Ignitor

STEP 5 - Start Ignition Sequence

STEP 7- Check Gas Valve

Does the heater fire?NO Make certain all gas valves are open. The correct fuel is provided

to the heater, gas pressure and volume are correct.Replace the Gas Valve

OK

SERVICE CODESLOW PRESSURE - Water pressure relatedproblem or blown fuse. Clean filter and all baskets.Do a back pressure test.Check Fuse. If the fuse is blown, check for shortcircuits in the control wiring.HI LIM SW. Low water flow problem. Highlimit(s) open.Replace limit(s), do a Temperature Rise Test.EXT. SW. 1 - Fusible Link or Exhaust Temp. LimitSwitch open. Too much heat in the cabinet (FusibleLink) or flue (Exhaust Temp. Limit Switch).Fusible Link open; check for sooted heat ex-changer, low gas pressure, down draft conditionand or water flow problem. Do a Gas Pressure Testand Temperature Rise Test.Exhaust Temp Limit Switch check for blockage ofvent.AIR FLOW SW - Insufficient vacuum to close theair pressure switch. Make certain the fan isrunning. Check the air hose from the fan to the AirPressure Switch for holes and kinks. If the fannever switches to high speed replace the IgnitionControl.AGS - Automatic Gas Shutdown simply means theIgnition Control did not sense flame rectification.Make certain all gas cocks are open, and there issufficient gas pressure and volume (gas line sizedproperly). If the heater fires and then the flamegoes out quickly, it indicates the rectification signalis not returning to the Ignition Control. Check forpoor or missing ground wire.Temp Sensor - Water temperature sensor open orshorted. The sensor is a 10 K Ohms thermistor. Asensor failure may indicate poor water chemistry.Carefully test the water, concentrating on TotalAlkalinity and pH.

Has fan speed slowed?NO

Replace Ignition Control.YES

TEMPERATURE RISE

17

STEP 124 VAC

at Transformer?

No 1. Check incoming power2. Check Transformer wiring.3. Replace Transformer.

STEP 2 24 VAC at Red wire of

terminal block?

No Fuse is blown. Look for short circuits. Do not jumper or bypass fuse. Replace fuse with same size & amperage.

Yes

STEP 3 24 VAC at

White wire of terminal block?

No Check Fireman’s switch. If a remote is installed make sureit is calling for heat.

Yes

STEP 4 24 VAC at

White wire of Pressure Switch?

No

Yes

1. Check each Limit individually.

2. Check if damage to disc, head, exchanger.3. Perform Temperature Rise Test.

4a & 4b

STEP 524 VAC at

Black wire of Pressure Switch?

No

Yes

Is Pump On? Perform Back Pressure test.If 2 PSI or more replace pressure switch.If less, check pump, filter, plumbing andheat exchanger for water flow restrictions.

STEP 624 VAC at

Black/Yellow wireof Ignition Control?

No

Yes

Is Temp Board calling for heat?

Do Thermistor Test.

Yes Good Replace Temp Board.

Replace Thermistor. Failed

STEP 7Is Fan On?

NoIs there 120 VAC at F2?

STEP 8

Yes No

Check supply wire.

Yes

Is there 120 VAC at F1?

Yes

No Yes

Make sure there is24 VAC at IND, if there is, replace Ignition Control.

Check wiring to Fan.If wiring is OK, replace Fan.

24 VAC at TH of Ignition Control?

No

Yes

1. Check for vent blockage or dirty air filter.2. Perform Air Flow Test.3. Replace Venturi Pressure Switch.

STEP 9

Is Ignitor glowingNo

Yes

Check Ignitor and supply wiring.Perform Ignitor Resistance Test.Replace Ignitor.

24 VAC at Brown wire

of Gas Valve?

Check Burner and Vent Limits.

10a & 10b

9

8

Yes

Does heater fire?Is Gas Valve On?Do a supply side gas pressure test.Replace Gas valve.

STEP 10

Yes

Yes, but goes out after a few seconds.Heater is not sensing rectification.Check commons, make surecombustion chamber is grounded.If all is OK replace Ignition Control.

No

No

Go to Step 7

HiE2 TROUBLESHOOTING w/ Digital Ignition Control

WhiteWhite

RedRed

RedRed

BlackBlack

WhiteWhite

GAS VALVE

BURNER LIMIT

VENT LIMIT

FAN OR COMBUSTION BLOWER

YellowYellow

WhiteWhite

TEMPERATURE CONTROL

HIGH LIMIT150° F

HIGH LIMIT135° F

PRESSURE SWITCH

120 VACONLY

THERMISTOR

Whi

teW

hite

Bla

ckB

lack

Whi

teW

hite

RedRed

Black/YellowBlack/Yellow

VENTURI or DIFFERENTIAL PRESSURE SWITCH

HOT SURFACE IGNITOR

FIREMAN’SSWITCH

CONNECTION

BrownBrown

BlackBlack

PurplePurple

WhiteWhite

BrownBrown

1

TRANSFORMER

23

4a

4b

4 5

6b

6

10

10a10b

6a

9

BURNER

FUSE

Black/YellowBlack/Yellow

IGN 240

L1L2IGN/FSTHIND

GND

F1F2

FC24V

FENWAL DIGITALIGNITION CONTROL

7

8

IGN 120

VAL

Bla

ckB

lack

Gra

yG

ray

18

MODEL

EHE(HI E2) 2920

MINIMUM

TEMP. DIFF.

350

MAXIMUM


50° F 19.898 K Ohms 78° F 9.735 K Ohms

51° F 19.435 K Ohms 79° F 9.483 K Ohms

52° F 18.871 K Ohms 80° F 9.284 K Ohms

53° F 18.382 K Ohms 81° F 9.079 K Ohms

54° F 17.902 K Ohms 82° F 8.864 K Ohms

55° F 17.473 K Ohms 83° F 8.655 K Ohms

56° F 16.988 K Ohms 84° F 8.450 K Ohms

57° F 16.549 K Ohms 85° F 8.253 K Ohms

58° F 16.150 K Ohms 86° F 8.057 K Ohms

59° F 15.710 K Ohms 87° F 7.871 K Ohms

60° F 15.314 K Ohms 88° F 7.687 K Ohms

61° F 14.923 K Ohms 89° F 7.509 K Ohms

62° F 14.547 K Ohms 90° F 7.335 K Ohms

63° F 14.193 K Ohms 91° F 7.166 K Ohms

64° F 13.823 K Ohms 92° F 7.001 K Ohms

65° F 13.477 K Ohms 93° F 6.840 K Ohms

66° F 13.138 K Ohms 94° F 6.685 K Ohms

67° F 12.813 K Ohms 95° F 6.531 K Ohms

68° F 12.492 K Ohms 96° F 6.384 K Ohms

69° F 12.186 K Ohms 97° F 6.238 K Ohms

70° F 11.893 K Ohms 98° F 6.099 K Ohms

71° F 11.593 K Ohms 99° F 5.963 K Ohms

72° F 11.309 K Ohms 100° F 5.829 K Ohms

73° F 11.032 K Ohms 101° F 5.700 K Ohms

74° F 10.765 K Ohms 102° F 5.572 K Ohms

75° F 10.502 K Ohms 103° F 5.449 K Ohms

76° F 10.250 K Ohms 104° F 5.327 K Ohms

77° F 10.000 K Ohms

Safety Circuit TestLeave black probe on Transformerterminal with yellow wire.Move red probe to each component

Hot Surface Ignitor TestIgnitor must be disconnected fromthe Ignition Control and cool to the touch.Resistance through the Hot Surface Ignitorshould be 40 to 75 Ohms.

Thermistor TestRemove thermistor leads from temperature board. Set meter totest resistance above 20 K Ohms. Using chart at the right,compare the actual water temperature to the resistance readingto determine if the thermistor is OK.


DCV

2000K

200K

20K2K

hFE

2

20

2001000

200750

PNPNPN

OFF

200m

DCA

20m

200m

10A

200

ACV

200µ

2000µ

Test Hot Surface Ignitor at Ambient Temperature- range 40 to 75 Ohms-

120 VACTransformer

Yellow Wire

Fireman’s Switch block

ACV above 30 V

DCV

2000K

200K

20K2K

hFE

2

20

200

1000200

750

PNPNPN

OFF

200m

DCA

20m

200m

10A

200

ACV

200µ

2000µ

DCV

2000K

200K

20K2K

hFE

2

20

200

1000200

750

PNPNPN

OFF

200m

DCA

20m

200m

10A

200

ACV

200µ

2000µ

Temperature Rise Test

19

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ThermostatR0318800

Gas ValveNatural - R0096400Propane - R0096900

On/Off SwitchE0146600

GeneratorW0036901

Rear Header RedundantHigh Limit(275� F)R0012800

Fusible LinkR0012200

Fireman’s Switch BlockR0097800

High Limit(135� F) R0023000

High Limit(150� F) R0022700

White

Red

321

TP (2)

TH/TP (1)

TH (3)O

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PIL

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PilotGenerator

FusibleLink

Hi-Limit135° F Hi-Limit

(150° F)

Gas Valve

Temperature Control

Orange

Red

SENSENPOTPOT

TH/PP+

(PP)Valve(TH)

Red

Red

White

Black

TP/TH

TH

TP 1

2

Black

Black

3a3b

4a

5aBlack

to TH

Yellow to

TP

White to TP/TH

Red to TP

Laars

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Yellow to Gas Valve (PP)

Thermistor10 K Ohms

Orange

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Laars

Temperature Control

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D C

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ThermostatE971

115 VACNeutral

ON-OFF SwitchE782

E786

Twist Lock PlugE784

Hi LimitE771

E

F

Pressure Switch

104089-02

G

White

Black

Black

Black

Orange

Yellow Yellow

Primary ControlN060

TransformerN023

White Oil Pump

B A

Hi LimitE722

Black

White

Black

MotorN010

Ground

Current Flow

Wire Nut

Neu

tral

Cadmium CellN061

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Check voltage at ACheck voltage at A No

Yes

Check voltage at BCheck voltage at B

Check circuit breakerCheck circuit breaker

No Bad ON/OFF Switch (E782)Bad ON/OFF Switch (E782)

Yes

Check voltage at CCheck voltage at C•Loose Twist Lock Plug•Short in Wire Harness (R575)•Bad Twist Lock Plug

•Loose Twist Lock Plug•Short in Wire Harness (R575)•Bad Twist Lock Plug

No

Yes

Check voltage at DCheck voltage at D No Bad Hi Limit (E771)Bad Hi Limit (E771)

No

Yes

Check voltage at ECheck voltage at E•Loose Twist Lock Plug•Short in Wire Harness (R575)•Bad Twist Lock Plug

•Loose Twist Lock Plug•Short in Wire Harness (R575)•Bad Twist Lock Plug

Check voltage at FCheck voltage at F

Yes

No•Water flow problem •Bad Pressure Switch •Misadjusted Pressure Switch•Blocked Siphon Loop Connection

•Water flow problem •Bad Pressure Switch •Misadjusted Pressure Switch•Blocked Siphon Loop Connection

Check voltage at GCheck voltage at G

Yes

No Bad wire in Armored Cable (BX)Bad wire in Armored Cable (BX)

Heater Doesn’t FireHeater Doesn’t Fire

Yes

Press RESET button on Primary Control Once 1) If unit fire and stays on, unit lost prime to Oil Pump2) If unit fires and goes out, or doesn’tstay lit, or goes into RESET after 45 seconds …. this is a Oil Burner or combustion problem CALL QUALIFIED OIL SERVICE

Press RESET button on Primary Control Once 1) If unit fire and stays on, unit lost prime to Oil Pump2) If unit fires and goes out, or doesn’tstay lit, or goes into RESET after 45 seconds …. this is a Oil Burner or combustion problem CALL QUALIFIED OIL SERVICE

If you press RESET on Primary Control, and RESET button on Oil Burner Motor, and nothing happens

1) Turn off power to heater, then temporarily place a jumper from T to T on the Primary Control and turn power on. If unit fires, either the Thermostat (E971) or the High Limit (E722), or the Fireman’s Switch has a problem.2) If unit doesn’t fire, remove one of the yellow wires from either terminalmarked F on the Primary Control. If unit fires now, either:

Bad Cadmium Cell (N061)Bad Primary Control, orthere is a fire in the combustion chamber…. CALLOIL SERVICE

If you press RESET on Primary Control, and RESET button on Oil Burner Motor, and nothing happens

1) Turn off power to heater, then temporarily place a jumper from T to T on the Primary Control and turn power on. If unit fires, either the Thermostat (E971) or the High Limit (E722), or the Fireman’s Switch has a problem.2) If unit doesn’t fire, remove one of the yellow wires from either terminalmarked F on the Primary Control. If unit fires now, either:

Bad Cadmium Cell (N061)Bad Primary Control, orthere is a fire in the combustion chamber…. CALLOIL SERVICE

Caution; Possible Electrocution: This circuit is high voltage, take extremely care when checking.

�� 24

Documents

Heater Troubleshooting Guides - F.W. Webb Company · A. Low water flow through heater. heater should be 5.5” to 10.0” WC for Natural Gas or B. Gas pressure on heater manifold