HTP EFT Combi Floor User manual

Service Manual

EFTC-140F Hot Water Combination Boiler

Advanced Heating

& Hot Water Systems

120 Braley Road, East Freetown, MA 02717 • 1-800-323-9651 • www.htproducts.com

LP-528 REV. 8.01.14

EFTC-140F Hot water combination boiler

Service Manual

EFTC-140F

(Hot Water Combination Boiler)

•NaturalGas

(

NG

)

– Factory Default

•LiquidPropaneGas

(

LP

)

–Field-Convertible

(Refertothegasconversionmanual.)

Model

WARNING

–Donotstoreorusegasolineorotherammablevaporsandliquidsinthevicinityofthisoranyotherappliance.

–WHATTODOIFYOUSMELLGAS

 ·Donottrytolightanyappliance.

 ·Donottouchanyelectricalswitch;donotuseanyphoneinyourbuilding.

 ·Immediatelycallyourgassupplierfromaneighbor’sphone.Followthegassupplier’sinstructions.

 ·Ifyoucannotreachyourgassupplier,calltheredepartment.

–Installationandservicemustbeperformedbyaqualiedinstaller,serviceagencyorthegassupplier.

Iftheinformationintheseinstructionsisnotfollowedexactly,areorexplosionmayresult,

causingpropertydamage,personalinjury,ordeath.

Heat Exchanger bears the ASME “H” Stamp

LP-528 REV. 8.01.14

1

LP-528 REV. 8.01.14

2

Chapter1ProductCharacteristics

Specications 6

Dimensions 7

ComponentsDescription 8

Flow chart 9

Time chart 10

Operationowchart 11

Wiringdiagram 13

Connector function 15

Chapter2Componentsdescription

MainControlBoard 17

Temperaturesensors 18

Burner Overheat Switch 19

Waterleveldetectionsensor 20

Detectionsensor 21

Jumpedwireconnection 22

AirPressureswitch 23

CondensateBlockageAPS 24

Flowsensor 25

Ignitiontransformer 26

FlameDetectionSensor 27

Gasvalve 28

BLDCFan 29

Burnerassembly 30

FireTubeHeatexchanger 31

Condensatetrap 32

InternalDHWstoragetank 33

InternalCH/DHWcirculationpumps 34

DHWMixingValve 35

Chapter3Howtousecontrolpanel

Functionexplanation 36

Contolpanel 37

LCDSpecication 38

ControlPanelMode 38

DHWTemperatureControl 41

CHSupplywatertemperaturecontrol 42

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Outdoortemperaturedisplay 42

Waterowrate(GPMorLPM) 43

CHReturnwatertemperature 43

FanSpeed(RPM) 44

ProgramLockmode 44

CHSupplywatertemperature 45

DHWOutletWaterTemperature 45

ExhaustGasTemperature 46

Internalstoragetankwatertemperature 46

Overheattemperaturesensor 47

Viewsupplypowertime 47

ViewBurnerOperatingTime(Unit:1hr) 48

ViewBurnerOperatingTime(X1000hr) 48

ViewIgnitioncycles(X10times) 49

ViewIgnitioncycles(X10,000times) 49

PumpConditionDisplay 50

FaultCodeHistory 51

ClearErrorCodeHistory 51

SystemReset 52

ChangeDHWFlowRateMeasurementUnit 52

InternalStoragetankPreheatingMode 53

Changemaximumoutdoortemperature 53

Changeminimumoutdoortemperature 54

Fan,MaxRPMAdjustment 54

Fan,MinRPMAdjustment 55

ResetBurnerOperatingTime 55

DeleteIgnitingCycles 56

BoostFunction 56

CH anti-cycling time 57

BurnerONtemperature 57

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Warmweathershutdown 58

MaximumCHsupplytemperature 58

MinimumCHsupplytemperature 59

MaximumDHWSetTemperature 59

CHCapacity 60

DHWHeatingCapacity 60

InternalCHprimarypumppostruntime 61

InternalCHpumpoverruntimer(ON) 61

InternalCHpumpoverruntimer(OFF) 62

InternalDHWStorageTankSetPoint 62

InternalDHWStorageTankDierential 63

DelayTime(fromDHWtoCHMode) 63

InternalCHPumpPostPurgeTimer 64

InternalCH&DHWPumpsTestMode 64

Chapter4Troubleshooting

Flame Detection 65

GasDetection 66

APS/BurnerOverheatSwitch 66

StorageDHW/ExhaustOverheat 67

Errorcode 68

ErrorCode10 71

ErrorCode11 72

ErrorCode16 73

ErrorCode20 74

ErrorCode28 75

ErrorCode29 76

ErrorCode30 77

ErrorCode32 78

ErrorCode33 79

ErrorCode35 80

LP-528 REV. 8.01.14

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ErrorCode36 81

ErrorCode37 82

ErrorCode38 83

ErrorCode40 84

ErrorCode41 85

ErrorCode42 86

ErrorCode43 87

ErrorCode61 88

ErrorCode66 89

ErrorCode68 90

ErrorCode72 91

ErrorCode76 92

ErrorCode80 93

ErrorCode81 94

ErrorCode85 96

ErrorCode94 96

Chapter5 Replacementinstructions

BlowAssembly 97

GasValve 98

FlowSensor 99

ElectronicMixingValve 99

APS(AirPressureSwitch) 100

InterPrimaryCHCirculationPump 100

InternalDHWStorageTank 101

FlameDetectionSensor 101

Main Controller 102

IgnitionTransformer 103

Chapter6 Componentsdiagram

RepairPartsDiagram 104

Memo

108

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ModelName EFTC-140F

GasInputRate

MAX

140,000Btu/h

MIN

28,000Btu/h

AFUE

93.2%

HotWaterCapacity

35°FRise

7.1Gal

45°FRise

5.5Gal

77°FRise

3.2Gal

Installation

Indoor/Floorstandtype

FlueSystem

SealedCombustionDirectVent

VentRun

2″(50ft),3″(100ft)Schedule40PVC,CPVC,PP,SS

OriceSize

NG(Orice/Needle)

0.232″(5.9mm)

LP(Orice/Needle)

0.185″(4.7mm)

GasSupplyPressure

NG

3.5″WCto14″WC

LP

3.5″WCto14″WC

ManifoldPressure

LowFire 2″/3"VENT

NG:-0.0039″WC/-0.002″WC

High Fire 2"/3″VENT

NG:-0.374″WC/-0.216″WC

PowerSupply

MainSupply

120V60Hz/6A

Maximum

PowerConsumption

160W

IgnitionSystem

DirectElectronicIgnition/AutomaticFlameSensing

BurnerSystem

SingleOricePremixedFuelModulationMetalFiberInfrared

GasValveSystem

Air ratio valve

Minimum Flow Rate

0.5GPM

InternalPipeMaterial

Copper

Dimensions

W15.7″-H53.0″–D26.8″

ShippingWeight

250lbs.

InternalStorageTankWaterCapacity

11Gallon

BoilerHeatExchangerCapacity

4Gallons

TotalWaterCapacity

15Gallons

MainController/ControlPanel

GTX-920C/P-920C_CB-HTP

CHPressure

Min15~Max30PSI

DHWPressure

Max150PSI

ConnectionSizes

DHWInlet/

Hot Water Outlet

3/4″NPT

CHSupply/Return

1″NPT

GasInlet

1/2″NPT(1/2x3/4BellCouplingProvidedtoUpsizeGasLine)

Materials

Cabinet

ColdRolledCarbonSteel

HeatExchanger

PrimaryHeatExchanger:StainlessSteel

SubHeatExchanger:StainlessSteel

SafetyDevices

FlameRod,OverheatCutODevice,GasValveOperationDetector,

ExhaustTemperatureHighLimitSensor,WaterTemperatureHighLimit

Sensor

Chapter1ProductCharacteristics

■

Specication

LP-528 REV. 8.01.14

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Description Diameter

A GasConnectionAdapter

1/2″NPT(1/2x3/4BellCouplingProvidedtoUpsizeGasLine)

B ‘CHsupply’Adapter 1″

C ‘CHreturn’Adapter 1″

D ‘DHWoutlet’Adapter 3/4″

E ‘DHWinlet’Adapter 3/4″

F CondensateAdapter 1/2″

G DrainAdapter 1/2″

H

ExhaustVentConnection

3″

I IntakePipeConnection 3″

■Dimensions

Chapter1ProductCharacteristics

LP-528 REV. 8.01.14

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NO NameofComponent

1

ExhaustOutletCollar

2

MainPCBBracket

3

BLDCFAN

4

AutomaticAirVent

5

FlameDetectionSensor

6

MainPCB

7

ExhaustGasPipe

8

Manual Switch

9

PowerPort

10

CHCirculationPump

11

AirPressureSensor

12

Tilt Switch

13

SubHeatExchangerAssembly

14

InternalCirculationPump

15

WaterDischargePipe&Connector

16

CondensateOutletConnector

17

CondensateCollector

18

DHWInletConnector

NO NameofComponent

19

WaterMixingvalve

20

WaterFillValve

21

DHW Outlet Connector

22

CH Return Connector

23

CHSupplyConnector

24

MainHeatingExchangerAssembly

25

ConrmationWindowFlame

26

GasInletConnector

27

IgnitionTrans

28

Igniter

29

GasValve

30

AirPressureSensor

31

AirIntakePipe

32

AirIntakeCollar

■ComponentsDescription

K1-14CCB K1-19CCB

Chapter1ProductCharacteristics

LP-528 REV. 8.01.14

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[ Domestic Hot Water Mode ]

[ Space Heating Mode ]

■Flowchart

Chapter1ProductCharacteristics

LP-528 REV. 8.01.14

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FAN

3s1.5s3s

120s(1st:60s+2nd60s)

3s1.5s3s 1.0s10s1.0s3s

■Ifnormalignition

■Ifameextinguishes

■Ifabnormalignition(Alarmafterthe10trial)

IGNITION

GASVALVE

FLAMEDETECTION

Chapter1ProductCharacteristics

■Timechart

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■Operationowchart

Chapter1ProductCharacteristics

LP-528 REV. 8.01.14

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■Operationowchart

Chapter1ProductCharacteristics

LP-528 REV. 8.01.14

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■WiringDiagram

Chapter1ProductCharacteristics

LP-528 REV. 8.01.14

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■WiringDiagram

Chapter1ProductCharacteristics

Mixing Valve

LP-528 REV. 8.01.14

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Connector

Descriptions

HT

SELV

no.oflocationand

type

Pinnr. BoardSilk

CN9

65001WS-12

1 - GROUND -

2 L PowerSupplyLine HT(120VAC)

3 CP1 Pump1:DHWPump HT(120V~)

4 IT Ignitor HT(120V~)

5 L(HT) Pump2:CentralHeatingPump HT(120V~)

6 GV GasValve HT(120V~)

7

-

- -

8 N PowerSupplyNeutral HT(120V~)

9-12

ACPowerCOMLine HT(120V~)

CN1

SMW250-05

1

RS-485

RS485+ SELV(5VDC)

2 RS485 - SELV(5VDC)

3 GND -

4 RS485+ SELV(5VDC)

5 RS485 - SELV(5VDC)

CN4

LWD1140-06

1

FAN

Unuse -

2 GND SELV(26VDC)

3 VDD SELV(14VDC)

4 Fanpower(startcoil) SELV(26VDC)

5 Fanpower(endcoil) SELV(26VDC)

6 Fanspeedfeedbacksignal SELV(14VDC)

CN8

SMW250-04

1

MCUISP

GND SELV(5VDC)

2 ISP/Resetport SELV(5VDC)

3 ISPTOOL0Dataport SELV(5VDC)

4 VCC SELV(5VDC)

CN11

LWD1140-16

1

HWL Unuse SELV(12V~)

8

2

LWL LowWaterLevelLeakageSensor SELV(12V~)

10

3

HD CentralHeatingDemand SELV(5V)

11

4

TH

ConnecttotheDisplay

Control(Thermostat)

SELV(14V)

12

5

APS AirPressureSwitch SELV(14V)

13

6

- NotUsed -

14

7

BL BurnerLimit SELV(14V)

15

8

HL CondensateBlock SELV(14V)

16

■Connectorfunction

Chapter1ProductCharacteristics

LP-528 REV. 8.01.14

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Connector

Description

HT

SELV

no.oflocationand

type

Pin

nr.

Board

Silk

CN7

LWD1140-14

1

F.S FlameDetectSensor SELV(5VDC)

8

2

OP.S Operationwatertemperaturesensor SELV(5VDC)

9

3

DH.S DHWtemperaturesensor SELV(5VDC)

10

4

I.S

Returenwatertemperaturesensor SELV(5VDC)

11

5

BG.S Exhausttemperaturesensor SELV(5VDC)

12

6

ST.S Storagewatertemperaturesensor SELV(5VDC)

13

7

SP.S CHOverheattemperaturesensor SELV(5VDC)

14

CN14

SMW250-09

1

IWM

GND SELV(14VDC)

2 IWMSteppermotorposition SELV(14VDC)

3 VDD SELV(14VDC)

4 IWMSteppermotorcoilXphase SELV(14VDC)

5 IWMSteppermotorcoilYphase SELV(14VDC)

6 VDD SELV(14VDC)

7 IWMSteppermotorcoil/Xphase SELV(14VDC)

8 IWMpowerIWMSteppermotorcoil/Yphase SELV(14VDC)

9 NotUsed -

CN3

SMW250-06

1

WPS

NotUsed SELV(5VDC)

2 NotUsed SELV(5VDC)

3 NotUsed SELV(5VDC)

4

FLUX1

VCC SELV(5VDC)

5 WaterFlowSensor SELV(5VDC)

6 GND SELV(5VDC)

CN5

SMW250-10

1

RPM

FANRPMCheck SELV(5VDC)

2 GND SELV(5VDC)

■Connectorfunction

Chapter1ProductCharacteristics

LP-528 REV. 8.01.14

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Description/Part# MainControlBoard/7855P-008 CheckPoint N/A

Function Thispartcontrolsallcomponentscontainedinthecombinationboiler.

Failure Event Abnormalmaincontrolleroperation.

Eects

Whenthemaincontrollerhasabnormalcondition,componentsmaynotoperate

properly.

ErrorCode Er38,Er70

Diagonostic Checkeachconnectionand/orwiresdamageonthePCB.

Color/WireNumber N/A

Chapter2Componentsdescription

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Description/Part#

CH Supply Temperature Sensor: 7855P-031

Storage Temperature Sensor:

7855P-057

DHW Temperature Sensor:

7855P-094

Exhaust Temperature Sensor:

7855P-092

Check Point CN7

Function

The controller compares each sensor with setting temperature then goes to

safety shut down when measured temperature is over the setting temperature.

Failure Event

Sensor malfunction or overheating condition detected.

Eects

Improper temperature measurement.

ErrorCode

Er 16, Er 28, Er 30, Er 32, Er 33, Er 35

Diagonostic

①

Visibly check for breakage of wires and/or each connections

②

Check each sensor’s resistance range with a multi-meter.

Color/WireNumber

①

CH Water High Limit Sensor (black/purple): Connector

⑭

,

⑦

②

Storage Temperature Sensor (black/orange): Connector

⑬

,

⑥

③

Exhaust Temperature Sensor (black/white): Connector

⑫

,

⑤

④

DHW Temperature Sensor (black/yellow): Connector

⑩

,

③

⑤

CH Supply Temperature Sensor (black/white): Connector

⑨

,

②

NO Item Standard

1

Temperature –

Resistance Type

Idling Condition

Temperature(

℃

) Resistance(k

Ω

)

0 ± 0.1

℃

-10.99

25 ± 0.1

℃

-3.906

85 ± 0.1

℃

0.552 ± 3%

( )Blank is for reference measurement

2 Fixed Number (25/85) 3482.4K ± 2%

3

Fixed Number of Heat

Dissipation

2.5mW/

℃

(Min.) (While not boiling)

4 Fixed Number of Heating

8(15)Sec (Max)(63.2% reaching time

while boiling)

5

Range of Workable

Temperature

- 4 ~ 230 º

F

①②③④ ⑤⑥⑦

⑧⑨⑩⑪⑫⑬⑭

CHWaterHighLimitTemperatureSensor

ExhaustTemperatureSensor

StorageTemperatureSensor

DHWTemperatureSensor

CHSupplyTemperatureSensor

CN7

Chapter2Componentsdescription

LP-528 REV. 8.01.14

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