Heater Troubleshooting Guides - F.W. Webb Company

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Heater Troubleshooting GuidesTable Of ContentsLRZE 2, 3LRZM . 4, 5LXi . 6, 7LITE 2 LD . 8, 9LITE 2 LJ . 10, 11LITE 2 LG . 12, 13LX or LT STANDARD BURNERS 14, 15LX or LT LOW NOx BURNERS . 16, 17HiE2 18, 19SERIES 1 & 2 SPARK IGNITION . 20SERIES 1 & 2 MILLIVOLT . 21HOT SHOT (100 K) . . 22, 23DP OIL FIRED . 241

LRZE merWater Temperature Sensor15RedValve Monitor CircuitJ9Fuse250 V – 2 ampRed2Red/White1Black/WhiteH2OJ12BlackIgnition Control7150 ºF(red dot)IGN/FSJ6Vent Temp Limit464 FRed MarkingFDiagnostic LEDFCCOMP/IGNL1BlackIGN/12024VACIGN/240Gray24 VACBlackL23 J3PurpleBrownBlack/YellowJ15Orange6Fusible Link305 FB11W4BlueBlueVALJ165130 ºFAGNDWhiteHighLimitsJ178RedBlack9BlackBlackPower Interface Board(PIB)120 or 240 VACPower SupplyWhite10FAN/PUMP ownGas Valve13Hot Surface IgniterWhite1214Flame SensorDBurnerSTEP 1 – Check in coming power (make certain filter pump motor is ON).NO Make certain filter pump is on.240 or 120 VAC between Black (A) wireCorrect wiring.and Red (B) wire?YESNOReplace TransformerYESNOLocate and correct short circuit,replace Fuse.Make certain Universal Control is calling for heat (red LED on).STEP 4 – Check power to Water Press. Sw.24 VAC between Purple (4) wire on PIB NOand Yellow (1) wire on Transformer?Recheck voltage at Red (3)wire. If voltage is 24 VACreplace PIB.YESNOYESDo a Back Pressure Test. Ifpressure is higher than 2 PSI,replace Water Pressure Switch.If less, clean filter, baskets orrepair pressure problem.STEP 6 – Check thru Vent Temp LimitNOCorrect blockage in vent.Replace Vent Temp LimitYESSTEP 7 – Check thru Fusible Link24 VAC between Blue (7) wire on PIBand Yellow (1) wire on Transformer?YESRecheck power at Blue (7)wire. If 24 VAC at Bluebut not Black, replace PIB.NOMake certain control is calling for heat.24 VAC between Black/Yellow (10)wire on PIB at J3 and Yellow (1) wireon Transformer?NOReplace both High Limits.Do a Temp. Rise Test.Correct flow problem.Recheck power at Black (9)wire. If 24 VAC at Black, butnot Black/Yellow (10),replace PIB.YESSTEP 11 – Check power at Ignition Control24 VAC between Black/Yellow (11) atW terminal of Ignition Control andYellow (1) wire of Transformer?NOCorrect problem withBlack/Yellow wire or itsconnectors.YESSTEP 5 – Check thru Water Press. Sw.24 VAC between Orange (6) wire afterVent Temp Limit and Yellow (1) wire onTransformer?24 VAC between Black (9) wire on PIBand Yellow (1) wire on Transformer?YESSTEP 10 – Check power to Ignition ControlYES24 VAC between Gray (5) wire on PIBand Yellow (1) wire on Transformer?NOSTEP 9 – Check thru High LimitsSTEP 3 – Check Fuse24 VAC between Red (3) wire on PIBand Yellow (1) wire on Transformer?24 VAC between Black (8) wire on PIBand Yellow (1) wire on Transformer?YESSTEP 2 – Check Transformer24 VAC between Red (2) wireand Yellow (1) wire on Transformer?STEP 8 – Check power to High LimitsNOCheck wires to Fusible Link,replace Fusible Link.Correct excessive heat problemin cabinet. Possible rollout.STEP 12 – Check Hot Surface Igniter (Igniter)NOIs Igniter (12)Turn heater OFF.glowing?Disconnect Igniter at C & D. Turn heater ON.Check voltage in the connector ends of C & D goingYESto the Ignition Control (not to the Igniter). If yourmeter is a true RMS meter the voltage should read105 to 130 VAC. If your meter is not a true RMSmeter the voltage should read 64 to 130 VAC.If the voltage is within range replace the Igniter. Ifthe voltage is low recheck incoming power. If thevoltage is above 130 VAC replace both the Igniterand Ignition Control.STEP 13 – Go to back page

LRZE TROUBLESHOOTINGSTEP 13 – Check for IgnitionAfter the Igniter begins to glow, waitapproximately 40 seconds. Did theburners ignite?NOCheck voltage between Brown (13) wire at Gas Valve and Yellow (1) wire of transformer. Is there 24 VAC?NOYESCheck supply gas pressure (see chart below). Did burners ignite?YESNOYESCheck voltage at VAL of Ignition Control.If 24 VAC, replace brown wire. If novoltage replace Ignition Control.Check manifold pressure (see chart below). If supply was correct but there isno pressure on manifold replace the Gas Valve. If pressure is high check forplugged or wrong orifices. If pressure exists but is low correct supply problem.STEP 14 – Check Burners operationNODo Burners stay on past 7 seconds?YESSTEP 15 – Check Burners operationDo Burners stay on past 5 minutes?NOYESDoes flamelook blue oryellow?24 VAC between Brown(15) and Yellow (1) wires?YESReplacePIB.NOGo back toStep 13.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 thefollowing: 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 gasvalve receives power, the voltage slowly drops until the gas valve shuts off, then returns to normal, theproblem is due to loss of current.YellowRecheck gas pressure, burner orifices and airsupply (see manual for more details).BlueHeater is operating.Fault CodesDISPLAY FAULTREMEDYCAUSE3. Pressure switch fault.1. This is normal display when the pump is OFF. No servicerequired.2. Clean filter or clear blockage, check position of valvesin plumbing system.3. Adjust or replace pressure switch.FAULTHIGH LIMIT1. Water temperature in heaterexceeds the internal limit.2. Limit switch fault.1. Verify function of high limit switches. Perform Temperature RiseTest (see chart below). Identify and correct cause of overheating.2. Identify and correct loose connections or replace switches.FAULTFUSELINK/FIELD1. Fusible link fault.1. Identify and correct loose connections or replace Fusible Link.1. Air flow restricted at intake ordischarge.1. Check for proper clearances around heater and for adequateroom ventilation if enclosed. Inspect for blockage or restrictionat discharge of flue.2. Oscillating pump pressure.2. Clean filter or identify and repair cause of pump oscillation.3. Low gas supply pressure.3. Identify and repair incorrect supply pipe size or pipe line blockage.4. No flame at burners.4. Identify and correct loose wiring connections, or problemwith Igniter. Flame Sensor, Gas Valve or Ignition Control.5. Check Ignition Control LED.5. If the LED is on continuously, replace the ignition control. If theLED is blinking, check for causes of the unrecognized flame.1. Faulty wiring or connection.1. Inspect Sensor wiring. Ensure Sensor is connected intoPower Interface Board (PIB).2. Inspect Sensor wires. Replace Temperature Sensor.Display showsNO FLOW1. Pump is not running.2. Low pump pressure.FAULTCHECK IGN CONTROLFAULTSHORTED H20 SENSORORFAULTOPEN WATER SENSORTemperatureRise Chart2. Faulty sensor.Gas PressureChart

LRZM WHITEFireman’sSwitchConnectionHi-Limit150º F(red t130º FPOT POTBLACK8TemperatureBoardPressureSwitch5SEN SENValve (TH) (PP) TH/PP94Vent Temp Limit464 FRed MarkingFusible Link305 FAquaLink RSWires to control or fireman’s switch.Minimum wire size: 14 AWG, 105º CMaximum length: 10 to 15 feet.WHITE1PilotTo dissipate excesscurrent, the LED willflash approximatelyevery 7 secondswhen the heater isenabled but thethermostat settinghas been satisfied.If the LED does notflash, try reversingthe Generator leadsat the Gas Valve.Generator2THGasValve10Coil wiresThermistorRED3WHITEPP-THPPSet gas valve knob to the Pilot position. Set thermostatrocker switch to OFF. Set meter to VDC above one.STEP 1 – Try to light pilotDoes pilot light?NOYES1. Verify gas is on.2. Check for air in gas line.3. Check for clogged pilot tube or orifice.STEP 2 – Check pilot operationDoes pilot stay on when gasvalve knob is released?NOYESSTEP 3 – Check pilot outputIs there 500 mV betweenPP and PP-TH terminals?NOYES1. Check P/G output.2. Check for shorted wires.3. Check pilot coil (yellow wires).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.NOYESSTEP 5 – Check Vent Temp LimitNOIs there 500 mV throughVent Temp Limit?YESSTEP 6 – Check Fireman’s SwitchNOIs there 500 mV throughFireman’s Switch?YESSTEP 7 – Check High LimitsIs there 500 mV throughat White wire of PressureSwitch?YESIs there 500 mV @ BlackWire of Pressure Switch?NOYESMake certain filter pump is ON.Perform Back Pressure Test. If2.5 PSI or more, replace switch.If less, check pump, filter, etc.for pressure problem.Set rocker switch to ON. Set thermostat to maximum.YESSTEP 9 – Check ThermostatIs there 200 mV @ Blackwire of Temp. Board onterminal TH/PP?NOZero volts - Replacerocker switch.500 mV do thetests below .YESSTEP 10 – Check Gas ValveIs there 200 mV @ THterminal of the Gas Valve?NOYESSTEP 4 – Check Fusible LinkIs there 500 mV throughFusible Link?STEP 8 – Check Pressure SwitchNOReplace Fusible Link.Check for Roll out, Soot, Down drafting,Low Gas Pressure, etc.Move rocker switchto OFF. Rotate GasValve Knob to ON.Move rocker switchto ON. Does heater fire?NOCheck #1 burner andorifice. Check gaspressure. If all OKreplace Gas Valve.Check for blockage in the vent.Replace Vent Temp Limit.Perform Thermistor Test (see back pg.)Check that a control system (if installed)is calling for heat or Fireman’s Switchloop is closed.Check wire harness to High Limits fordamage, if OK replace both High Limit.Check for damage to by pass disc,headers, or exchanger.Do a Temperature Rise Test.Disconnect pot wires (orange) andjump pot terminals. If voltage drops to200 mV, replace Temp. Control.Replace Temp. BoardAftercorrectingproblemreturn toStep 9 andproceed.

LRZM TROUBLESHOOTINGTotal 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 wiresshould 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 canhave 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 ChartGas Pressure ChartSupply PressureMinimumMaximumNatural Gas5.5 Inches WC(1.4 kPa)10.0 Inches WC(2.5 kPa)LP Gas10.0 Inches WC(2.5 kPa)14.0 Inches WC(3.5 kPa)4.0 Inches WC (1.0 kPa)LP Gas9.0 Inches WC (2.2 kPa)SymptomAPPROX. RESISTANCE IN 1,000’SOF OHMS (kOhms)50 (10)60 (15)70 (21)80 (26)90 (32)100 (38)Manifold Pressure NominalNatural GasThermistor (Water Temperature Sensor) ChartWATER TEMP INHEADER ºF (ºC)Cause19.915.311.99.37.35.8RemedyPump not operating.A.B.C.No powerPump defectiveIncorrect wiringA.B.C.Check circuit breaker and power.Replace.Recheck wiring.Pilot outage.A.Inlet gas pressure lowA.B.Inlet gas pressure too high causingan unstable blowing pilot.Weak or defective thermocouple.Damaged pilot or thermocoupleDirty pilotPlugged or undersized pilot orifice.B.C.D.E.F.Consult gas utility company. Inlet gas pressure toheater should be 5.5” to 10.0” WC for Natural Gas or10.0” to 14” for Propane Gas.Pressure should be regulated within limits shownabove.Replace thermocouple.Replace.Blow dust or lint out of pilot.Clean or replace pilot orifice.A.Remove and clean each orifice.B.C.D.E.F.G.Check burner orifices for blockage(spider webs)Blocked fluePilot out of position (delayed ignition)Blocked heat exchanger.Fiber board out of place.Altered vent cap.Low gas pressureB.C.D.E.F.G.Remove blockage.Correct pilot position.Clean or correct as necessary.Clean or correct fiber board as necessary.Install factory provided vent cap.Check and correct gas pressure.Spillage at drafthood.A.B.C.D.E.Cold chimneyVent pipe pitches down to chimneyBlocked chimney.Altered draft hood.Prefabricated chimney with incorrect cap.A.B.C.D.E.Allow heater to operate five (5) minutes to create draft action.Reinstall vent cap to pitch up from heater to chimney.Remove blockage.Install factory provided draft hood.Install UL listed vent cap.Lazy flame withyellow tip.A.Low primary air.A.Check for blocked louvers or openings to heater.Not enough heatA.B.Inadequate gas supplyLow manifold gas pressure.A.B.C.D.Heater size inadequate.Low Temperature Rise.C.D.Gas meter too small. Gas line from meter to heater too small.Gas pressure on heater manifold should be adjusted to 4.0” WC NaturalGas, 9.0” WC Propane.Replace with heater of higher input rating.Check and correct water flow.Heater pounding orknocking.A.Inadequate water flow through heater.A.Check Temperature Rise (see chart above). If temperature rise isabove the maximum check for damaged or incorrectly set bypass.Heater condensingA.Low water temperature.A.Flue product moisture will condense at the start-up until the watertemperature reaches normal operating conditions.Pressure relief valveopens.A.Restriction in water flow system at ordownstream of heaterA.Check for proper operation of all valves, bypass valve and anyequipment between pool and heater outlet.Pilot is lit but mainburners will not comeon.A.B.C.D.E.F.A.B.C.D.E.F.Turn knob to “ON” position.Investigate reason for overheating and replace Hi-limit switches.Adjust pressure switch or replace as necessary.Investigate reason for flame rollout and replace Fusible link as necessary.Check and replace Gas Valve as necessary.Check continuity through thermostat circuit with wires disconnected.G.Gas valve not at “ON” position.Hi-Limit switches failed.Pressure switch failed or out of adjustment.Fusible Link failed.Gas valve failed.Broken wire in thermostat circuit ordefective thermostat.Heater wired incorrectly.G.Check heater wiring against wiring diagram.Heater short cyclesA.B.Low water flow through heater.Failed High-limit switch.A.B.Increase size of pump or increase piping size as necessary.Check Hi-limit switches and replace as necessary.C.D.E.F.Flame roll-out atstartup.A.5

LXi Troubleshooting Guide — Serial Number G11LB0001 or newerNote: If Blower is ON, go to Step 13 on back page.STEP 1 – Check Power at Dist. Brd. (make certain filter pump motor is ON).NO Make certain filter pump is on.240 or 120 VAC between Black (C) wireCorrect wiring.and Red (B) wire on Power Dist. Brd.?YESIf wired 240 VAC check voltagebetween Black (E)wire and Blue (F) wire. If wired120 VAC check voltage betweenBlack (E) and White (D) wires. Ifthe correct voltage is present,replace Transformer, if not checkConversion Board position.STEP 2 – Check Transformer24 VAC between Red (2) wireand Yellow (1) wire on Transformer?NOYESSTEP 3 – Check Fuse24 VAC between Red (3) wire on PIBand Yellow (1) wire on Transformer?NOLocate and correct short circuit,replace Fuse.YESSTEP 4 – Check power to Water Press. Sw.24 VAC between Purple (4) wire on PIB NOand Yellow (1) wire on Transformer?YESSTEP 8 – Check power to High Limits24 VAC between Black (8) wire on PIBand Yellow (1) wire on Transformer?24 VAC between Gray (5) wire on PIBand Yellow (1) wire on Transformer?YES24 VAC between Black (9) wire on PIBand Yellow (1) wire on Transformer?YESSTEP 6 – Check power to Fusible Link24 VAC between Orange (6) wire on PIBand Yellow (1) wire on Transformer?NO24 VAC between Black/Yellow (10)wire on PIB and Yellow (1) wire onTransformer?24 VAC between Blue (7) wire on PIBand Yellow (1) wire on Transformer?YESNONOReplace both High Limits.Do a Temp. Rise Test.Recheck power at Black (9)wire. If 24 VAC at Black, butnot Black/Yellow (10),replace PIB.YESSTEP 11 – Check power at Ignition ControlRecheck voltage at Red (3)wire, if voltage is 24 VACreplace PIB.24 VAC between Black/Yellow (11) atW terminal of Ignition Control andYellow of Transformer?Do a Back Pressure Test, ifpressure is higher than 2 PSI,replace Water Pressure Switch,if less clean filter, baskets orrepair pressure problem.Recheck voltage at Gray (5)wire, if voltage is 24 VACreplace PIB.STEP 12 – Check BlowerNOIs Blower ON?Check Fusible Link Air Box and ,Vent Temp Limit individually.Replace failed part.Correct excessive heat problemin vent or air box.Correct incomingpower problem.STEP 13 – Go to back pageNOCorrect problem withBlack/Yellow wire or itsconnectors.Check voltage between F2 terminal of IgnitionControl and ground (A). Is voltage 105 VAC orhigher?NOYESYESSTEP 7 – Check Fusible LinkNOYESSTEP 10 – Check power to Ignition ControlYESNORecheck power at Blue (7)wire. If 24 VAC at Bluebut not Black, replace PIB.STEP 9 – Check High LimitsYESSTEP 5 – Check Water Pressure SwitchNOYESCheck voltage between F1 terminalof Ignition Control and ground (A).Is voltage 105 VAC or higher? If no,replace Ignition Control, if yescheck voltage between Black(L)wire to Blower on PDB and ground(A). If voltage is 105 VAC or higherreplace Blower, if lower checkwires, replace PDB

Blower is ON – See Note below.LXi Troubleshooting Guide — Serial Number G11LB0001 or newerSTEP 13 – Check Air Pressure Switch24 VAC between Orange (NO) wire at the Air Pressure Switchand Yellow (1) wire on Transformer?NOMake certain Blower is on and combustion chamber is sealed. Check air tubes for kinksor holes. Make certain front air tube is connected to the positive ( ) side and back/lowerair tube is connected to negative (-) side of the Air Pressure Switch. If all are OK replacethe Air Pressure Switch.YESSTEP 14 – Check Power to PSWNO24 VAC between Orange (12) wire at the Ignition Control andYellow (1) wire on Transformer?Check wire connections. Replace Orange wire.YESSTEP 15 – Check Hot Surface IgniterAfter Blower comes on wait at least 15 seconds (Pre-Purge).Is Igniter glowing?NOCheck voltage between K and J of the Ignition Control. If 105 to 130 VAC, check wires andconnectors to the Igniter, if OK, replace Igniter. If voltage is less than 105 VAC checkincoming voltage between L1 and L2, if voltage is 105 to 130 VAC replace Ignition Control.YESSTEP 16 – Check for IgnitionNOAfter the HSI begins to glow, waitapproximately 40 seconds. Did the burners ignite?Check voltage on Brown (13) wire at terminal VAL of the Ignition Control. Is there 24 VAC at VAL?NOReplace IgnitionControl.YESSTEP 17 – Check Burners operationDo Burners stay on beyond 7seconds?NOYESHeater is operating.YESCheck supply gas pressure. IfOK, replace Gas Valve.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 valvereceives power, the voltage slowly drops until the gas valve shuts off, then returns to normal, the problem is due toloss of current.Note: If the blower runs continuously, unplug F1/F2 connector from the Ignition Control, if the blower goes off replace the IgnitionControl. If the blower stays on, check for shorted wires between the Ignition Control and PDB or from the PDB and the Blower.Service CodesTEMPERATURE RISEMODEL 250Serial # A & BSerial # C & NewerMIN.7 F8 FMAX.10 F12 FMODEL 300Serial # A & BSerial # C & NewerMIN.MAX.8 F 11 F11 F 18 FMODEL 400Serial # A & BSerial # C & NewerMIN.MAX.13 F 17 F14 F 21 FGAS PRESSUREInches of Water ColumnManifoldSupplyNatural2.5LP9.05.5 to 10.511 to 14

LITE 2 LD-DIRECT IGNITION TROUBLESHOOTING w/Digital Ignition ControlTemperature ow4a White3aHi-Limit150 F (red FuseFusibleLink7YellowYellow/GreenAquaLink RS240 VACTransformerWhiteIGN 240F1F224 VACIGN 120FCYellowHi-Limit135 FWhite/RedYellow/BlackBlackL1L2YellowMVMV8Hot Surface IgnitorIGN/FSTHINDVALGNDBrown6FENWAL DIGITALIGNITION CONTROLGas ValveBlackTanFlame Proving RodRedTanSTEP 124 VAC atTransformerNOFuse is blown. Look for short oroverload of controls. Do notjumper or bypass. Fuse protectstransformer.STEP 6NO24 VAC atIs temperature Board calling for heat?Black/Yellow wireYESat the IND ofIgnition Control?NOReplaceDo a Thermistor Test.ThermistorYESIs thermistor withinrange? See chart on YES Replace Temp.back page.Board.Too much heat in control area.Look for down drafting, Roll-out,Soot, or Low Gas Pressure.Replace Fuse Link.Remove the connector at F1 & F224 VAC at the BlackNO of the Ignition Control. Perform acontinuity test between F1 & F2wire at TH of theterminals on the Ignition Control.Ignition ControlIs there continuity?YESNOYES1) Check incoming Power Supply.2) Check Transformer Wiring.3) Replace Transformer.YESSTEP 224 VAC at Red NOWire of FuseLink?YESSTEP 3NO24 VAC atWhite Wire ofFuse Link?YESSTEP 3a24 VAC atboth FiremanSwitch terminal’sNOCheck that a control system (ifinstalled) is calling for heat orthe Fireman’s Switch is closed.YESSTEP 424 VAC atNOWhite Wire ofPressure Switch?YES1) Check each limit individually.4a & 4b2) Check if damage to disc,heads, or exchanger.3) Take Temperature Rise.STEP 5NO24 VAC atBlack Wire ofPressure Switch?Perform back pressure test.If 2 PSI or more, replaceswitch. If less, check pump,filter, etc., for water flowproblems.YESWait for 15second delay.Check wire connectors. Replace Ignition Control.STEP 7NODoes Ignitorheat up?YES1. Is Ignition Control wired for proper voltage?2. Is Ignitor properly connected?3. Do Ignitor Test. Is Ignitor within range?NOYESSTEP 8Replace Ignition Control.24 VAC at VALof the IgnitionControl?NOYESSTEP 9Does heaterfire?NOReplace Ignitor.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.Verify Ignitor wiring. OKReplace GasAre all gas valvesopen? Is gasValve.pressure correct?8

Safety Circuit TestHot Surface Ignitor TestLeave black probe on Transformerterminal with yellow wire.Move red probe to each componentIgnitor must be disconnected fromthe Ignition Control and cool to the touch.Resistance through the Hot Surface Ignitorshould be 40 to 75 Ohms.TransformerFusible Link240 VACSet meter to test resistance.1000DCVOFF750ACV200200DCA200μ20ACV above 30 V22000μ200m20m200m2000K10A200KhFE20K2K 0m20mYellow Wire200m2000K10A200KhFE20KTest Hot Surface Ignitorat Ambient Temperature- range 40 to 75 Ohms-2K 200NPNPNPThermistor 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 ChartTempResistanceTempResistance50 F19.898 K Ohms78 F9.735 K Ohms51 FOFF1000DCV750ACV200200DCA200μ2052 FResistanceat 20 Kor above53 F54 F2000μ2200m20m200m2000K55 F10A200KhFE20K2KNPN20056 FPNP57 F58 F59 F60 F61 F62 F63 F64 F65 FTemperature Rise Test ChartTemperature RiseMODELLite, Lite 2, Series 1 & Series 2with 2” header connectionsSeries 1with 1½” header 6 F67 F68 F69 F70 F71 F72 F73 F74 F19.435 K Ohms18.871 K Ohms18.382 K Ohms17.902 K Ohms17.473 K Ohms16.988 K Ohms16.549 K Ohms16.150 K Ohms15.710 K Ohms15.314 K Ohms14.923 K Ohms14.547 K Ohms14.193 K Ohms13.823 K Ohms13.477 K Ohms13.138 K Ohms12.813 K Ohms12.492 K Ohms12.186 K Ohms11.893 K Ohms11.593 K Ohms11.309 K Ohms11.032 K Ohms10.765 K Ohms75 F10.502 K Ohms77 F10.000 K Ohms76 F10.250 K Ohms79 F80 F81 F82 F83 F84 F85 F86 F87 F88 F89 F90 F91 F92 F93 F94 F95 F96 F97 F98 F99 F100 F101 F102 F103 F104 F9.483 K Ohms9.284 K Ohms9.079 K Ohms8.864 K Ohms8.655 K Ohms8.450 K Ohms8.253 K Ohms8.057 K Ohms7.871 K Ohms7.687 K Ohms7.509 K Ohms7.335 K Ohms7.166 K Ohms7.001 K Ohms6.840 K Ohms6.685 K Ohms6.531 K Ohms6.384 K Ohms6.238 K Ohms6.099 K Ohms5.963 K Ohms5.829 K Ohms5.700 K Ohms5.572 K Ohms5.449 K Ohms5.327 K Ohms9

LITE 2 LJ TROUBLESHOOTINGNO RMALHOT SURFACE IGNITORMODEPOOL84--- FBLACKGREENUPD OWNPUMP8MVMVFLAME �135º FHIGH LIMITPRESSURESW ITCHWHITEW HITE5aSAFETYBLACK3b3aREDWHITEW HITEWHITEW HITE4b5b150º150º FHIGH LIMIT(RED DOT)2GAS65cINLET TEMPPOW ER SENSORON2 AMP NORMALYELLOW21PUMPFIREMAN’SSW ITCH4aFIREMANSW ITCH2 AMP,3/4” long31BLOW ERFUSIBLE LINK7aWHITESWHITESA7cREDWHITESWHITESFUSEREDBEXT POWERREDREDFUSE7b7dTRANSFORMER VOLTAGESBETWEEN BLUE(1) & BLUE(2) – 24 VACBETWEEN BLUE(!) & WHITE(3) – 12 VACBROWNBROW NHOT SURFACE IGNITORPOWER CONTROL BOARD115 or 230 VAC2 AMP, 1 ¼” LONG FUSEFor Thermostat troubleshooting refer to the installation manual.STEP 1 - Check Transformer - Set meter to ACV above 240NO 1) Check incoming power. (A & B)24 VAC between2) Turn off incoming power. CheckBlue 1 & Blue 2 wires?positioning of Conversion Block.3) Replace Transformer.YESSTEP 5 - Check High LimitsNO24 VAC at white wireof Pressure Switch? (5a)YES1) Check incoming power. (A & B)2) Turn off incoming power. Checkpositioning of Conversion Block.3) Replace Transformer.12 VAC betweenNOBlue 2 & White 3 wires?YESSTEP 2 - Check Fuse (insert common probe in with blue 1 wire,touch other probe to far end of fuse)NO 1) Check for short circuits.24 VAC at far end of fuse?2) Replace fuse.YESFor the next tests insert and leave the common probein with the blue(2) wire.STEP 6 - Check Pressure SwitchNO Perform Back Pressure Test. If 2.5 PSI or24 VAC at black wiremore, replace Pressure Switch. If less,of Pressure Switch? (6)check pump, filter, etc., for water flowproblems.YESFor Ignitor Test, remove common probe from blue(2) wire.STEP 7 - Check Hot Surface IgnitorNO Turn power off, disconnect Ignitor at 7aDoes Ignitor heat up?and 7b. Perform Ignitor Test.Is resistance between 25 and 300 Ohms?YESYESNOSTEP 3 - Check Fireman’s Switch CircuitNO Power Control is not sending power.24 VAC at 3a?Replace Power Control Board.YES24 VAC at 3b?YESNOFireman’s switch circuit is open.Make sure the external control iscalling for heat.Check wires for lose connections.Replace Ignition board.YES24 VAC on white wire NOat Fusible Link? (4b)YESYESRemove 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.ReplaceIgnitor.For Gas Valve test reinsert the common probe in with the blue(2) wire.STEP 4 - Check Fusible Link24 VAC on red wire NOat Fusible Link? (4a)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.Too much heat in control area.Look for down drafting, Roll-out,Soot,or Low Gas Pressure.Replace Fusible Link.STEP 8 - Check Gas ValveAfter 10 seconds of Ignitorheat up, is there 24 VAC atbrown wire to gas valve?YESDoes heater fire?NONOReplace PowerControl Board.Make certain all gas valvesare open, the correct fuelis provided to the heater, gaspressure and volume arecorrect.OKReplace GasValve.10

Temperature Rise Test ChartHot Surface Ignitor TestTemperature RiseMODELBtusLite, Lite 2, Series 1 & Series 2with 2” header connectionsSeries 1with 1½” header or must be disconnected from the Ignition Controland should be cool to the touch.Depending on the temperature of the ignitor, the resistance between the two leads of a good ignitor will be 25to 300 Ohms, typically 60 to 80 Ohms.Set meter to test 200m20m200m2000K10A200KhFE20K2K 200NPNThermistor 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.PNPThermistor Test ChartTempResistanceTempResistance50 F19.898 K Ohms78 F9.735 K Ohms51 F52 FOFF1000DCVACV750200200DCAResistanceat 20 Kor NPN200PNP53 F54 F55 F56 F57 F58 F59 F60 F61 F62 F63 F64 F65 FHEATER 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.66 F67 F68 F69 F70 F71 F72 F73 F74 F75 F76 F77 F19.435 K

LRZE TROUBLESHOOTING . STEP 15 – Check Burners operation. Do Burners stay on past 5 minutes? YES. NO. 24 VAC between Brown (15) and Yellow (1) wires? DISPLAY FAULT. CAUSE. Display shows. NO 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 .

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