Laars NEOTHERM NTV Bedienungsanleitung

Document 1292

Modulating Boiler

Model NTH

Sizes 399-850 MBTU/h

Water Heater

Model NTV

Sizes 399-850 MBTU/h

Every reference

that you’ll need,

to service the

Commercial

NEOTHERM

Service Manual

for

NEOTHERM

Service Manual - NeoTherm 500

How to Use This Manual

How to Use the Troubleshooting Information

This manual is divided into ve main sections:

Section A - Troubleshooting Instructions

Section B - Troubleshooting Procedures

Section C - Combustion

Section D - NeoTherm Control System

Appendix

Start the troubleshooting process using the charts in Section A. The

instructions in Section A will lead you to more detailed procedures in

Section B.

Section C covers possible combustion problems and the combustion

setup procedure.

For details on the User Interface used on your unit, see Section D.

If the unit presents a Hold or Lockout message, you can get more infor-

mation from the listing in the Appendix.

Contact Laars Technical Support if you can’t diagnose the problem using

the information in this manual:

LAARS Product Support

Phone: (800) 900-9276

(603) 335-6300

Fax: (800) 335-3355

Service Manual - NeoTherm 500

Finding Information in this PDF File

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very useful to you unless you can nd it. We’d like to help you to nd the

information you need, quickly and easily.

There are four ways to locate information in this PDF* le.

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Table of Contents -

The Table of Contents is located at the beginning of the manual. (The

bookmark for Contents will take you there.) Use this to identify the sec-

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Service Manual - NeoTherm 500 iii

Safety Notes

Please read this section before beginning any

troubleshooting procedures.

If the information in this manual is not followed exactly, a re or ex-

plosion may result, causing loss of life, personal injury, or property

damage.

Necessary Training -

This product must be installed and serviced by a professional service

technician, qualied and/or licensed in hot water boiler and heater instal-

lation and maintenance. Any changes to safety-related conguration

parameters must only be done by qualied and/or licensed burner/boiler

operators and mechanics.

Carbon Monoxide Hazard -

Improper installation and/or operation could create carbon monoxide gas

in ue gases which could cause death, serious injury, or property dam-

age. Improper installation and/or operation will void the warranty.

Fire or Explosion Hazard -

Improper conguration can cause fuel buildup and explosion. Improper

user operation may result in death, severe physical injury, or property

damage. 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 -

If any odor of gas is detected, or if the gas burner does not appear to be

functioning in a normal manner, close the main gas shutoff valve. The

inlet gas pressure to the appliance must not exceed 13” w.c. (3.2 kPa).

• Do not try to light any appliance.

• Do not touch any electrical switch. Do not shut off the power switch.

Do not use any phone in your building.

• Immediately call your gas supplier from a nearby phone. Follow the

gas supplier’s instructions.

• If you cannot reach your gas supplier, call the re department, your

heating contractor, gas company, or factory representative.

Service Manual - NeoTherm 500

Electrical Shock Hazard

Electrical shock can cause severe injury, death or property damage. Only

a professional technician, trained in electrical safety, should work on

this unit. Whenever the troubleshooting procedures make this possible,

turn off the power to the unit before working inside the cabinet. The only

exceptions would be when it is necessary to test the voltages between

the points listed in this manual. 120V AC is present in this unit behind

the metal cover marked with the safety label. Be especially careful when

working on the unit if this cover has been removed. Always replace

the cover when the service procedure is complete. Before making any

changes, disconnect the power supply to prevent electrical shock or

damage to the equipment. It may be necessary to turn off more than one

power supply disconnect.

All electrical wiring is to be done in accordance with local codes, or in the

absence of local codes, with: 1) The National Electrical Code ANSI/NFPA

No. 70 - latest Edition, or 2) CSA STD. C22.1 “Canadian Electrical Code

- Part 1.” This appliance must be electrically grounded in accordance

with these codes.

Hot Water -

This unit can produce water which is hotter than 125°F (52°C). This can

cause severe burns instantly or death from scalding. Always shut off the

system and allow it to cool for one hour before opening any pipe connec-

tions that may contain hot water.

Children, disabled and elderly persons are at the highest risk of being

scalded. See the Installation and Operating manual for instructions be-

fore setting the temperature at the NeoTherm unit.

For NTV units - Adjust the outlet control (limit) or use temperature limiting

valves to obtain a maximum water temperature of 125°F (52°C). Instruct

all users to feel the water temperature before getting into the bath or

shower.

The NeoTherm unit is protected against over-pressurization. A pressure

relief valve is included with each NeoTherm unit.

Installation Codes -

All installations must be made in accordance with 1) American National

Standard Z223.1/NFPA54-Latest Edition “National Fuel Gas Code” or

2) CSA B149.1 “Natural Gas and Propane Installation Code” and with

the requirement of the local utility or other authorities having jurisdiction.

Such applicable requirements take precedence over the general instruc-

tions contained in this manual.

Service Manual - NeoTherm 500

Table of Contents

Section A - Troubleshooting - Start Here

Sect. Title................................................................................Page

A1 Troubleshooting - Start Here ............................................... 1

A2 Unit Will Not Fire - Blower is Not Running........................... 2

A3 Blower Runs Continuously, No Display ............................... 4

A4 Control Unit is in “Standby” Mode........................................ 5

A5 Changing Control Settings, Change Not Complete -

Unit with Original (White) User Interface ............................. 7

A6 Unit is Running, But Building is Still Cold ............................ 8

A7 Control Unit Says “Run”, But Boiler is Not Firing................. 9

A8 Open Safety Chain - Fault #63 ........................................... 9

A9 Unit Runs in High or Low Fire Only -

Unit with Current User Interface ........................................ 10

A10 Unit is Noisy....................................................................... 10

Section B - Troubleshooting Procedures

Sect. Title Page

B1 Quick Check of Components in the

Safety Chain ...................................................................... 11

B2 Troubleshooting the 24V AC Power Supply ...................... 15

B3 Checking the Safety Interlocks .......................................... 16

B4 Checking the Low Water Cutoff Switch ............................. 18

B5 Controller for Low Water Cutoff ......................................... 19

B6 Removing and Replacing the

Low Water Cutoff Switch ................................................... 20

B7 High Water Temperature Limit Switch ............................... 22

B8 Checking the Flow Switch ................................................. 22

B9 Testing the Flow Switch ..................................................... 23

B10 Removing and Replacing the Flow Switch ........................ 24

B11 Removing and Replacing the Gas Valve ........................... 26

B12 Checking the High Gas Pressure Switch........................... 29

B13 Checking the Low Gas Pressure Switch ........................... 30

B14 Testing the Low Gas Pressure Switch ............................... 31

Service Manual - NeoTherm 500

Table of Contents (continued)

B15 Removing and Replacing the High and Low Gas

Pressure Switches............................................................. 32

B16 Checking the Condensate Trap Water Level Switch ......... 35

B17 Testing the Condensate Trap Level Switch ....................... 36

B18 Removing and Replacing the Condensate Trap................ 36

B19 Checking the Air Pressure Switch -

Blower Proving Switch....................................................... 38

B20 Test Procedure for Air Pressure Switch ............................. 39

B21 Removing and Replacing the Air Pressure Switch ............ 39

B22 Checking the Blower.......................................................... 41

B23 Removing and Replacing the Blower ................................ 42

B24 High Stack Temperature Fault ........................................... 46

B25 Removing and Replacing the

Stack Temperature Limit Switch ........................................ 47

B26 Checking the System Sensor ............................................ 48

B27 Checking the DHW Sensor................................................ 48

B28 Inlet Water Temperature Sensor........................................ 49

B29 Removing and Replacing the

Inlet Water Temperature Sensor........................................ 49

B30 Outlet Water Temperature Sensor..................................... 50

B31 Removing and Replacing the

Outlet Water Temperature Sensor .................................... 50

B32 Testing the Temperature Sensors...................................... 51

B33 Troubleshooting the Outdoor Reset System ..................... 52

B34 Servicing the Transformer ................................................. 52

B35 Removing and Replacing the Pressure Relief Valve ......... 54

B36 Ignitor Assembly ................................................................ 55

B37 Flame Sensor .................................................................... 56

B38 Pump Fault ........................................................................ 57

Service Manual - NeoTherm 500

Table of Contents (continued)

Section C - Possible Combustion Problems

Sect. Title Page

C1 About Correct Combustion ................................................ 59

C2 Combustion Adjustment Procedure -

Units with Original (White) User Interface ......................... 60

C3 Combustion Adjustment Procedure -

Units with Current User Interface ...................................... 62

C4 Troubleshooting Combustion Problems ............................ 64

C5 Cleaning the Burner and Heat Exchanger......................... 65

Section D - Using the NeoTherm Control System

Sect. Title Page

D1 Identifying the User Interface on Your Unit ........................ 73

D2 Using the Original (White) User Interface.......................... 74

D3 Reacting to Lockouts on the Original (White)

User Interface .................................................................... 76

D4 Removing and Replacing the Original (White)

User Interface .................................................................... 77

D5 Using the Current User Interface....................................... 78

D6 Reacting to Lockouts on the Current User Interface ......... 84

D7 Removing and Replacing the Current User Interface........ 85

D8 When to Replace a SOLA Controller ................................. 86

D9 Removing and Replacing the SOLA Controller ................. 87

Appendix

Sect. Title Page

App1 Error Codes ....................................................................... 89

App2 Ignition and Firing Sequence........................................... 104

App3 Wiring Diagram................................................................ 105

vii

Service Manual - NeoTherm 500

viii

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