03/19/2009
13
BI502
Replacement Parts
@WFS3
Water sensor, 3 ft.
@WFS255612
Outdoor sensor (OT)
@EBSTU5623
Controller, temp. sensing
UFUSE0440
2-amp fuse, fast blow (AGC2)
4038
Triac switch module
5127 Heating
relay
5535
Safety hi-limit, manual, 205°
5537
First hi-limit, auto-reset, 180°
5453
Relief valve, 30 PSIG
5456A Gauge
press/temp.
5640
60A GE circuit breaker
5639
30A GE circuit breaker
5652
60A SQ D circuit breaker
5650
30A SQ D circuit breaker
5520
Electric element, 240, 4.5 kW
5541
Transformer, 24V, 40VA
TROUBLESHOOTING/REPAIR HELPS
1.
This WarmFlo controller contains several interference suppression components, but as an electronic
logic product, unpredictable and unusual transients or interference may sometimes cause strange
results. If the WarmFlo controller is “acting strange”, one immediate step would be power down
reset. Simply turn off boiler power or breaker number 1, when the green LED goes out, count to 1Ø,
and re-energize power supply.
2.
Inoperative temperature sensor, if the internal program can detect a bad sensor (shorted, open wire,
etc. – not necessarily bad value) the front panel green LED will be pulsing. By checking the pulsing
pattern, the appropriate sensor can be identified.
-
OT sensor – 100 ms blink every second
-
ST sensor – two, 100 ms blinks every second
-
Both bad – ½ second on, ½ second off, alternating
3.
The temperature sensor can be further evaluated with diagnostic program from standard PC or
Analyzer software. This includes the ability to “fool” the sensor or set in an offset for various
troubleshooting purposes. This software disk comes with a special cable needed for PC or Analyzer
hookup.
-
ET-SOFT-TS – PC software disk and cable
-
ET-SOFT-TSP – Palm software disk and cable
4.
The terminal blocks for control wire hook-up are designed for a wire insertion and screw clamp
down. If there is no wire connected and the screw is loose, the screw may not necessarily make a
good electrical contact to the inside components. Example - If you are jumpering the thermostat
terminals without thermostat wire connection or if you are attempting to measure voltage on the
screw head, you may get erroneous or unpredictable results if the screw is not tightened down.
5.
The outdoor sensor (OT) must be sensing the actual outside temperature for this controller to
correctly operate. Do not simply leave the outdoor sensor “hang in the room” and attempt to run this
system.
6.
Temperature sensing bypass – the inside control board, left side, contains a “E” tab which can be
used to directly step in the heating stages and in essence bypass the temperature sensing and control
functions. The “E” tab has the highest priority and overrides all temperature sensor functions. In
other words, when jumpering from W to E all four stages are hard on.
Note
: Verify pump is
operating prior to using the E terminal. Since activating this E terminal causes full electric element
output, this function should only be used to verify all stages or troubleshoot proper 24Ø current at
each element.
