The malfunctions of Burnham boilers can be eliminated on one`s own in a number of cases, if the causes of their emergence are known. Therefore, we provide the troubleshooting table below. It will help to conduct correct diagnostics and discover malfunction.
Burnham ES2 boiler troubleshooting
| Display | Status | Boiler / Control Action(s) | |
|---|---|---|---|
| Blank | Boiler and Circulator off | No 120 Vac power at boiler, check breaker and wiring between breaker panel and boiler. | |
| StA | 1 | Boiler not responding to Heat Request | Boiler is not seeing Heat Request. Check thermostat or zone wiring for loose connection, miswiring, or defective thermostat or zone control. |
| StA | 2 | Boiler Running but Circulator is not Running | Check wiring for loose connection, miswiring. When there is a Domestic Hot Water Heat Request wired to the Outdoor Air Reset card the Circulator will be off for the duration of the priority time. This to allow all of the boiler output to be provided for fast Indirect Water Heater recovery. Check Priority Time (Pfc.) function using Outdoor Air Reset IQ Option Card Adjustment Mode (see Reset Card Adjustment Mode instructions). |
| StA | 10 | Retry Delay | The burner failed to light (no flame signal). After a 5 minute delay, IQ Control will attempt to light the burner again. There is no limit to the number of retries. |
| StA | 10 | Recycle Delay | The burner loses flame during running mode (5tH code "9"). After a 10 second delay. IQ Control will attempt to light the burner again. If the burner loses flame during running mode (^fl code "8") during the next six recycles, IQ Control will progress to a soft lockout. |
| StA | 13 | Soft Lockout | When a soft lockout occurs, boiler will shut down. Boiler automatically restarts once condition that caused the lockout is corrected and the one-hour time delay is completed. Boiler can be restarted sooner than the time delay by using Adjustment Mode function and manually resetting boiler (see Adjustment Mode instructions). |
| StA | 14 | Hard Lockout | When a hard lockout occurs boiler shuts down. Boiler will NOT automatically restart once the condition that caused the lockout is corrected. It will be necessary to go to Adjustment Mode function to manually reset the boiler (see Adjustment Mode instructions). |
| StA | 15 | Wait for Limit to Close | Heat Request occurs and start of operating sequence is halted due to an open limit. Open limits may include Flame Roll Out Switch, Blocked Vent Switch, or Auxiliary. Limit or Low Water Cutoff IQ Option Cards (when installed), refer to IQ Option Panel display for additional information. |
| StA | 18 | Flame Out of Sequence | Flame Signal is still present when expected to be 0 (no flame). |
| StA | Waiting for Damper to Open | Heat Request occurs and the IQ control is waiting for the damper to open (end switch to dose). | |
| StA | Waiting for Damper to Close | The damper end switch is dosed and the control waits for the damper end switch to open (*end switch is open when damper is closed). This is checked at the beginning of a heat cyde before opening the damper. If the damper doesn’t close in 60 seconds, the IQ Control goes to Status B I. |
Burnham ALPINE boiler troubleshooting
| Lockout Number | Condition | Possible Cause |
|---|---|---|
| Anti Short Cyde | Minimum time between starts has not been reached. Normal delay used to avoid excessive cycles. | |
| Boiler Safety Limit Open | Boiler Safety Limit wired to terminals J6-1.2 or 3 OPEN: • Condensate Trap Float Switch contacts open. • Air Pressure Switch contacts open. • Auto Reset High Limit contact open. | • Loose wiring to limit device. • Auto Reset Supply high limit sensor detected temperatures in excess of 200°F. • Defective Auto Reset Supply High Limit Switch. • Plugged Condensate Trap - also check to ensure boier is level. • Air Pressure Switch contacts open - check for blocked vent. • See possible causes for 'Hard Lockout 4’. NOTE Block Vent Special Note Before a call for heat the air pressure switch is closed. When there is a call for heat with a blocked vent the air pressure switch will open (due to excessive pressure of the fan against a blocked flue pipe) after the fan starts. The control stops the start sequence and stops the fan. After the fan stops the pressure switch re-closes and the cyde continues. The displays shows the cause of trip for only the time the pressure switch is open. |
| Boiler Safety Limit Open. (ILK Off) | Boiler Safety Limit, or External Limit wired to termi- nals J5-1 OPEN: • Jumper for External Limit wired to terminals 11 and 12 or device connected to it open. • Jumper for Low Water Cutoff (LWCO) Switch or device connected to it open. • Jumper for Low Gas Pressure Switch or device connected to it open. | See possible causes for 'Hard Lockout 4’. Loose wiring to limit device. External Limit defective or jumper not installed. Low Gas Pressure Switch contacts open (if installed). LWCO switch not installed and jumper missing. If yellow light on LWCO is on. system is low on water. If neither yellow or green light is on. check LWCO harness. |
| Return sensor fault | Shorted or open return temperature sensor. | Shorted or mis-wired return sensor wiring. Defective return sensor. |
| Supply sensor fault | Shorted or open supply temperature sensor. | Shorted or mis-wired supply sensor wiring. Defective supply sensor. |
| DHW sensor fault | Shorted or open Domestic Hot Water (DHW) temperature sensor. | Shorted or mis-wired DHW sensor wiring. Defective DHW sensor. |
| Stack sensor fault | Shorted or open flue gas (stack) temperature sensor. | Shorted or mis-wired stack sensor wiring. Defective stack sensor. |
| Ignition faiure | Flame failure after 5 tries to restart. | No gas pressure. Gas pressure under minimum value shown on rating plate. Gas line not completely purged of air. Defective Electrode. Loose burner ground connection. Defective Ignition Cable. Defective gas valve (check for 24 Vac at harness during trial for ignition before replacing valve). Air-fuel mixture out of adjustment - consult factory. |
| Flame rod shorted to ground | Flame rod shorted to ground | Shorted or mis-wired flame rode wiring. Defective flame rod. |
| Delta T inlet/outlet high | Temperature rise between supply and return is too high. | Inadequate boiler water flow. Verify that pump is operating and that pump and piping are sized per Section VI of this manual. |
| Return temp higher than supply | Sage2.1 is reading a return sensor temperature higher than the supply sensor temperature. Condition must be present for at least 75 seconds for this error code to appear. | Flow through boiler reversed. Verify correct piping and pump orientation. No boiler water flow. Verify that system is purged of air and that appropriate valves are open. Sensor wiring reversed. Supply or return sensor defective. |
| Supply temp has risen too quickly | Supply water temperature has risen too quickly. | See possible causes for 'Hard Lockout 4’. Inadequate boiler water flow. Verify that pump is operating and that pump and piping are sized per Section VI of this manual. |
| Fan speed not proved | Normal waiting for fan speed to match purge and kght-off setpoinL | |
| Supply high limit | Sage2.1 suppty sensor detected temperatures in excess of 210°F. | • Heating load at time of enor was far below the minimum firing rate of the boiler. • Defective system pump or no flow in pnmary loop. • Defective boiler pump or no flow in boiler loop. • Control system miswired so that the boiler operation is permitted when no zones are calling. |
| DHW high limit | Sage2.1 DHW sensor detected temperatures in excess of Setpoint. | • DHW load at time of error was far below the minimum firing rate of the boiler. • Control system miswired so that boiler operation is permitted when no DHW are calling. |
| Stack High limit | Sage2.1 Flue gas (Stack) sensor detected temperatures in excess of 204°F. | • Heat exchanger needs to be cleaned. • Boiler over-fired. • Air-fuel mixture out of adjustment - consult factory. |
| Flame detected out of sequence | A flame signal was present when there should be no flame. | • Defective gas valve - make sure inlet pressure is below maximum on rating plate before replacing valve. |
| Light off rate proving failed | Blower is not running at Light-off rate when it should or fan speed signal not being detected by Sage2.1. | • Loose connection in 120 VAC fan wiring. • Loose or miswired fan speed harness. • Defective fan |
| Purge rate proving failed | Blower is not running at Purge rate when it should or fan speed signal not being detected by Sage2.1. | • Loose connection in 120 VAC fan wiring. • Loose or miswired fan speed harness. • Defective fan |
| Invalid Safety Parameters | Unacceptable Sage2.1 control Safety related parameter detected. | Safety Parameter verification required. Contact factory. |
| Invalid Modulation Parameter | Unacceptable Sage2.1 control Modulation related parameter detected. | Reset the control. |
| Safety data vehfication needed | Safety related parameter change has been detected and a venfication has not been completed. | Safety related Sage2.1 control parameter has been changed and verification has not been performed. |
| 24VAC voltage low/high | Sage2.1 control 24Vac control power is high or low. | • Loose connection in 24Vac VAC power wiring. • Loose or miswired 24Vac harness. • Miswired wiring harness causing power supply short to ground. • Defective transformer. • Transformer frequency, voltage and VA do not meet specifications. |
| Fuel Valve Error | Power detected at fuel valve output when fuel valve should be off. | • Loose or defective gas valve harness. Check electrical connections. • Defective gas valve (check for 24 Vac at harness during trial for ignition before replacing valve). |
| Hardware Fault | Internal control failure. | • Reset the control. If problem reoccurs, replace the Sage. |
| Internal Fault | Internal control failure. | • Reset the control. If problem reoccurs, replace the Sage. |
| Unknown Fault | Unknown Fault | • Reset the control. If problem reoccurs, replace the Sage. |
| Condition | Possible Cause |
|---|---|
| Display Blank, Fan off, LWCO lights off, no green power light on Sage2.1 Controller | No 120VAC Power at boiler. Check breaker and wiring between breaker panel and boiler. |
| Display Panel Blank, Fan running | Loose 120VAC connection wiring between boiler J-Box and transformer Loose 24 Vac connection wiring between transformer and Sage2.1 Loose 5 Vdc connection wiring between display and Sage2.1 |
| Boiler fires, but display panel is blank | Loose 5 Vdc connection wiring between display and Sage2.1 Defective display |
| Boiler not responding to call for heat, Status screen reads “Central Heat T-Stat Off’ | Boiler is not seeing call for heat. Check thermostat or zone wiring for loose connection, miswiring, or defective thermostat/zone control. |
| Boiler not responding to a call for heat, “Standby” status is showing. | Boiler is not firing. There is no call for heat or there is a call for heat and the temperature is greater than setpoint. |
| Boiler not responding to Domestic Hot Water Heat Request | Boiler is not sensing Domestic Hot Water Heat Request. Check wiring for loose connection, miswiring, or defective indirect water heater aquastat. |
| Boiler Running but System or Boiler Circulator is not running | Check wiring for loose connection, miswiring. When there is a Domestic Hot Water Heat Request the System or Boiler pumps will be forced “off’ when there “Run Pump for” parameter is set to “Central heat, off DHW demand” or “Central Heat, Optional Priority”. This has been set to allow all of the heat to be provided for fast indirect water heater recovery. After one hour of “priority protection” or the end of the Domestic Hot Water Heat Request the system and boiler pumps will be free to run. |
| Home is cold during mild weather days | Increase Low Boiler Water Temperature parameter 5°F per day. |
| Home is cold during cold weather days | Increase High Boiler Water Temperature parameter 5°F per day |
Burnham ALP105 boiler troubleshooting
| CONDITION | POSSIBLE CAUSES |
|---|---|
| Display Blank, Fan off, LWCO lights off | • No 120VAC Power at boiler. Check breaker and wiring between breaker panel and boiler |
| Display Panel Blank, Fan running | • Loose I20VAC connection wiring between boiler J-Box and MCBA • Blown “FI” fuse in MCBA (see Figure 58 for location). Replace with 5A fuse provided |
| Display reads MIJ. 125" continuously, Fan running | • Defective AT250 transformer • Blown MF3" fuse in MCBA (see Figure 58 for location). Replace with 4A slow-blow fuse provided |
| Boiler not responding to call for heat, Status code on display ="0" (see Figure 50) | • Boiler is not seeing call for heat. Check thermostat or zone wiring for loose connection, miswiring, or defective thermostat/zone control. |
| Boiler fires, but display panel is blank | • Loose ribbon cable • Defective display |
Burnham ALP105 – 2 boiler troubleshooting
| CODE | CONDITION | POSSIBLE CAUSES |
|---|---|---|
| b 08 | Pressure switch circuit open | • Blockage in intake or vent system. • Vent and/or intake system not constructed in accordance with Part VI. • Blocked or leaking pressure switch tubing • 1 leat exchanger or burner blockage • Terminals exposed to high winds • Blockage in condensate trap above vent. |
| b 18 | MCBA supply sensor detected temperatures in excess of200®F | • Heating load at time of error was far below the minimum firing rate of the boiler • Defective primary pump or no flow in primary loop (Piping Method 1) • Control system miswired so that boiler operation is permitted when no zones are calling |
| b 19 | MCBA return sensor detected temperatures in excess of200°F | • See possible causes for Mbl8” • Flow through boiler reversed • Sensor wiring reversed |
| b 24 | MCBA is reading a return sensor temperature higher than the supply sensor temperature. Condition must be present for at least 75s for this error code to appear. | • Flow through boiler reversed. Verify' correct piping and pump orientation. • No boiler water flow. Verify1 that system is purged of air and that appropriate valves are open. • Sensor wiring reversed. • Supply or return sensor defective. |
| b 25 | Supply water temperature has risen too quickly | • See possible causes for Mbl8” • Inadequate boiler water flow. Verify' that pump is operating and that pump and piping are sized per Part VIII of this manual |
| b 26 | Boiler safety limit, or external limit wired across terminals 3&4, is open. | • See possible causes for MbI8” • Defective supply sensor. |
| b 30 | Temperature rise between supply and return is too high. | • Inadequate boiler water flow. Verify' that pump is operating and that pump and piping are sized per Part VIII of this manual |
| b 61 | Pressure switch circuit closed with fan off | • Blockage in pressure switch hose • Pressure switch wires shorted together • Defective pressure switch • Loose or miswired fan speed harness (if Mb61" error code is observed while fan is running) |
| b 65 | Fan is not achieving set point speed | • Loose or incorrect fan speed control connection • Defective fan |
| E 00 | A flame signal was present when there should be no flame. | • Defective gas valve - make sure inlet pressure is below maximum on rating plate before replacing valve. |
| E 02 | Flame failure after 5 tries to restart | • No gas pressure • Gas pressure under minimum value shown on rating plate • Gas line not completely purged of air • Defective Electrode • Loose burner ground connection • Defective Ignition Cable • Defective gas valve (check for 24 VDC at harness during trial for ignition before replacing valve) • Air-fuel mixture out of adjustment - consult factory |
| E 03 | Gas valve error | • Loose or defective gas valve harness. Check electrical connections. • Defective gas valve (check for 24 VDC at harness dunng trial for ignition before replacing valve) |
| E 04 | Power failure occurred after lockout | • Some other error on this list occurred and power to the boiler was then interrupted. Reset control and see if hard lockout reoccurs. |
| E 05 E 06 E 07 E 11 | Internal control failure | • Reset the control. If problem reoccurs, replace the MCBA. |
| E 12 | Low water cut-off circuit open | • If yellow light on LWCO is on. system is low on water • If neither yellow nor green light is on. check LWCO harness and check for 24VAC across AT140 transformer |
| E 13 E 14 E 15 E 16 E 17 | Internal control failure | • Reset the control. If problem reoccurs, replace the MCBA. |
| E 18 | MCBA supply sensor detected temperatures in excess of200°F for an extended period of time | • See possible causes for t18" error. Also, check safety limit for proper operation. |
| E 19 | MCBA return sensor detected temperatures in excess of 200eF for an extended period of time | • See possible causes for T>19" error. |
| E 28 | Blower is not running when it should or fan speed signal not being detected by MCBA | • Loose connection in 120 VAC fan wiring • Loose or miswired fan speed harness • Defective fan |
| E 29 | Blower fan speed has not returned to zero rpm | • Miswired fan speed harness • Defective fan |
| E 31 | Shorted suppfy temperature sensor | • Shorted or miswired supply sensor wiring • Defective supply sensor |
| E 32 | Shorted return temperature sensor | • Shorted or miswired return sensor wiring • Defective return sensor |
| E 35 | Flue gas temperature sensor short circuit | • Shorted or miswired flue temp sensor wiring • Defective flue temp sensor |
| E 36 | Supply water temperature sensor circuit open | • Loose or miswired supply sensor wiring • Defective supply sensor |
| E 37 | Return water temperature sensor circuit open | • Loose or miswired return sensor wiring • Defective return sensor |
| E 40 | Flue gas temperature sensor circuit open | • Loose or miswired flue temp sensor wiring • Defective flue temp sensor |
| E 44 | Internal control failure | • Reset the control. If problem reoccurs, replace the MCBA. |
| E 52 | Flue gas temperature over 230°F | • Heat exchanger needs to be cleaned • Boiler over-fired • Air-fuel mixture out of adjustment - consult factory |
| E 60 | Internal control failure | • Reset the control. If problem reoccurs, replace the MCBA. |