Burnham 3 IQ control acting strange

inspkerr · October 28

Hello

I just installed a series 3 with I Q controls - they are new to me , I'm used to older boilers . I've studied all the modes and made adjustments as needed. I have a heat exchanger that makes domestic hot water with its own circ.pump , the boiler provides voltage that runs this circ. no mater what i change in the programing i cant get the DHW circ. to run. The boiler is also short cycling , it has an optional card you plug in that controls DHW and outside reset , I did get an error code of 89 on the lower board where you plug in the cards that means communication error - loose wire between IQ option panel and IQ boiler control . I'm not getting any error codes in the upper boiler control other than 17 this means self test , it cycles through- call for heat -damper open sometimes starts for a short time shuts down then shows 17, what's also strange is there is a operating mode status you can view with a TT option that shows a call for heat - it shows off or on , even when there is a call for heat it sometimes shows off, Does Anyone have experience with this system ? any help would be appreciated , Thanks - Paul

HVACNUT · October 29

Burnham TS- 888-432-8887

109A_5 · October 29

" I did get an error code of 89 on the lower board where you plug in the cards that means communication error - loose wire between IQ option panel and IQ boiler control. "

If error 89 still exists I would suspect the Outdoor Reset and the DHW functions would not work. Since the data that card provides is not being passed on to the Boiler Control via the EnviraCOM network. I'd check the all the connections between the option card, the IQ panel and the boiler control board for bent or misaligned pins or connectors not properly seated or misaligned.

inspkerr · October 30

thank you , been in conversation with burnham rep , thanks for there number very helpful but busy with questions. All connections and pins look good , i can get it to fire but wont come up to set temp. I’ve removed the DHW wiring connections but still behaves the same , rep told me to ceck pilot flame voltage and it seems fine around 10 milliamps , circ. Runs when it does fire but drops out after burner does , no error codes just a 17 self test after cycle thermostat is constantly calling but circ drops out after cycle , have the damper locked open to speed things up with call for heat it sometimes spins a full circle - crazy , I’m at a loss will try the tech reps again , circ is moving water well and no air in system .Thanks for your help - Paul

109A_5 · October 30

If you jumper it like this will it run longer ? Any pictures of the system ? Its amazing how sometimes pictures help.

109A_5 · October 30

If you have a multimeter, using the AC volts function and the boiler's wiring diagram in the I/O manual it would probably make short work of the control / limit circuit troubleshooting.

109A_5 · October 30

By back probing the wiring harness connectors pins at the Boiler Control connectors (the Red arrows are some examples) the issue (if any) with control / limit circuit can be isolated. I believe the Green arrow points to the contact that is controlled by the thermostat and the contact at the Orange arrow is controlled by logic and the Flame Sense.

inspkerr · October 30

Great minds working in the same direction, Tec support had me jumper those out through a molex plug off the board. still did the same thing - not coming up to set point or even close - I realize outdoor temp will have a factor in this , short cycle - cuts out at 120 degrees - outside temp in lower 50s . and circulator drops when flame goes out, rooms still calling for heat, then - restarts , sometimes it fires for 15 seconds, next time a little longer, will try to post some pics. thanks, you guys any suggestions appreciated - Paul

109A_5 · October 31

To me you have to isolate the cause of it dropping out. Knowing what it is not can help also. Like if the voltage at P6-2 is consistently present as long as there is a call for heat and after the flame drops out.

In another direction the Boiler Limit temperature sensor could be flaky or its cable compromised.

Once it drops out (with a call for heat still present) is the time for it to restart consistently about the same ?

inspkerr · October 31

it seems restart is somewhat consistent - 5min. I will time it, when it does fire it may shut right back down or run for s couple min. and shutdown then repeat, Tec. help thinks it's the main boiler control board. He had me jumper across the molex plug p-7 on the option panel it bypass flame roll out and vent switch … still behaved the same, but after looking at the wiring diag. I see what you are saying, this did not test p-7 on the boiler control he had me doing so many things, I can't remember if we checked that , you mentioned voltage at p-6 -2 are you referring to p-6 on the boiler control that relates to the vent damper - I have that locked open, or p-6 on the option panel ? Thanks for your help - Paul

109A_5 · October 31

P6 is the damper connector to the control board, P6 is the connector designation the '2' in P6-2 is the pin number. I don't like guessing, sure it could be main boiler control board or it could be a bad wire to pin crimp it could be bad male to female pin fitment issue, it could be a flaky end switch in the damper… on and on. By making strategic AC Volt meter measurements during the failure event the actual cause can most likely be pin pointed and the defective part or wire connection determined then repaired or replaced. It it all about the reason it is actually failing. Changing the most expensive part first (main boiler control board) is just not my style. For all I know from here it could be a bad Gas Valve, see what I mean ? Thorough, logical, strategic troubleshooting for the win. Guessing often wastes time and money.

Burnham 3 IQ control acting strange

Comments

Categories