Gradient syncFURNACE mOD-200 - Troubleshooting; Fault Codes and Corrective Actions

syncFURNACE OD Instruction & Installation Manual – Rev 09 Pg. 62 of 81
11. TROUBLESHOOTING >
syncFURNACE OD has built in fault protection. Below is a list of the fault codes built into the controller
and the corrective action required to place the product back into normal operation. Note: the controller
screen color will turn red when a fault has occurred.
Potential Fault Codes:
Code #
Description
Lockout Type
ALM 1
No RPM from Comb Blwr @ Startup
Lockout – Manual Heat Demand Reset Only
ALM 2
Unstable Comb Blwr RPM
Lockout – Manual Heat Demand Reset Only
ALM 3
No Power @ Ignition (Hi-Limit Safety Open)
Lockout for 1hr, Auto Reset – Max 3 Trials per
Day, Reset Daily
ALM 4
Ignition Mod Lockout – Burner Fail to Ignite
Lockout for 1hr, Auto Reset – Max 3 Trials per
Day, Reset Daily
ALM 5
Flame Failure During Burner Operation
Lockout for 1hr, Auto Reset – Max 3 Trials per
Day, Reset Daily
ALM 6
Flame Detected After Gas-Valve Shut-off
Lockout – Manual Heat Demand Reset Only
NO
FLOW
No Flow Detected After Demand Turned On
Lockout – Manual Heat Demand Reset Only
LOW
PRES
Low Water Heater Fluid Pressure Detected
Lockout – Demand Reset Only When Water
Heater Fluid Filled & Re-pressurized
Code #
Corrective Action
ALM 1
1. Check for partially or fully blocked chimney system
2. Check wiring at combustion blower, verify both low voltage control & main power
3. Identify & replace failed component – wiring, combustion blower and/or controller
ALM 2
1. Check for partially or fully blocked chimney system
2. Check wiring at combustion blower, verify both low voltage control & main power
3. Identify & replace failed component – wiring, combustion blower and/or controller
ALM 3
1. Identify which/if high-limit safety has opened – verify wire harness continuity –
**NOTE: safeties are connected to HIGH VOLTAGE LINE (115Vac)**
a. Vent Limit Switch – Heat exchanger temperature above switch setpoint –
Switch is NOT resettable, DO NOT BYPASS – Heat exchanger must be
replaced – Contact Gradient Thermal Inc.
b. Water Supply Hi-Limit Switch – Actual supply water temperature above switch
setpoint – Hi-Limit switch will auto-resets once temp drops 10°F below
setpoint
c. Condensate Trap Pressure Switch – Undersized drain or partial or full trap
blockage
2. Corrective action for limit switch –
a. Vent Limit Switch – Contact Service/Repair Contractor & Gradient Thermal
Inc.
b. Water Supply Hi-Limit Switch –
i. Check for pump(s) failure
ii. Check combustion blower, does it only run at MAX speed?
iii. Check the load of the heating zone, is the installation sized properly?
iv. Check pressure and supply sensor for failure
c. Condensation Trap Pressure Switch –
i. Ensure proper size & slope of condensation drain
ii. Check internal condensation trap for partial or full blockage
iii. Clean trap and remove all blockages from heat exchanger outlet to
floor drain
iv. Test and visually inspect to ensure free flowing condensate to drain
3. If all safeties are closed and not receiving power, check controller to see if its
applying power to the safety line / ignition module as per internal wire diagram.
4. Verify function of ignition module and flame sensor / spark ignitor