Product Manual
05/19/2016 16 BI514
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 – 1 blink every second
- ST sensor – 2 blinks every second
- Both bad – 3 blinks every second
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.
- WF-ANZ* – Handheld/Analyzer
- ET-SOFT-HTG – PC 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 (if you’re using the outdoor reset configuration). 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.
7. Use general heating system logic information and basic understanding of the terminal block wiring
functions measure various voltage points to determine proper operation.
8. Acquiring the PC software with serial port hookup cable is a positive tool for understanding and
troubleshooting the WarmFlo controller. Either test set device can display all temperatures, real time
evaluation of WarmFlo functions and provide temperature offsets for assimilating winter conditions.
Sensor Temperature Calibration - Both remote sensors are digital electronic and factory calibrated.
Normally these do not require field calibration or verification. However, if sensor temperature error is
determined, there are two field calibration techniques. Proceed with extreme caution.
1. The outdoor sensor (OT) can be calibrated with ice (32F). This is not a checking temperature
situation. If you proceed with this function, the sensor automatically goes to 32F. Notice a small
push button next to the sensor terminal block, with the sensor at 32F, push and hold for
approximately ten seconds. When the green LED next to the fuse “blinks” at you, release and now
the outdoor sensor is set at 32F.
2. Use PC software to calibrate sensor. See other paragraphs.