Hurlcon / Astralpool Gas Heater Faults & Fixes - HX JX MX HINRG VIRON ICI

Astralpool & Hurlcon Gas Heater Error Codes:

• F0 - Heater locked off. Can't read temperature. Reset Power. May have faulty temperature sensor.
• F1 -  Thermostat reads very high temperature. Allow water to cool.  Check filters are clean and there is sufficient water flow. Cycle mains power to reset. May have faulty temperature sensor.
• F2 - Heater has gotten too hot.  Check filters are clean and there is sufficient water flow. Wait several minutes for water to cool. Cycle mains power to reset. If error re-occurs, replace Hi-Limit Switches, and brass plugs. 
  • Inlet High Limit 45° (choose threaded or non-threaded types.)
  • Outlet High Limit 52-55° (choose threaded or non-threaded types.)
  • Threaded Brass Plug
• F3 - Temperature fault. Cycle mains power to reset.  
• F4 - Flame roll-out detected. This means the flames have been detected outside the burner area. If this occurs do no re-light heater. Turn off gas.  Often caused by a blocked heat exchanger, corrosion or other reason for flames not to be contained within the firebox.
• F6 - Heater Burning too hot. Or Failed Flue High Limit.
• F7 - Condensate tank limit. Cycle power to reset. Condensate tank may be corroded, or heat exchanger breaking down. Often the sign of end-of-life of a Viron heater.
• F8  - Commonly caused by faulty temperature sensor in the heat exchanger.
• F9 - High temp in heat exchanger. Blocked Heat Exchanger or High combustion temps. Heater needs dismantling to inspect. 
• L -  Heater locked out. Heater has tried to ignite too many times. It will automatically retry after 2 minutes.  This allows combustion gases to escape before retrying. If it re-occurs, it may be faulty flame sensor, igniter, ignition module, blown burner, bad heat exchanger, etc.
• Q or Ø - Heater is detecting water pressure, and is ready to ignite when temp is below set-point.  If this symbol is not appearing, when pump is running, check that filters are clean, valves are in correct positions, or replace a faulty pressure switch. 
• * - Igniting. Spark or Hot Surface Ignitor (HSI) are trying to light. 
• ^ - Flame Detected. Heater operating. Symbol looks like an upside-down V.
• Heater Rumbling. Gas supply pressure is out of spec or heat exchanger fault.  Turn off Heater. Needs gas pressure adjusted, or other issues.
• Smoke coming from heater. Turn off heater immediately. Turn off gas.  Do not use heater.
• Water coming from heater. See below.

MORE INFORMATION:

HX 70 / HX 120 / JX 130 / JX 160 Common Faults & Fixes Here

Hurlcon Astralpool Viron & ICI Issues:
Due to the Viron heater's extreme efficiency, they can have a few more tedious problems, similar to higher-end cars.  We see many issues caused by water & gas supply. We've listed some symptoms and causes below. Note that some symptoms can be caused by more than one thing. 

 Symptoms of Gas Supply Issues:
- sooting heat exchanger
- burnt heat exchanger
- rumbling or whining of heater
- blocked condensate tank

Symptoms of water issues:

- corroded brass plugs & sensors
- corroded or overheated heat exchanger
- blocked heat exchanger
- leaking manifolds
- leaking heat exchangers

Symptoms of water flow issues:

- overheated, burnt heat exchangers
- leaking manifolds
- boiling / banging / whistling of the heater

Symptoms of air supply issues:
- blocked condensate tank
- damaged heat exchanger fins
- damaged firebox insulation
- damaged blower assembly

MX 125 thru 500 Issues:

MX heaters, being based on older Minimax heaters, were a basically robust burning system. 

Early models were let down by plastic manifolds that warped, and a mild steel tube end plate. Poor water quality accelerated corrosion and warping. We see many MX heaters that have leaked over time. It's best to have these assessed in person.