Came home to a cold electric boiler, Thermolec B-23U-FFB

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Patrick T

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Good day, first time poster

I have a Thermolec B-23U-FFB, installed 10 years ago. It has worked perfectly heating our radiant floor system. The system is independent and not tied in with a back up. lucky for us, we have a heat pump for our AC cooling needs and it is now heating the house fine.

I made sure the two 60 A breakers in the service panel had not tripped. The two 60 A breakers in the heater had not tripped either.

I saw on line I should check the Manual Reset cutout on the tank. I pushed the center red button and it did click and needed to be reset. Power it back up and still nothing.

Per Thermolec's Trouble shooting guide, "Call for Heat and boiler doesn't start, no lights on circuit board. Try the following;

I checked the 240V/24 V transformer at 24 V side, no voltage.
I checked the 240V/24 V transformer at 240 V side, no voltage.
I checked the breaker that the transformer taps into, 240 V supply side, zero V Line side.
Shut power off, disconnected all cables to that breaker, one pole showed continuity, other pole did not!

Clearly a bad breaker. What caused the Manual Reset to trigger? Did this cause the breaker to fail?

Next potential steps;

Move the one good breaker to the side that powered the 240V/24 V transformer and power up system to see if the circuit board lights up and starts heating.

if yes, Watch carefully to see if the temperature stays at the 105 F set point. This may take a while due to now cold slabs. (or lower room T-stats to just heat one smaller loop.". If it does heat and the heat is limited=done.

If the heat continues to rise, check SSR1's for stuck contacts?

My questions;

is it OK to perform this test above with just one breaker? Only half of the 4 heating elements would be able to operate
Is it common to see one pole go bad in a two pole breaker?
What would cause the Reset device to trigger, a bad temp sensor on the tank? can I test the sensor?

thank you for any help,

Patrick
 

Patrick T

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Fitter30

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Think the heater is full of minerals. Minerals are a insulator. Odd that the breaker went bad they reset pushing the handle far to the off position.
 

Patrick T

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Think the heater is full of minerals. Minerals are a insulator. Odd that the breaker went bad they reset pushing the handle far to the off position.
it's a closed loop system, mineral content is from very little water. Just one pole was found bad, not both. A tripped breaker would be both poles
 

Fitter30

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it's a closed loop system, mineral content is from very little water. Just one pole was found bad, not both. A tripped breaker would be both poles
Double breaker with a tie bar between the two will trip both on one pole see hi amps. Contactor contact above 2 vac is bad across them.
 

Patrick T

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Double breaker with a tie bar between the two will trip both on one pole see hi amps. Contactor contact above 2 vac is bad across them.
This breaker is not a standard double pole breaker you find in a service panel. This type is a part of the boiler. It does not have two breakers with a tie bar. It's a Square D QOU 620 with a single lever to open close. Often used in HVAC equipment

In any case, I changed the breaker and it works now.
 

Fitter30

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Your breaker looks like it's a oem breaker their catalog doesn't recognize that breaker number. Which is normal. Being a oem breaker it could be built with different specs than a catalog breaker.
 

Patrick T

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All was working fine for a while but this morning I heard a buzzing sound. I think it's one of the (4) relays that run the (4) heating elements. I shut the breakers off for 10 min. Turned them back on and it's running again.
 

Fitter30

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All was working fine for a while but this morning I heard a buzzing sound. I think it's one of the (4) relays that run the (4) heating elements. I shut the breakers off for 10 min. Turned them back on and it's running again.
Check all the electrical connections for tightness.
 

Patrick T

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All connections tight. Thermolec tech support said relays do go out. I replaced the two relays that were fed by the bad breaker. two more on order.

Working again and quite
 
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