HydroTherm MultiPulse AM Series Troubleshooting Manual Download Page 1

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AMP8-1203

AM SERIES PULSE BOILER

TROUBLESHOOTING GUIDE

FOR CERTIFIED CONTRACTORS ONLY

5211 CREEKBANK ROAD
MISSISSAUGA, ONTARIO L4W 1R3 CANADA
(905) 625-2991 • FAX (905) 625-6610

260 NORTH ELM STREET
WESTFIELD, MA 01085
(413) 568-9571 • FAX (413) 568-9613

Summary of Contents for MultiPulse AM Series

Page 1: ...PULSE BOILER TROUBLESHOOTING GUIDE FOR CERTIFIED CONTRACTORS ONLY 5211 CREEKBANK ROAD MISSISSAUGA ONTARIO L4W 1R3 CANADA 905 625 2991 FAX 905 625 6610 260 NORTH ELM STREET WESTFIELD MA 01085 413 568 9...

Page 2: ...r on start up 25 b Combustion operating noise 26 c Vibration noise 27 d Objectionable exhaust noise 27 e Objectionable localized 28 SECTION 3 SERVICING REPAIR PROCEDURES Service Tools List 29 Fan Pres...

Page 3: ...of the Combustion Prove Switch PS1 contacts N O NORMALLY OPEN On AM 150 the blocked inlet switch PS3 contacts N C NORMALLY CLOSED are also checked If the PS1 contacts are OPEN and the PS3 contacts AM...

Page 4: ...ction for additional sequencing details AUTOMATIC RESTART FEATURE The GC 4A ignition control is equipped with an automatic reset feature If the control completes an ignition sequence 5 attempts for ig...

Page 5: ...5 FIGURE 1 AM 100 SCHEMATIC LADDER WIRING...

Page 6: ...6 FIGURE 2 AM 150 SCHEMATIC LADDER WIRING DIAGRAM...

Page 7: ...7 FIGURE 3 AM 300 SCHEMATIC LADDER WIRING DIAGRAM...

Page 8: ...ights the burner Do not try to light the burner by hand 5 Turn gas control knob clockwise to OFF Do not force 6 Wait 5 five minutes to clear out any gas Then smell for gas including near floor If you...

Page 9: ...this check Rocker Switch With a voltmeter check for 115V If no 115V operate switch If no On AM 100 150 terminals 3 4 115V check wiring to switch On AM 300 terminals 2 3 If ok replace switch If 115V bu...

Page 10: ...ttings are proper replace limit If lights remain OFF high limit is OK Transformer Rocker Switch ON With a voltmeter If no 24V replace transformer check for 24V across T T terminals to ground If 24V tr...

Page 11: ...reen leaving the module If GC 4A light remains OFF proceed with this check POSSIBLE CAUSE VERIFICATION SOLUTION Wiring Check if green ground wire from If screw is loose secure screw If GC 4A is secure...

Page 12: ...er Switch ON is blinking Pressure Switch is is factory set at 5 W C wait 3 min 45 sec defective Replace switch If GC 4A remains ON Pressure Switch is ok Reconnect purple wire and proceed with check Bl...

Page 13: ...tion and use one of the two procedures below MODEL NO MINIMUM FAN PRESSURE PS2 AM 100 150 1 4 W C AM 300 0 8 W C 1 If measured fan pressure exceeds the minimum for fan prove switch PS2 operation POSSI...

Page 14: ...ecure on shaft not remove obstructions rubbing against housing and free from obstruction If ok proceed with verification AM 300 Blocked Air Inlet Check for obstructions in air supply If obstructed rem...

Page 15: ...ube for breaks Chamber G C C valve at the GCC valve plate on the plate to Combustion AM 300 at the fitting on the ACC Prove Pressure Switch PS1 wall Check unions are tightly connected Pressure Switch...

Page 16: ...OFF and If no 24V no green light check 24V ON After 35 seconds with a wiring If intact and secure replace voltmeter check for 24V across the GC 4A gas valve terminals MV MV If read 24V green light OF...

Page 17: ...on head of boiler Jumper Fan If plug shows carbon tracks or Prove Switch PS2 Turn Rocker excessive carbon deposits clean Switch ON and observe the spark plug and proceed with check during the ignition...

Page 18: ...examine exhaust line and Rocker Switch ON Observe the fan terminal for blockage pressure at the condensate drain ECC chamber pressure On the AM 150 only If the pressure is 0 2 W C or less recheck the...

Page 19: ...ng position turn Rocker restriction including inlet air orifice Switch ON gas OFF Observe fan located in inlet adapter on AM 300 operation and direction of rotation See FIG 7 DO NOT LUBRICATE MOTOR If...

Page 20: ...k condensate drain and exhaust line for partial blockage Check GCC gasket for crimps or If crimps carbon trails replace carbon trails gasket following instructions with replacement If ok proceed with...

Page 21: ...mal drainage Circa 1994 boiler and later are equipped with gas valves which do not have replaceable regulators These 5 yr tune up kits do not include a replacement regulator CONDITION 3B BOILER SHORT...

Page 22: ...as required inspect drain valve and bushing attachment for wetness Pipe Connections Check supply return water Tighten or replace as necessary connections to boiler O Ring ECC Remove lower jacket pane...

Page 23: ...Relief valve discharge should be piped to floor drain CONDENSATE DRAINS AFTER BOILER SHUTS OFF NOTE It is not unusual for condensate to drain from boiler for several minutes maximum of 15 minutes aft...

Page 24: ...dy Hum like a muted motor sound when listening closely at exhaust terminal OBJECTIONABLE NOISE START UP CHARACTERISTICS Typically requires adjustment or changes to the boiler installation If uncorrect...

Page 25: ...e repair it Inlet Orifice inlet adapter is intact not loose Follow Disassembling AM 300 or broken Drain hole must be clear procedure described in this manual See Procedures section Fig 7 for detail If...

Page 26: ...as necessary Jacket Access Panel that insulation is in place Air Cushion Chamber A C C Lid A C C Lid Gasket Turn Rocker Switch gas valve top If gasket has gaps tears etc knob OFF Check if lid is secu...

Page 27: ...reduction permanently attach the check Exhaust piping CPVC one foot extension you have added SCH 40 length should not exceed installation limitations The sound you are hearing may be the normal operat...

Page 28: ...under Procedures section Replace jacket panel Gasket between Boiler With the boiler running for 5 minutes If noise hot spot is suspect remove Economizer check boiler sides rear about 15 jacket insula...

Page 29: ...rn boiler Rocker Switch and gas valve top knob OFF 2 Locate the plastic tube connecting the Fan Prove Pressure Switch PS2 to the 3 16 barb tee on the boiler Disconnect the plastic tubing from either t...

Page 30: ...st line from the flue box 3 Clean the bottom portion of the CPVC adaptor that s in contact with the flue box of any old silicone material 7 Turn the gas supply OFF at the up stream service valve befor...

Page 31: ...he bottom The orifice may be slightly tilted when installed 5 Secure orifice in place with PVC cement Replace fan assembly in boiler Reassemble boiler lid and panel and turn gas ON Restart boiler afte...

Page 32: ...AP LINE PRESS TEST PLUG FOR DETAIL SEE FIG 6 AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA A A MANIFOLD PRESS TAP GAS VALVE GAS INLET U TUBE MANOMETER FOR DETAIL SEE FIG 6 A A MANIFOLD PRESS TAP G...

Page 33: ...art to break the O ring seal Place the top portion of the boiler on it s side taking care not to damage the jacket or electric box 4 Check the bottom head of the boiler and remove any remnants of the...

Page 34: ...ACC rear outside wall See fig 7 4 Remove the boiler from the installation and locate it for further disassembly 5 Remove the jacket form the boiler as follows retain all screws for reuse Refer to fig...

Page 35: ...to hold the gasket on the plate edge 3 Lay an approximately 4 piece of the 1 4 square braided gasket next to and overlapping the butt joint Use high temperature silicone RTV to hold in place c Place D...

Page 36: ...disconnected from the boiler a Use the new flue box gasket and follow directions supplied to reattach the flue box b To reconnect the air inlet adapter clean the old silicone from the ACC s inlet ada...

Page 37: ...amber ACC a Remove the 4 1 4 nuts securing the top lid Lift off the lid and the spring and set them aside b Lift the fan assembly disconnect the motor leads Remove assembly and set aside c Disconnect...

Page 38: ...high limit well gas lines gas valve and the air intake and exhaust adapter Warning Do not over tighten plastic threaded adaptors Install the high limit 12 Mount the electric box and secure it to the j...

Page 39: ...TTERS OR STOPS BEFORE GREEN LIGHT GOES OUT YES NO ON OFF BLINKING ON OFF BLINKING MPTS 44 YES NO ON OFF NO YES USE SPARK PLUG CHAMPION FI 21503 DO THE FAN PROVE PS2 SW CONTACTS CLOSE WHEN FAN OPERATES...

Page 40: ...1 2 NPT Male to 2 Socket PVC Adapter 56 3040 1 3 Male PVC Inlet Adapter w Locknut BM 7155 1 8 Gasket Air Cushion Chamber BM 7192 1 12 Gas Supply Tube NG BM 7112 1 Gas Supply Tube NG BM 7154 1 Gas Sup...

Page 41: ...Trap Ass y LP BM 7088 1 23 Ignition Wire Ass y BM 7157 1 24 Repl Pressure Sensing Tube BM 7158 1 28 Seal UChannel BM 7127 1 Seal U Channel BM 7214 1 29 Heat Exchanger 30psi BM 7111 1 Heat Exchanger 10...

Page 42: ...M 7162 1 60 Junction Box w Terminal Strip 4 x 4 BM 7163 1 61 Indicator Lamp Red BM 7232 1 1 1 62 Indicator Lamp Green BM 7233 1 1 1 Silicone Sealant 11 oz 10 6631 1 1 1 Urethane Tape 4 ft long BM 7137...

Page 43: ...ap Screw St Stl 1 4 x 20 x 1 LG 57 2907 4 81 900 Elbow 1 2 FPT to 1 2 Comp NG LP 56 5515 1 900 Elbow 1 2 FPT to 5 8 Comp NG 56 5516 1 900 Elbow 1 2 FPT x 1 2 FPT 56 3303 1 82 Connector Flare 1 2 NPT x...

Page 44: ...nel BM 7169 115 Jacket Side Panel Right BM 7173 116 Jacket Side Panel Left BM 7172 Touch Up Spray Paint Kit 60 2852 60 2852 60 2852 Repl Piping Tree Kit 30psi 2 BM 7224 Repl Piping Tree Kit 100psi 2 B...

Page 45: ...A AA 31 29 78 85 74 84 21 18 20 17 12 83 22 6 3 2 68 68 70 70 69 69 72 73 76 77 14 71 66 67 64 15 86 75 104 105 106 107 108 46 4 1 16 28 30 81 82 7 32 34 65 35 13 19 A 79 67 FIGURE 9 GENERAL ASSEMBLY...

Page 46: ...FIGURE 10 MODEL AM 100 CONTROL PANEL FIGURE 11 MODEL AM 150 CONTROL PANEL 97 49 94 47 98 63 53 57 99 52 48 95 50 96 54 55 58 61 62 51 53 57 63 94 50 96 95 61 62 49 97 47 54 55 52 99 58 48 3 2 1 1 2 34...

Page 47: ...4 1 12 86 15 14 85 88 23 5 21 4 83 87 7 89 64 AAA AAA 53 77 92 2 24 83 6 65 66 71 72 76 17 18 20 37 30 80 8 29 36 68 39 38 32 33 34 40 84 19 67 75 42 93 A 79 67 1 60 59 57 91 47 58 50 84 95 94 54 55...

Page 48: ...5211 CREEKBANK ROAD MISSISSAUGA ONTARIO L4W 1R3 CANADA 905 625 2991 FAX 905 625 6610 260 NORTH ELM STREET WESTFIELD MA 01085 413 568 9571 FAX 413 568 9613...

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