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10

FAULT AND ALERT CODES

FAULT AND ALERT CODES

1. LOW GAS PRESSURE

The minimum gas supply pressure is measured while gas is flowing (dynamic pressure) along with all additional gas appliances 

operating on the same gas supply system. Cyclone XL water heater can operate smoothly when gas supply pressure is as low as 3.5” 

WC dynamic for natural gas and 8.0” WC dynamic for LP models. There is no low gas pressure switch installed to the heater. If the gas 

supply pressure is below the minimal as indicated on the heater rating plate, issues such as ignition failure, rough ignition and so on 

may arise.

CHECK/ REPAIR:

• 

Determine proper minimum pressure from rating plate. 

• 

Use manometer or gauge to check gas pressure during all stages of operation with all other appliances firing. 

• 

If pressure falls below rating plate requirement, supply pipe may be too small for application or supply regulator may be operating 

improperly. See Gas Pressure section below.

HIGH ALTITUDE

The water heaters covered in this Service Handbook are certified for elevations up to 10,100 feet (3,078 meters). For higher elevations 

call the toll free support phone number shown on the back cover of this Service Handbook for technical assistance.

GAS SUPPLY SYSTEMS

Low pressure building gas supply systems are defined as those systems that cannot under any circumstances exceed 14” W.C. (1/2 

PSI Gauge). These systems do not require additional pressure regulation. Measurements should be taken to insure that gas pressures 

are stable and fall within the requirements stated on the water heater rating plate. Readings should be taken with all gas burning 

equipment off (static pressure) and with all gas burning equipment running at maximum rate (dynamic pressure). The gas pressure 

supplied to this unit must be below the maximum and above the minimum pressures listed on the unit’s rating plate and must not drop 

more than 1.5” W.C. when unit is operating at the high fire rate along with all additional gas appliances operating on the same gas 

supply system. Pressure drops that exceed 1.5” W.C. may cause rough starting, noisy combustion or nuisance outages. Increases or 

spikes in static pressure during off cycles may cause failure to ignite or in severe cases damage to appliance Gas Control Valves. If 

your low pressure system does NOT meet these requirements, do not operate this unit. The installer is responsible for ensuring that the 

gas supply pressures meet the requirements described above and listed in the table. Failure of the gas supply to meet these 

requirements is not covered under the warranty.
High Pressure building supply systems use pressures that exceed 14” W.C. (1/2 PSI Gauge). These systems must use field supplied 

regulators to lower the gas pressure to less than 14” W.C. (1/2 PSI Gauge). Water heaters require gas regulators that are properly sized 

for the water heater’s BTU input and capable of delivering the rating plate specified pressures. Gas supply systems where pressure 

exceeds 5 PSI often require multiple regulators to achieve desired pressures. Systems in excess of 5 PSI building pressure should be 

designed by gas delivery professionals for best performance. Water heaters connected to gas supply systems that exceed 14” W.C. 

(1/2 PSI Gauge) must be equipped with a gas supply regulator capable of preventing the gas supplied to the unit from exceeding 14” 

W.C. under any upstream supply pressure or condition.

SUPPLY GAS REGULATOR

The maximum allowable gas supply pressure for the water heaters covered in this Service Handbook is 14.0 inches W.C. (3.49 kPa) 

static for natural and propane gas. Install a positive lock-up gas pressure regulator in the gas supply line if inlet gas pressure can 

exceed these pressures at any time. Regulators must be sized to equal or exceed the BTU input requirements of the heater model and 

installed, used, and maintained according to manufacturer’s specifications.
If a positive lock-up regulator is installed follow these instructions:

1. 

Positive lock-up gas pressure regulators must be rated at or above the input Btu/hr rating of all the gas appliances that are on the same 

system as the water heater.

2. 

Supply gas regulators shall have inlet and outlet connections not less than the minimum supply gas line size for the water heater they 

supply.

3. 

Refer to the gas pressure regulator’s manufacturers installation instructions to determine its installation location requirements.

4. 

After installing the positive lock-up gas pressure regulator(s) an initial nominal supply pressure setting of 7.0” W.C. (1.74 kPA) for 

Natural Gas and 11.0” W.C. (2.74 kPA) for Propane (LP) while the water heater is operating is recommended and will generally provide 

good water heater operation. Adjustments to the regulator maybe required to maintain a steady gas supply pressure.

5. 

When installing multiple water heaters in the same gas supply system it is recommended that individual positive lock-up gas pressure 

regulators be installed at each unit from the supply gas connection on the water heater.

Содержание Cyclone XL 100 Series

Страница 1: ...ED BY A QUALIFIED SERVICE TECHNICIAN PRINTED 0220 100314732 2000568400 Rev A Service Handbook COMMERCIAL GAS WATER HEATERS COMMERCIAL GAS WATER HEATERS MODELS BTHS 750A 1000A SERIES 100 101 INSTALLATI...

Страница 2: ...21 13 Flow Switch Stuck Closed 22 VENTING 24 General Venting Information 24 INTAKE AIR CONNECTION 25 ELECTRICAL CONNECTIONS ALL MODELS 26 Power Fluctuations and Electrical Noise 26 Dedicated Power Wir...

Страница 3: ...procedures described in this service handbook If you do not understand the instructions given in this service handbook do not attempt to perform any procedures outlined in this service handbook SERVI...

Страница 4: ...charged from the valve due to excessive pressure build up This condition is not covered under the limited warranty The Temperature Pressure Relief Valve is not intended for the constant relief of ther...

Страница 5: ...e module The UIM includes the display circuit board and the control system s LCD Touch Display Used to adjust various user settings and view operational information 3 Central Control Board CCB enclosu...

Страница 6: ...red non sacrificial anode rods at the top Protective current is fed by the control system to the titanium electrodes at the end of each anode rod This current flows through the water to the conductive...

Страница 7: ...lation 35 Burner flange gasket 36 Observation sight glass 37 Burner 38 Flame rod 39 Flame rod gasket 40 Blower discharge gasket 41 Burner gasket 42 Spark rod 43 Spark rod gasket 44 Ignition cable 4 3...

Страница 8: ...View 1 Burner Blower Assembly 2 Blocked Intake Air switch 3 Powered anode rods 4 Temperature Pressure Relief Valve 5 2 NPT hot water outlet connection 6 Temperature Probe 7 Spark Ignition Control 8 12...

Страница 9: ...ivated Spark Ignition Transformer is energized 24 Volt Gas Valve is energized gas flows to Main Burner Is flame sensed at the Main Burner control system monitors the flame sensor Control System Locks...

Страница 10: ...supply pressures meet the requirements described above and listed in the table Failure of the gas supply to meet these requirements is not covered under the warranty High Pressure building supply syst...

Страница 11: ...he pressure port on the gas valve inlet flange See Figure 8 4 A digital manometer see Tools Recommended on Page 2 is needed to check supply gas pressure To monitor supply gas pressure attach a sensing...

Страница 12: ...ble The unit will begin an ignition cycle When the Gas Control Valve icon appears on display screen immediately look through the sight glass for a brief blue flame if you are getting an Ignition Failu...

Страница 13: ...e at the moment the gas control valve icon appears on the display follow these steps 1 Install a gas pressure gage at the gas valve s inlet pressure port and confirm that the gas supply pressure DOES...

Страница 14: ...0 hrs 0 mins ago Error Code A7 1201 Restriction in air intake Check intake pipe and termination for blockage Press the Advanced button for CAUSES The Blocked Air Intake Switch has detected a possible...

Страница 15: ...proper operation If flame is not present cycle the unit Off by turning the Enable Disable switch to Disable wait for 5 seconds and cycle the unit On by turning the Enable Disable switch to Enable to...

Страница 16: ...ycle the flame sensing current is normally greater than 8 0 A with a clean Flame Sensor Over time the Flame Sensor can degrade and this will reduce flame sensing current With heavier use more heating...

Страница 17: ...e replaced unless damaged The CCB monitors the current through the anodes and will declare a fault if there is a disconnected wire or if there is no water in the tank Side Mounted Power Anodes 2 Top M...

Страница 18: ...Replace the Temperature Probe if shorted resistance is below 390 Ohms See Temperature Probe section below TEMPERATURE PROBE This section of the Service Handbook provides information on the Temperatur...

Страница 19: ...n the UIM The electrical circuit breaker that serves the water heater must be turned off and on again to reset the Control System Note the Control System will not reset unless the condition has been c...

Страница 20: ...ter when replacing the Temperature Probe If the Control System continues to lock out displaying Energy Cut Out ECO on the UIM and the water temperature inside the water heater is becoming excessive at...

Страница 21: ...e exhaust temperature is normally around 100 F leaving the water heater If the heater is running during the standby mode the flue exhaust temperature tends moving up during the standby heating cycle T...

Страница 22: ...side the pump s outlet is installed correctly if it s a new heater installation Confirm the flow switch is installed vertically with flow arrow pointed upward Confirm the flow switch s vane can swing...

Страница 23: ...rm the flow switch is installed correctly with flow arrow vertically pointing upward 4 Remove inspect the flow switch s vane free from debris 5 Replace the flow switch if malfunction is detected with...

Страница 24: ...mbustion air from the room where they are installed and discharge all flue gases to the outdoor atmosphere through a sealed vent exhaust pipe Power vent configurations have one vent pipe connected to...

Страница 25: ...essure Port Figure 18 AIR INTAKE SCREEN Service Notes Plastic debris left on the edges of intake air pipe sections after cutting must be removed on Direct Vent installations This debris can collect in...

Страница 26: ...of local codes with the National Electrical Code ANSI NFPA 70 or the Canadian Electrical Code CSA C22 1 If any of the original wire as supplied on the water heater must be replaced it must be replaced...

Страница 27: ...still be energized and the display will read Water Heating Disabled The Enable Disable Switch can be used to disable operation and reset error codes To operate the water heater make sure the switch is...

Страница 28: ...imum equivalent lengths required in the Instruction Manual that came with the water heater Exceeding the maximum length or number of elbows allowed will also lead to Blocked Exhaust and or Blocked Air...

Страница 29: ...speeds during the Pre Post Purge operating states and runs at a lower speed during the Trial For Ignition operating state The Igniter Status icon is displayed on the UIM during the Trial For Ignition...

Страница 30: ...eed RPM Low Fire Speed RPM Ignition Speed RPM BTHS 750 4475 2300 2000 BTHS 1000 6000 2300 2000 Note 10 High Heating Speed RPMs are based from the Nominal Certification Heating Speed RPMs Table 3 Blowe...

Страница 31: ...e ignition cable from the spark igniter and the yellow wire from the Flame Sensor 9 Disconnect the 3 Pin and 5 Pin plugs from the Combustion Blower Assembly 10 Disconnect the 24 Volt power wires to th...

Страница 32: ...e 21 Burner Assembly The Control System is programmed to start sparking a few seconds before the Gas Control Valve opens See the Sequence of Operation Flow Chart page 9 Service Notes The animated ligh...

Страница 33: ...All instructions for ignition and temperature control originate from this circuit board Diagnostic and operational messages are generated by the CCB and sent to the UIM See Figure 24 page 40 Most of t...

Страница 34: ...RE 1 Ensure power to the water heater is turned off 2 Remove the water heater s top cover UIM and the bottom plastic cover 3 Remove the temperature probe connectors 4 Unlock clips on both sides and re...

Страница 35: ...J3 J13 J4 J17 J10 J9 J14 J15 J1 J6 J12 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 4 4 4 4 4 4 4 4 4 4 4 5 5 5 5 5 5 6 6 6 6 6 6 7 7 8 8 8 9 9 7 10 8 Figure 22 Central Contro...

Страница 36: ...9 Neutral J3 Socket UIM Pin DESCRIPTION 1 5V 2 AIN Reset 3 Data 4 Data 5 D Grd J4 Socket Flue Probe Flow Switch Pin DESCRIPTION 1 Flue Probe 2 Flue Probe 3 Flow switch 4 Flow Switch J5 Socket Blower...

Страница 37: ...t Used 6 Condensate 7 Gas Pressure Switch 8 Gas Pressure Switch 9 Gas Control Valve 10 Gas Control Valve 11 24V 12 24V Return J15 Socket Pressure Switches Table 14 Pin Table 15 Description 1 Blocked A...

Страница 38: ...the UIM Table 18 CPAM Fault Warning Codes Corrective Action Code Description Corrective Action Cc Anode Shorted Check wiring for shorts clean anode Ce Hardware fail ADC error Reset power if still fai...

Страница 39: ...s V 24V 24V Rtn Condensate Gas PS Gas V Switch 1 Red 2 Black CCB J6 120V Out Neutral 120 to Spark Red Black Red Black Upper Temperature Probe ECO 1 Red 2 Black CCB J9 Upper Probe ECO Thermistor 4 Red...

Страница 40: ...ser Interface Module Tank Temperature 103 F Operating Set Point 120 F Status Heating MENU HELP GAS OFF O N Figure 24 UIM User Interface Module Screen ICOMM REMOTE MONITORING SYSTEM This water heater i...

Страница 41: ...41 NOTES NOTES...

Страница 42: ...42 NOTES NOTES...

Страница 43: ...43 NOTES NOTES...

Страница 44: ...44 Tech Support 800 527 1953 Parts 800 433 2545 www hotwater com Copyright 2020 All rights reserved...

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