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Version 1.0

from Calcutt Boats

Service and

Troubleshooting

Manual

Diesel Hot Water Heating System

for Boats and Recreational Vehicles

Содержание SCH25

Страница 1: ...Version 1 0 from Calcutt Boats Service and Troubleshooting Manual Diesel Hot Water Heating System for Boats and Recreational Vehicles...

Страница 2: ...eating com All rights reserved No part of this manual may be reproduced or transmitted in any form by any means electronic or mechanical including photocopying and recording information storage retrie...

Страница 3: ...r High 15 3 9 1 Overheat 15 3 10 2 Fuse Blown 16 3 11 3 Fuel Pump Solenoid 16 3 12 4 Ignitor 16 3 13 5 Combustion Fan 17 3 14 6 Water Pump 17 3 15 7 Flame Out 18 3 16 8 Compressor 19 3 17 Bypass Mode...

Страница 4: ...5 3 2 Igniter 34 5 3 3 Fuel Nozzle 35 5 3 4 Flame Sensor 36 Appendices 37 Appendix 1 Technical Bulletins 37...

Страница 5: ...IMUM TORQUE VALUES The fasteners used to assemble this heater are all US thread size Most threaded fasteners should be tightened to a specific torque value Over tightening the fastener can weaken it a...

Страница 6: ...Page 2...

Страница 7: ...e of heat a 25 000 BTU burner EXHAUST HOT WATER OUT AIR INTAKE COLD WATER IN FLAME OBSERVATION WINDOW HOURMETER FUEL INLET FUEL RETURN CABLE TO CONTROL BOX NEGATIVE TO BATTERY SERVICE SWITCH DIAGNOSTI...

Страница 8: ...e 4 1 1 Component Views COMPRESSOR FUEL PUMP COMBUSTION FAN FUEL REGULATOR HOURMETER THERMAL CUTOFF IGNITER FUEL BLOCK FLAME SENSOR HOURMETER FUEL SOLENOID BURNER COUNTERFLOW TUBE FUEL BLEED RETURN VA...

Страница 9: ...Page 5 BURNER COUNTERFLOW TUBE COMBUSTION CHAMBER NOZZLE...

Страница 10: ...r 8 Nozzle block 9 Nozzle 10 Igniter 11 Combustion fan 12 Thermal cutoff 13 Compressor 14 Air filter When the heater is turned on service switch on and remote switch on and there is a call for heat fr...

Страница 11: ...gulator Fuel is only allowed to pass the regulator when there is a negative pressure between the regulator and the nozzle In between the fuel regulator and the nozzle is a fuel solenoid This fuel sole...

Страница 12: ...Page 8 combustion fan has faulted In this case all of the burner components will shut down immediately...

Страница 13: ...plications Fan heaters Solenoid Valves Motorised Valves Fan speed switches if any Fault bypass and reset buttons These buttons allow testing of the heating system by bypassing the fault sensing circui...

Страница 14: ...y allow the circulating pump and cabin fan circuitry of the control board to run in response to both a thermostat calling for heat and an external heat source engine supplying adequate heat to the sys...

Страница 15: ...PUMP FAN T1 T2 T3 T4 T5 T6 T7 T8 T9 T10 T11 T12 T13 T14 SENS SENS S_OUT A S HI TEMP FUEL FAN COMP IGN BURNER JS2 BYPASS RESET TC F1 T1 W1 W2 A1 S W P T2 F2 T3 F3 T4 F4 PUMP 10 PUMP JUMPER IN OFF POSIT...

Страница 16: ...Page 12 Figure 3 Wiring Diagram...

Страница 17: ...s ON and if the remote panel is switched ON a small red LED near the lower right hand side of the digit on the remote panel will also glow If this light does not come on check to see if the service sw...

Страница 18: ...The burner will shut down The diagnostic code will be displayed The control board will purge the burner with the combustion fan for two minutes and then stop The circulating pump will run until the la...

Страница 19: ...lt switch the service switch or the remote panel switch OFF then ON again 3 9 1 Overheat The high temperature limit has been reached The burner will shut down The diagnostic code 1 will be displayed T...

Страница 20: ...n fuses with one of the proper size Then reset the fault by switching the service switch or the remote panel switch OFF then ON again 3 11 3 Fuel Pump Solenoid The fuel pump or fuel solenoid has short...

Страница 21: ...ound for 10 seconds The control board will purge with the circulating pump for two minutes In order to restart the burner check the combustion fan Then reset the fault by switching the service switch...

Страница 22: ...the air leak otherwise this fault will continue to occur Check the connections on the fuel tank fuel pump the regulator and at the nozzle for air leaks Find source of air entry and repair Make sure t...

Страница 23: ...e burner will shut down The diagnostic code 8 will be displayed The buzzer will sound for 10 seconds The control board will purge the system with the combustion fan and circulating pump for two minute...

Страница 24: ...voltage will be between 4 and 5 volts if the combustion fan is operating correctly 1 volt if the combustion fan is not drawing any current open TP3 Combustion Fan Current The voltage will be between...

Страница 25: ...ill show a voltage of between 4 8 and 5 volts Good fuses will show 0 volts 3 20 LCD Readout Remote Panel This panel will display the diagnostic explanation which will match up to the diagnostic code o...

Страница 26: ...osit in combustion chamber 3 23 Smokey Smelly Exhaust The heater may run without faulting but you may experience signs of soot exhaust smoke and or a pungent smell This is usually caused by the wrong...

Страница 27: ...be air in the line This should be bled using the bleed tap on the top of the heater whilst the heater is restarted a few times If any of the above issues were found to be a problem correct the situat...

Страница 28: ...witch and allow the heater to completely power down this will take 2 minutes To check the glow of the igniter do the following 1 IMPORTANT Disconnect the air compressor wires from the main harness Dis...

Страница 29: ...m solved IF NO Check the fuel solenoid Turn off the service switch and allow the heater to completely power down this will take 2 minutes IMPORTANT Disconnect the main power 12VDC from the heater Disc...

Страница 30: ...front cover and remove the cover Check that the connections to the RED BLACK and YELLOW wires on the flame sensor see 5 3 4 are secure This connection will have YELLOW heat shrink on both sides of th...

Страница 31: ...m When the burner chamber is hot this sputtering effect can cause the heater to backfire Intermittent sputtering is commonly caused by leaks in the fuel line To check the fuel line do the following 1...

Страница 32: ...hreads Proceed to Q2 IF NO The problem is not with the heater There may be a cut in the fuel line running from the fuel tank to the fuel inlet of the heater or the hose clamps may not be secured in pl...

Страница 33: ...If YES Check the voltage to the heater using a multi meter and at the same time restart the heater At this point the heater will begin its ignition sequence Monitor the voltage during the ignition seq...

Страница 34: ...Page 30...

Страница 35: ...e To clean the fuel nozzle refer to Servicing the 5 3 3 Once the fuel nozzle has been cleaned attempt to run the heater Proceed to Q2 Q2 Is the flame a bright yellow colour after replacing the air com...

Страница 36: ...dentally turned ON If the heater were to attempt to fire with the front cover off it will project open flame towards the user 3 Remove the screws from the front cover using a Philips head screw driver...

Страница 37: ...from the front cover using a Philips head screw driver and remove the cover 4 Disconnect the wires to the fuel solenoid 5 Unscrew the fuel solenoid coil housing from the solenoid body counter clockwi...

Страница 38: ...river and remove the cover 4 Disconnect the igniter wires 5 Remove the pin that holds the igniter in the igniter tube and remove the igniter 6 Place the new igniter in the igniter tube being careful t...

Страница 39: ...5 Unscrew the fuel nozzle counter clockwise using a 5 8 wrench 6 When the fuel nozzle is removed a fuel filter is visible inside the fuel block Remove this filter and clean it using solvent and high...

Страница 40: ...to completely power down this will take 2 minutes 2 IMPORTANT Disconnect the main power 12VDC from the heater Disconnecting the 12VDC power ensures that the heater will not attempt to fire if the ser...

Страница 41: ...Page 37 Appendices Appendix 1 Technical Bulletins...

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