2
TABLE OF CONTENTS
SECTION 1: OPERATION
Boiler Operating Lights - Location and function .................................................................................................. 3
Sequence of Operation (with lights) ................................................................................................................... 3
Wiring Diagrams (AM-100/-150/-300) ................................................................................................................ 5
Lighting and Operating Instructions ................................................................................................................... 8
SECTION 2: TROUBLE SHOOTING
Preliminary Operational Check ...........................................................................................................................9
- Boiler is not running:
Condition
GC-4A Light
Red Light
Amber Light
A
Off
Off
Off .................................... 9
B
Off
Off
On .................................. 10
C
Off
On ................................................................... 11
D
On ................................................................................................... 12
E
Blinking ............................................................................................... 13
- Boiler is running:
Condition 1. Boiler ignites: runs for 8 seconds then shuts off ....................................................... 15
Condition 2. Boiler attempts ignition (8 seconds) - shuts off with a “cough” or no ignition ............ 16
Condition 3. Boiler is “short cycling” .............................................................................................. 19
Condition 4. Boiler and condensate water leaks ........................................................................... 22
Condition 5. Boiler noise (control and adjustment) ....................................................................... 24
a) Prolonged stutter 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 Pressure Check .........................................................................................................................................29
Gas Supply Pressure Check ............................................................................................................................ 29
Gas Input Rate Check (Metered and Differential Methods) .............................................................................. 30
Adjusting Input Rate .........................................................................................................................................30
Flue Box Adaptor Repair (AM-300) ..................................................................................................................30
Fan Inlet Gasket Replacement (AM-300) ......................................................................................................... 31
Air Inlet Orifice Repair (AM-300) ...................................................................................................................... 31
Igntion Wire Check ...........................................................................................................................................31
Wire Harness Assembly Replacement (AM-100 and 150) ............................................................................... 31
Exhaust Cushion Chamber (ECC) and/or “O” Ring Replacement (AM-100 and 150) ...................................... 33
Disassembling AM-300 Boiler ......................................................................................................................... 33
Leak Check (AM-300) .......................................................................................................................................35
-Reassembly AM-300 Boiler ...................................................................................................................... 35
-Reposition Boiler in it's location (AM-300) ................................................................................................ 36
Heat Exchanger Replacement (AM-100 and 150) ............................................................................................ 37
Boiler Reassembly (AM-100 and 150) .............................................................................................................. 37
Quick-Check Trouble Shooting Guide – GC-4A ............................................................................................... 39
SECTION 4: REPLACEMENT PARTS LIST
Part Identification/Figs. 9 thru 12 (AM-100 / -150 / -300) ................................................................................. 40
