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CONDITION 3A - BOILER SHORT CYCLES BUT AUTOMATICALLY RESTARTS

POSSIBLE CAUSE

VERIFICATION

SOLUTION

Recirculation of Exhaust

Visually check air inlet terminal(s) for

If there is recirculation, temporarily

at Inlet Terminals

exhaust recirculation (vapor path).

extend exhaust vent. If this
eliminates problem, proceed with

NOTE: On thru-the-wall installations

permanent fix.

the exhaust should extend a
minimum 12" beyond the inlet

If no recirculation proceed with

terminal.

trouble shooting procedures.

Recirculation of Exhaust -

Turn Rocker Switch & Gas Valve top

(1) If valve discs have torn edges or

Internal

knob to OFF. Remove lid from Air

holes - replace discs.

Cushion Chamber (ACC). On

(2) If foreign particles are between

AM-100 & -150 remove the fan

valve plate & valve retaining

assembly. Remove the gas

plate, remove them.

Cushion Chamber (GCC) & check

(3) If valve discs are missing, replace

the bottom of the valve plate. GCC

them.

valve discs must move freely and not

(4) If valve discs are “wrinkled” and

bind.

stiff - replace them and check
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 verification.

Recirculation of Exhaust -

With GCC removed, remove

If O-ring has burned, hardened or

Internal

combustion chamber inlet (flame

has decomposed sections, check

(AM-300 Only)

trap assembly). Check if O-ring

adjoining chamber and chamber

between Combustion Chamber &

inlet surfaces for obstructions which

inlet is intact. Check mating surfaces

may prevent flush mating of the two

of inlet and combustion chamber.

surfaces. Remove any obstructions,

These must be clean and free of

clean O-ring groove and replace

debris before re-assembly.

O-ring. (See “Procedures” section).

If O-ring is ok proceed with trouble-
shooting procedures.

Flame Trap (LP Boilers)

With GCC removed, check that

If any problems are evident, correct

(AM-100 & -150 Only)

flame trap seats properly (no

or replace the flame trap. If in doubt,

movement or rocking). Corrugated

replace flame trap and run boiler to

strips should be flush with flange

see if problem is corrected.

face (not coned) and show no
signs of “burn by” (no gaps/spaces).

If ok, proceed with checkout.

Содержание MultiPulse AM Series

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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