9600 CB & HWG
Contents
1. 8 OPERATINGLIMIT BLOWER ASSEMBLY CIRCULATOR PUMP S9 BLOCKED CONTROLBOX FLUE SUB ASSY DETECTOR IGNITER ASSY HEATMAKER GAS VALVE 9600 VENT THERMAL CUTOUT INTAKE THERMAL CUTOUT THERMAL CUTOUT Figure 6 Control Components Part Description Part Part Description Part 1 Combustion Coil Primary H X HWG 2400 086 23 Jacket Front Removeable 10 402 Combustion Coil Primary H X CB 2400 284 24 Jacket Top 10 406 2 Economizer Coil Secondary H X 10 078 25 Jacket Bottom 10 010 3 Upper Head 10 034 26 Control Boiler Integrated 2400 224 4 Inner Shroud 10 112 27 Transformer 40 VA 2400 006 5 Outer Shroud 10 124 28 Time Delay Relay 2400 062 6 Ignitor w Gasket after s n 391 126 2400 286 29 Wiring Harness 10 354 1912044 30 Stack Switch 2400 110 6 Ignitor before s n 391 127 791 045 2400 248 31 Operating Control 2400 056 7 Burner Flameholder w Gaskets 2400 082 32 Safety Limit 2400 055 Burner w Gaskets 250 Series 2400 308 33 Intake T C O 2400 058 8 Upper Insulation Blanket 10 048 34 Exhaust T C O 2400 058 93 Upper Insulation Board 1000 35 2400 020 10 Lower Insulation Board 10 106 36 Gas Valve 2400 014 11 Lower Insualtion Blanket 10 108 Gas Valve 250 Series 2400 015 poer asker 37 Capacitor Blower Start Run 2400 088 13 _ Gasket Burner 2 req d 58 Pump Grundfos 26 99 BF 24002. Time Input Rate Natural Gas 57 sec 252 600 BTU hr 58 248 300 59 244 000 70 205 700 71 202 800 72 200 000 74 194 600 80 180 000 82 175 600 84 171 400 94 153 200 96 150 000 98 146 900 Table 1 Time to Input Rate Conversion TUBE 9600 Figure 7 Checking Combustion the tester sample tube through the exhaust terminal and at least 6 152mm into the flue pipe The unit must operate for 5 minutes before taking a sample Take a sample and determine the CO2 or O2 CO2 8 to 8 5 natural gas O2 7 to 6 CO2 9 to 9 8 propane gas If the burner is not operating in this range it should be adjusted see Burner Adjustment 3 Burner Adjustment The Heatmaker 9600 CB amp HWG burner system is a pre mixed forced combustion system Outside air is drawn through the air orifice located in the rubber hose in the air induction system and mixed with the gas which is drawn in downstream of the air orifice All the air required for complete combustion comes into the system in this manner The gas is metered through the gas orifice located in the gas orifice union Adjusting the burner is limited to changing the gas orifice to achieve proper combustion The air orifice cannot be altered and the gas valve pressure should not be changed Before changing the gas orifice to adjust the burner make the following checks a Gas valve supply pressure is betwee
3. 1 CN1 4 1 21 4 31 CN5 31 PF CN3 1 i CN3 3L CN7 2 _ POWER puree I IGNITOR xX varve X Tf oce s p ARE OREL LAMPAS ER 24V i J AcCN24 45 PROVE i CN2 2 STACK OPEN sss eg Vas BB dq r CN5 9 CN6 7 CN6 4 CN6 5 CN6 3 CN6 1 CN6 5 CN6 2 SAFETY CONTROLS INTAKE TCO e STACK OPER CONTROLS SWITCH TCO ps ROOM OR TANK PRESSURE SWITCH ieee MODEL 250 ONLY BLOCK FLUE SEN VOLT EXHAUST TCO Figure 9 9600 Ladder Diagram Wire Color Legend RED BLK Black RED BLU Blue BRN Brown GY Gray OR Orange RED Red v Violet emm WHT White WHTIRED White Red E YEL Yellow NOTE Thermal Cutout IGNITOR Pes IBOSI BRN SAFETY I z LIMIT DOS gu WH 9009 i CIRCULATOR 9 2 CONTROL I CIRCULATOR RED CN6 CN gt WHT RED BLOWER NEUTRAL 120 VAC Fer RED D PRIMARY gk I LINE 120 1 WHT RED i T STAT AQUASTAT 1 IL RED T STAT AQUASTAT L 2 ih S 120VAC IN INTAKE I OR EXHAUST 1 Teo ll TCO OR T Q 1 lees CONTROL g JE SWITCH 1 I C J 1 one x
4. It is mounted on the 3 76mm exhaust pipe inside the unit between the top of the lower panel and the top Switch off electrical power when changing this safety 1Q Intake TCO The intake TCO is a temperature switch with normally closed contacts which open on a temperature rise at 180 F 82 C It is identical to the vent TCO and functions to interrupt power to the gas valve if the mixer tube temperature exceeds 180 F 82 C It is mounted on the mixer tube about 3 76mm above burner flange Switch off electrical power when changing this safety also 1R Thermal Cut Out TCO The thermal cut out is a probe type temperature switch with normally closed contacts which open on a temperature rise at 450 F 232 C It is located on the right side of the upper head with the probe extending down into the exhaust passage between the boiler coil and the economizer coil It functions to interrupt power to the gas valve if the flue gas temperatures exceed 450 F 232 C for any reason Switch off electrical power when replacing 1S Delayed Ignition Possible Causes Time of occurrence High lockups on LP occurs on start up Gas valve regulation problem occurs on start up Defective burner flameholder occurs primarily on burner shutdown 4 Natural gas orifice in LP unit occurs on startup High lock up pressures on LP fuel systems are the most common cause of delayed ignitions on Heatmaker boilers The high LP supply p
5. BRADFORD WHITE Corporation Page 2 LAARS Heating Systems TABLE OF CONTENTS SECTION 1 102 Operating Control denis 11 General Information bs is 1A ntroduction U u 3 1 Start Up Procedures 9 5 Out uee 1C Checkout ProcedureS a 9 1S Delayed Ignition EE 12 1D Cleaning the Combustion Chamber Coil 10 1T High Gas Consumption TD RS 12 1E Diverting Valve 10 10 Noisy Operation 4 12 1F Safety Limit Switch 10 1V Short Cycling 13 16 Boiler Control 2 2 42 54 10 TW Lock Outs amp Trip Outs 13 Stack Switch 11 1X Routine De Liming Procedure 14 iL dnte asas 1 WW 1J Transformer 111 11 i gt 7 poaa 11 SECTION2 JA J Bower i celis 11 Troubleshooting 1 Gas Valve 00041 0 11 2 Code 15 1N Time Delay Relay TDR 11 9600 CB amp HWG Service Manual 1 General Information 1A Introduction The Heatmaker 9600 CB condensing boilers and the Heatmaker 9600 HWG non automatic circulating tank water heaters have a dual heat exchanger H X design The primary H X is a copper coil type whi
6. ae Simon a mua s s Ls Figure 10 9600 Wiring Diagram ACaution Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing Quick Reference Trouble Shooter A SHORT CYCLING 1 2 3 9600 HWG tank aquastat set too high 9600 CB and 9600 HWG Units shuts down before reaching limit Continuously restarts without resetting a Limit out of calibration b Wrong air gas orifices for input or fuel refer to HeatMaker 9600 gas orifice chart ONLY c Thermostat heat anticipator set below 0 9 amps 9600 CB only 9600 CB boiler oversized for total load or small zone B HEATMAKER 9600 OVERHEATS QUICKLY OR KNOCKS DURING OPERATION Boiling noise in combustion chamber ginge Ia Air in combustion coil or in pump Purge system Pump failure or control failure 9600 HWG lime buildup in primary heat exchanger 9600 HWG restriction in storage tank piping Defective diverting valve element 9600 CB restriction in supply return piping C DELAYED IGNITION Unit starts or stops with a pop 1 2 3 4 Wrong gas orifice for fuel air orifice size LP Gas regulator lock up 3 or greater above run pressure correct regulator and check gas pipe sizing against piping chart in installation manual Set regulator for maximum run pressure of 9 Remove blower and inspect flameholder burner for h
7. hose A small pump should be used to do the filling from a plastic container The upper hose should then be placed in this container and the pump should run until the circulator solution is no longer foamy 7 Shut off pump and disconnect from hose Carefully drain solution from hoses and connect city water to lower hose to flush combustion coil Flush for approximately 5 minutes with city water 8 Remove hoses close drain cock close drain on cold return and replace lower front panel 9 Remove cover from thermostatic valve and remove tape Replace thermostat spring brass ring and valve cover and tighten bolts 10 Open shut off valves and purge air from petcock at top of thermostatic valve cover 11 Re open gas supply and turn on main disconnect switch to return heater to service 1Y Sequence of Operation On a call for heat from the room thermostat on 9600 CB series boilers or the tank aquastat on 9600 HWG series the boiler control is energized through the control the vent TCO and the safety limit It energizes the pump checks to ensure that the stack switch contacts close and the red PURGE light lights The pump and blower continue to run and for 15 seconds the red PURGE light goes out the red igniter light lights and the igniter heats for 20 seconds At the end of the 20 seconds the red VALVE FLAME light is lit and the gas valve is energized For 2 seconds the valve and igniter are energize
8. the valve body as this may cause damage to the valve 1N Time Delay Relay TDR The time Delay Relay controls the unit pump and keeps it operating for approximately one minute after the blower post purge stops This function dries out the moisture in the chamber to prevent corrosion Control voltage on the TDR is 24 volts from the limit circuit The contacts to supply pump power are 120 They open one minute after the 24 volt control voltage is interrupted Turn off disconnect switch before changing TDR 10 Operating Control The operating control functions as a high limit to prevent boiler outlet temperatures from exceeding 210 F 99 C on CBs and 185 F 85 C on HWGs during periods of low load or high return water temperatures It will reset automatically when the boiler temperature drops to 170 F 77 C To replace immersion type valve off boiler and drain about a Page 12 LAARS Heating Systems gallon of water from it Turn off electrical power and disconnect wires from operating control Remove operating control from diverting valve body and replace with new control Connect wires to control and open isolation valves Bleed air from the diverting valve petcock turn on electrical power and restart boiler The strap on type may be changed without draining 1P Vent TCO The vent TCO is a normally closed temperature switch which functions to shutdown the burner if flue gas temperatures exceed 180 200 F 82 939
9. 0F CONTINUITY NOCONTINUITY 0 OHMS ON LOW OHMS OHM SCALE ALLLIMITS OK PUSH SAFETY LIMIT RESET BOILER SHOULD CYCLE PROPERLY ON BUTTON BUTTON CLICKS A CALL FOR HEAT OR HOT WATER CHECKFOR m b CONTINUITY CONTINUITY ACROSS VENT EXHAUST TCO bay NO CHECK FOR CONTINUITY ACCROSS CONTINUITY NOOVERHEAT CONDITION SAFETY LIMIT CONTACTS HAS OCCURRED REPLACE VENT CONTINUITY EXHAUST TCO NOCONTINUITY CHECKFOR CONTINUITY ACCROSS OPERATINGCONTROLCONTACTS REPLACE SAFETY LIMIT CONTINUITY NOCONTINUITY LIMIT CIRCUIT APPEARS OK RECYCLE BOILER A FEW TIMES AFTER REPLACE OPERATING PLUGGINGIN CONTROL PLUG CONTROL NOTE AFTER COMPLETEING LIMIT CIRCUIT TESTING PLUG IN CONTROL PLUG AND RECYCLE BOILER A FEW TIMES IF BOILER A BOILER DOES NOT RECYCLE CONNECT A JUMPER TEMPORARILY BETWEEN THE RED WIRES IF BOILER STARTS REMOVE JUMPER AND TEMPORARILY JUMP EACH SAFETY CONTROL UNTIL THE DEFECTIVE CONTROL IS LOCATED NEVER LEAVE A SAFETY CONTROL JUMPED CHECK BOILER PUMP IF SAFETY LIMIT HAS TRIPPED Page 18 LAARS Heating Systems RED PURGE LIGHT FLASHING YOU MUST COMPLETE PAGE 16 FIRST RESET BOILER CONTROL BY SWITCHING POWER OF FOR 15 SECONDS AND THEN ON AGAIN WITH A CALL FOR HEAT HOT WATER AFTER APPROX TWO SECONDS GREEN LIGHT COMES ON AND BLOWER STARTS YES NO NO AFTERFIVEMINUTES RED AFTER45SECONDSRED 5 5 PURGE LIGHT FLASHES PURGE LIGHT FLASHES RED PURGE LITE FL
10. 386 14 Gasket Blower Inlet 1 req d 1 254 38 CB 250 2400 387 15 Gasket Blower Discharge 1 req d 10 324 HWG 2400 388 Gasket Blower Discharge 250 series 11 066 Vanes FESTE 9 280 2402388 16 Blower Assembly w Gaskets 2400 079 39 aa S AIE Blower Assembly w Gaskets 250 2400 310 alver Pressure Megi A50 Series 40 Valve Pressure Relief 125 PSI 2400 096 17 Orifice Air Ps Valve Pressure Relief 250 Series 2400 097 41 Diverting Valve Compl 2400 001 19 Union 1 252 iverting Valve Complete i Thermostat O Rings 20 VIKGISTHUS 10296 42 included 160 F 2400 129 Tube 250 Series 11 016 before S N 394 068 795 0014 21 Air Duct Hose 1 458 Thermostat O Rings Air Duct H 2 11 038 included 140 F 2400 130 2 Gs 39 T BS before S N 394 067 or 795 0013 Not E Rs SU ES orifice kit for type of m Terminal Intake 24005102 ot available separately pu i i and input desired 44 Terminal Exhaust 2400 104 45 Flange Wall Vent Pipe 2400 100 46 Exhaust Assembly 2400 390 Exhaust Assembly 250 Series 2400 402 Specify Serial Number 9600 CB amp Service Manual Page 9 1B Start Up Procedures 1 Make sure that the system is properly filled com A pletely purged of air and system valves are open COMBUSTION 2 Open system gas cock s and gas control knob on TESTER gas valve Gf closed C SAMPLE 3 Set the room thermostat aquas
11. ASHES YES STACKSWITCHCONTACTS NOT CLOSINGCHECKFOR FLUE BLOCKAGE SNOW LEAVESETC AGAINST VENT TERMINAL BLOCKAGE EXISTS CLEAR BLOCKAGE AND RECYCLE BOILER NO BLOCKAGE NO YES CHECK BLOWER PAGE 20 CYCLE BOILER MANY TIMES TO TRY TOCREATEA MALFUNCTION SHUT OFF POWER DISCONNECT WIRES TO STACK SWITCH TURN ON POWER AFTER TWO SEC ONDS BLOWER STARTS YES NO CHECK STACK SWITCH RECONNECT STACK SWITCH WIRES CHECK BLOWER CHECK STACK SWITCH 9600 CB amp HWG Service Manual Page 19 CHECKING STACK SWITCH YOU MUST COMPLETE PAGE 16 FIRST 1 SWITCHOFF BOILER SWITCH 2 REMOVE BOTH TUBES FROM STACKSWITCH AND DISCONNECT ELECTRICAL WIRES 3 CHECKFOR CONTINUITY ACROSS SWITCH TERMINALS CONTINUITY NOCONTINUITY 0 OHMS COOHMS DUC BID Em 1 ATTACHTUBESDISCONNECTED FROMSTACK SWITCH TOU TUBE MANOMETER SWITCHONBOILER TOOPERATE BLOWER YES MANOMETER INDICATES 1 5 W C ORGREATER NO RECONNECT STACK SWITCH TUBES AND CHECK FOR SWITCH TERMINALS WITH BLOWER OPERATING CLEAR OBSTRUCTED CONTINUITY NOCONTINUITY 0 OHMS coOHMS CH ss CLEAROBSTRUCTIONS amp 0 RECONNECT TUBES amp ELEC TRICAL WIRES TOSTACK REPLACE STACK SWITCH P N 2400 110 SWITCH START BOILER amp RUN THROUGH A FEW CYCLES NOTE CHECK TUBES ON STACK SWITCH FOR PROPER CONNECTIONS TUBE CONNECTION CLOSEST TO YOU SHOULD CONNECT TO BARBED TEE FITTING ABOVE AIR O
12. E CHECK LITE CHECK COMBUSTION IGNITER OK DEFECTIVE WIRES TO TCO GAS VALVE NO CHECK FOR GAS FLOW REPLACE REPLACE ISMETER MOVING IGNITER INTEGRATED BOILER YES CONTROL P 2400 224 FAULTY CHECK GAS AND AIR ORIFICE REPLACE GAS VALVE FOR PROPER SIZE CORRECT INCORRECT CORRECT WIRING INSTALL BOILER CYCLES THROUGH THREE CYCLES AFTER CORRECT RESETTING AND VALVE FLAME LITE FLASHES ORIFICES REPLACE INTEGRATED BOILER CONTROL P N 2400 224 Page 22 LAARS Heating Systems CHECKING INTERNAL PUMP YOU MUST COMPLETE PAGE 16 FIRST SWITCH POWER ON GREEN POWER LIGHT LIGHTS YES NO CALLFORHEAT EXISTS SEE TROUBLE SHOOTING THERE IS 24 VOLTS CHART PAGE 16 PINS 7 amp 9 ON CONTROL PLUG CN6 THERE IS 120 VAC AT TURN UP T STAT ORAQUASTAT OR CIRCULATOR PLUG CN5 CORRECT STAT PROBLEM REPLACE BOILER THERE IS 120 VAC AT PUMP CONTROL P N 2400 224 YES NO CORRECT WIRING BETWEEN MOTOR PUMP RUNS PUMP AND CONTROL BOX REPLACE PUMP PUMP IS PUMPING PUMP IS AIR BOUND OR IMPELLER HAS BROKEN ELIMINATE AIR OR REPLACE PUMP lt lt Z 9600 amp HWG Service Manual Page 23 TIME DELAY E RELAY PUMP e BLOWER NE x IGNITOR CN7 I CN5 1
13. M2 250 flue material can only be ABS or CPVC 55 2 2 0 S S O Diverting valve 2 Circulator 9 Mixer tube 4 Exhaust 5 Blower 6 Gas valve 7 Burner 8 Economizer 9 Combustion coil 10 Cold water inlet 11 Hot water outlet 12 Heat exchanger drain 13 Air vent Figure 1 Heatmaker 9600 Assembly View Page4 LAARS Heating Systems APORTION OF e HOTWATER VALVE IS RECYCLED TOMAINTAIN 160 F THERMOSTAT COMBUSTION COIL INLET TEMPERATURE AT 140 E COMBUSTION COIL ECONOMIZER A Cold Water Inlet From Tank or System B Economizer Outlet 10 F Rise above inlet D A B C Combustion Coil Inlet 130 140 F Typical D Combustion Coil Outlet E E Hot Water Outlet To Tank or System 160 170 F Typical Figure 2a Water Flow through a Heatmaker 9600 HWG Before S N 394 068 CB Before S N 795 0014 9600 CB amp HWG Service Manual 5 Manual Airvent Drain Taps Situated Under Heat Exchanger SECONDARY HEAT EXCHANGER 3 4 BYPASS THERMOSTATIC VALVE UNS Legend Mixing Valve Internal Pump Mixer Tube Flue Outlet Combustion Fan Air Pressure Switch Burner Secondary Heat Exchanger Primary Heat Exchanger Return From Primary Loop Gas Val
14. RIFICE Page 20 LAARS Heating Systems CHECKING BLOWER YOU MUST COMPLETE PAGE 16 FIRST WITH A CALL FOR HEAT RESET BOILER CONTROL BY SWITCHING OFF BOILER SWITCH FOR 15 SECS AFTER TWO SECONDS GREEN POWER LIGHT COMES ON YES NO BLOWER STARTS REFER TOGENERAL TROUBLE SHOOTING SECTION PAGE 16 YES NO CONNECT MANOMETER TO PRESSURE TAP ON CHECK FOR VOLTAGE 120 VAC GAS VALVE PRESSURE DURING BLOWER ATBLOWER WIRE CONNECTOR OPERATION WITHOUT GASFLOW VALVE FLAME WITHIN5 MINS AFTER GREEN LIGHT NOT LIT IS 4 IN W C LIGHT YES NO OVOLTS 120 VAC BLOWER O K REPLACE BLOWER CHECKTT LIMITS REPLACE BLOWER STACK SWITCH OK OPEN REPLACE BOILER REFER TO PAGE 17 CONTROL 2400 224 REFER TO PAGE 19 9600 amp Service Manual Page 21 RED VALVE FLAME LIGHT FLASHING YOU MUST COMPLETE PAGE 16 FIRST ARE GAS VALVES AND GAS METER TURNED ON IS THERE GAS IN LP TANK LP UNITS YES NO RESET BOILER BY SWITCHING POWER OFF FOR TURN ON VALVES FILL LP TANK ON LP UNIT 15 SECONDS WHEN VALVE FLAME LITE LIGHTS IF REQ D RESET BOILER BY SWITCHING IS THERE 24 VAC BETWEEN ORANGE AND YEL POWER OFF FOR 15 SECONDS RUN LOW WIRES ON GAS VALVE AND OR DOES GAS THROUGH TWO TOTHREE CYCLES VALVE CLICK YES NO DOES BURNERIGNITE AND APPEAR TO RUN PROPERLY CHECK TCOAND INTAKE TCO FOR CONTINUITY N NOCONTINUITY CONTINUITY YES coOHMS 0 OHMS NUISANCE LOCKOUT CAUSED FLASHING CHECK IGNITER REPLAC
15. SIDE OF UNIT FOR 15 SECONDS YES NO GREEN LIGHT COMES ON 1 ISSERVICE SWITCH ON 2 ISCIRCUITON 3 ARE FUSES ORCIRCUIT BREAKER OK NO CHECKFORVOLTAGE TESTLIMIT DID BOILER RUN THROUGHA 120 VAC BETWEEN CORRECT AND CIRCUIT COMPLETE CYCLE AS DE BLACK AND WHITE RECYCLE BOILER PAGE 17 SCRIBED INSEQUENCE OF WIRES AT BACK OF 120 RUNTHROUGHA EVENTS PAGE 20 VAC CONNECTORON FEW CYCLES BOILERCONTROL OPEN 0VOLTS CHECK NS STACK PUMP OPERATES SWITCH 120 V TO PUMP 2400 224 HAVE QUALIFIED ELECTRICIAN DEFECTIVE YES 120 REPAIRFAULT IN VOLTS WIRING TO THE REPLACE BOILER REFER TO FLOW CHECK FOR VOLTAGE 24 CHART FORSPECIFIC VAC BETWEEN VEO CONTROL2400 224 PROBLEM WIRES AT BACK OF VAC 24XFMR CONNECTORON AFTER 5 MINUTES ARE ANY BOILERCONTROL CORRECT REDLIGHTSFLASHING 24VOLTS YES NO 0 REPLACE BOILER CONTROL 2400 224 1 LIMIT CIRCUITOPEN PURGE SEE PAGE 18 SEE PAGE 17 VALVE FLAME SEE PAGE 21 2 NO CALL FOR HEAT REPLACE TRANSFORMER HOTWATER AND RUNBOILER THROUGH A FEW CYCLES POOR SWITCH CONTACT ON RELAYS ZONE VALVES OR THERMOSTATS CAN CAUSE A FLASHING GREEN LIGHT ON JOHNSON CONTROLS G856DBG 5201 9600 CB amp HWG Service Manual Page 17 TESTING LIMIT CIRCUIT YOU MUST COMPLETE PAGE 16 FIRST SWITCH BOILER OFF UNPLUG 9PIN CONTROL PLUG CHECK FOR CONTINUITY AT BACK OF CONTROL PLUG BETWEEN RED WIRES CONTROL BOILER TEMP BELOW 17
16. Service Manual parts8 heati Ng Document 2109 800 536 1582 Fax 866 448 9304 info parts4heating com Service Manual for 9600 CB amp HWG 55555 555 HWG M2 Series CB M2 Series HWG M2 250 CB M2 250 HWG M2 200 CB M2 200 HWG Me2 175 CB M2 175 HWG M2 150 CB M2 150 Hot Water Generator Condensing Boiler For Natural or For Natural or Propane Gas Propane Gas FOR YOUR SAFETY This product must be installed and serviced by a professional service technician qualified in hot water boiler installation and maintenance Improper installation and or operation could create carbon monoxide gas in flue gases which could cause serious injury property damage or death Improper installation and or operation will void the warranty AWARNING If the information in this manual is not followed exactly a fire or explosion may result causing property damage personal injury or loss of life Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a nearby phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or gas supplier Heating Systems Company A subsidiary of
17. ance lockouts are 1 moisture in the combustion chamber 2 poorcombustion 3 igniter failure 4 shortcycling Safety limit trip outs are generally caused by low flow or recirculation in the primary heat exchanger Moisture in the combustion chamber can be caused by a failure of the thermostatic element in the diverting valve If the element fails in the full open position it will cause the primary heat exchanger to operate in the condensing mode by allowing low outlet temperatures This condition should be suspected if boiler outlet temperatures are consistently below 160 F 71 C The moisture causes a loss in flame sensing and the boiler control will shut the unit down Poor combustion may cause a boiler control lockout by transmitting a very weak flame signal to the boiler control The boiler control senses a flame using the flame recertification principle This principle utilizes the fact that a flame is not only conductive but it converts AC voltages to DC The igniter which becomes a flame sensor after it is deenergized as an igniter has an AC voltage applied to it by the control If a flame exists the AC is converted to DC and conducted to ground through the burner or the primary heat exchanger Since natural gas or LP are neither conductive nor capable or rectifying an AC voltage to DC the burner control can determine if a flame exists or not by the presence of DC or AC current Poor combustion can make this decision difficult b
18. burner will lift out of the top of the chamber There should be no perforations other than the punched holes Replace in the reverse order with new gaskets 1T High Gas Consumption Improper burner operation caused by incorrect air fuel ratio CO2 or high O2 out of the specified range will cause high gas consumption It is most noticeable on LP fired units with low CO2 or high O2 however units operating on LP or natural gas with incorrect air fuel ratios will not provide their best efficiency If no combustion analyzing equipment CO2 or O2 is available an indication of the air fuel ration can be gotten by briefly sniffing the flue gases When running properly the Heatmaker s flue gases should have no smell If they have a strong piercing smell the gas orifice is probably too small Do not attempt to do re orificing without an O2 or CO2 kit 1U Noisy Operation There are two principal sources of excessive noise Combustion 2 Boiling kettling or knocking Combustion noise can occur when the burner is operating with a very rich or a very lean mixture A rich mixture high CO2 or low O2 gas orifice too large will cause a high pitched noise that is loudest at the vent terminal A lean mixture low CO2 or high O2 gas orifice too small will cause a very uneven rumbly noise and may sometimes be associated with a nuisance lockout situation and a strong piercing odor at the vent terminal Both noises may be eliminated by prope
19. ch operates in a non condensing mode secondary stainless steel H X economizer surrounds the primary H X to condense water vapor from the flue gases and extract the maximum amount of heat from the combustion process Condensate from the economizer drains into the bottom of the outer shroud of the boiler section and into the exhaust duct which provides for condensate drainage Flow rates through the primary H X controlled by a thermostatic diverting valve which diverts water as required from the outlet of the primary H X back to its inlet so that the primary H X temperature is always maintained above the condensation temperature of the water vapor in the flue gases circulator is built into the unit to provide enough head to circulate water through the H X s and to a secondary heating loop or separate hot water storage tank The forced draft premixed combustion system contains a blower to provide air flow through the unit the air inlet and exhaust piping The cylindrical burner is provided with an air gas mixture which is metered through fixed orifices A hot surface igniter glow coil is controlled by the Integrated Boiler Control which also controls the blower circulator and gas valve and provides for burner flame safety The Heatmaker 9600 is designed to use 3 PVC or ABS DWV pipe or PVC ABS or CPVC schedule 40 pipe for both air intake and flue material Vent terminations are provided with the unit CB HWG
20. d and burner will ignite Following this the igniter is deenergized and the red IGNITER light goes out and the pump and blower continue to run and the burner operator under the supervision of the boiler control If for any reason the full sequence is completed and the burner doesn t ignite the sequence will be repeated after a blower on time of 45 seconds 30 seconds post purge and 15 seconds prepurge for the next cycle During this part of the sequence the igniter remains on for 30 seconds and the balance of the sequence is unchanged If no ignition occurs again a third cycle will follow with the same sequence as the second After the third trial for ignition if the burner does not ignite the system will lock out valve flame light flashing and reset only be accomplished by momentarily switching the power off At the end of the heating cycle after the gas valve is deenergized the blower will continue to run for a 30 second post purge and the pump will run for about another minute If normal burner operation during a heating cycle is interrupted by any of the limit controls the blower will continue to operate for a 30 second post purge and the pump continues to operate until the call for heat is satisfied 9600 CB amp HWG Service Manual Page 15 SECTION 2 Troubleshooting Detailed Flow Charts on Page 16 22 If the burner locks out for any reason the cause of failure will be displayed by the f
21. ecause of poor conductivity There are many causes for poor combustion Incorrect burner adjustment is the most obvious however a blocked condensate drain or an improper flue installation can cause a restriction in the flue which will cause poor combustion If there is a restriction in the flue from condensate or rain water buildup a gurgling sound can be heard at the vent terminal Igniter failure may also cause a nuisance lockout but not very often If igniter failure is the cause there probably will be an indication of overheating in the igniter area resulting from gasket failure Short cycling may cause either burner control lockouts or tripouts of the manual reset safety limit Generally it will be tripouts however in some instances a lockout will occur and the boiler control Page 14 LAARS Heating Systems will require resetting If a lockout occurs for any of the reasons stated in this section the VALVE FLAME light on the boiler control will flash Tripouts of the manual reset safety limit can be caused by a failure of the thermostat in the diverting valve short cycling or a calibration change in the safety limit If the thermostat in the diverting valve fails in the closed position all of the water leaving the outlet of the primary heat exchanger will be recirculated back to the inlet and the temperature will rise rapidly This rapid temperature rise may cause the safety limit to trip before the operating control senses hi
22. gh temperature Short cycling may cause a tripout in the same manner A calibration shift in the safety limit may also cause it to trip out If the temperature of the water leaving the unit is well below 240 F 116 C and the recirculation line from the diverting valve to the pump inlet is not extremely hot the safety limit may be defective These same conditions may also indicate a pump failure however knocking generally occurs when a pump fails 1X Routine De Liming Procedure ROUTINE DE LIMING PROCEDURE in hard water areas This should be done on a regularly scheduled basis 1 Close the gas cock or manual gas shutoff see Figure 9 and shut off the main disconnect switch 2 Isolate the HeatMaker 9600 HWG unit from the system by closing the shutoff valves If recirc lines are piped isolate the return system from water heater 3 Remove the lower front panel from the water heater and connect a hose to the drain fitting Located under the cylindrical chamber Relieve pressure at drain 4 Connect a hose to the drain provided by installer on the cold return side piping to the appliance 5 Removecover from thermostatic valve and remove thermostat Wrap tape around over cutaway sections in the cover and replace all parts except thermostat Reinstall valve cover and tighten bolts 6 the water heater combustion coil with deliming solution from the hose connected under boiler coil assy until it exits from upper
23. lashing of one of the lights 2A Code GREEN POWER Light flashing control failure no light no power RED PURGE Light flashing blower or stack switch failure or possible flue blockage RED VALVE FLAMF Light flashing valve igniter or flame sense failure combustion related problem Note If the stack switch contacts are closed for any reason when the blower isn t operating a sequence will not occur and after 45 seconds the control will lock out and the PURGE light will flash If the stack switch contacts are open and do not close during purge period after 5 minutes the control will lock out and the PURGE light will flash If the boiler does not operate the green POWER light is on and no indicator lights are flashing check for an open vent TCO operating control or safety limit switch For additional troubleshooting information refer to the trouble shooting flow charts on the pages that follow WILL RESTART IF SWITCH CLOSES A POWER LED BLINKS ONCE WHEN 24V POWER IS APPLIED AND WHEN THE THERMOSTAT CALLS FOR HEAT A ON AS LONG AS CONTROL IS POWERED AND OPERATING PROPERLY A IF EITHER SWITCH OPENS DURING THE RUN CYCLE BURNER WILL STOP FOLLOWED BY POSTPURGE CIRCULATOR WILL RUN AS LONG AS THERMOSTAT IS CALLING FOR HEAT BURNER IGNITION SEQUENCE Normal Operation Page 16 LAARS Heating Systems GENERAL TROUBLE SHOOTING RESET BOILER CONTROL BY SWITCHING OFF POWER AT
24. n 4 and 14 in W C 2 3 and 8 1 oz in b Thedifferential pressure on the outlet side of the gas valve manifold pressure is between 0 05 and 0 35 in W C If a and b are correct proceed as follows When measuring CO2 natural gas units readings below 846 generally indicate lean mixture not enough gas Reading above 9 1 4 indicate a rich mixture too much gas Readings for LP units are higher below 9 1 496 is lean and above 10 3 4 is rich If the readings are below the minimum values install a larger gas orifice If the readings are above the maximum value install a smaller orifice LAARS Heating Systems Page 10 COMBUSTION COIL MANIFOLDS ECONOMIZER ECONOMIZER OUTLET RETAINERS 4 OUTERSHROUD CLAMPS 4 COLDWATER INLET PLASTICFLANGE 4 NUTS Figure 8 Disassembly 1D Cleaning the Combustion Chamber Coil Note In normal operation this procedure is seldom required Should it prove necessary the following procedure is used to access the coil for cleaning 1 Turn off gas and electrical power to unit 2 Remove upper and lower front covers 3 Disconnect flue and combustion air pipes and remove jacket top 4 Remove flue pipe assembly by disconnecting from outer shroud Remove mixer tube and blower assembly Remove igniter and burner flameholder Fit mask and eye protection Fit mask and eye protection 41907 Locate vacuum hose at flue outlet
25. nd one or more of the zones are very small If a small zone causes the problem then it may be necessary to only allow that zone to operate when another zone is calling This can be accomplished without repiping in a zone valve system by disconnection the end switch wire from the zone valve which controls the small zone s If the boiler is oversized cycle time may be reduced by reducing the boiler input An orifice kit is available to reduce input from 200 00 BTU HR to 150 000 BTU HR or 175 000 BTU HR System related short cycling can also occur on 9600 HWG Units It results from very high aquastat settings on the storage tank Settings higher than 160 170 F 71 77 C should be suspected of being the cause Many times tank aquastats are set high to compensate for an undersized system If they are set too high and the unit short cycles then the output from the system will actually be reduced Combustion related short cycling occurs when the burner is incorrectly adjusted Lean mixtures low CO2 or high O2 cause the boiler control to lose the flame signal The control then causes a restart and if the flame signal is sensed on the restart then the burner will operate again The intermittent sending and losing of the flame signal by the boiler control causes it to short cycle the burner If combustion related short cycling is suspected refer to Checking Combustion 1W Lock Outs amp Trip Outs The principal cause of nuis
26. of outer shroud and start vacuum cleaner 10 Bend air chuck extension 90 at a point about 2 3 from end Insert air chuck extension through burner hole in upper head Direct end of extension toward fins of heat exchanger and blow off accumulated residue Methodically move up and down and completely around the heat exchanger After completion of this remove the extension from the burner hole and inspect the condition of the heat exchanger with a flashlight and inspection mirror If there are areas on the heat exchanger that still have some residue repeat the process on those areas until the heat exchanger is clean After the heat exchanger is clean remove the vacuum cleaner from the outer shroud flue outlet and stop vacuum cleaner Carefully inspect the seal between the outer shroud and the upper head and the joint in the outer shroud If there is any evidence of leakage from either of these joints clean off the silicone in that area and prepare the surface for resealing Commercially available oven cleane is an appropriate cleaning agent Reseal the affected areas witih silicone reassemble all parts in the reverse order and check boiler operation 1E Diverting Valve The diverting valve is a thermostatically controlled device which keeps the primary heat exchanger H X from operating in the condensing mode When return water from the storage tank or the system is below 130 F 54 C the diverting valve recycles a portion of
27. ole Check that the blower flanges and gas piping are sealed D OCCASIONAL LOCKOUTS Requires interruption of power to re start or reset of safety limit 1 2 Q Air system causes safety limit to open Vent air form system eliminate source of air 9600 CB mostly Condensing in primary heat exchanger or moisture in combustion chamber a defective element in diverting valve b improper installation of intake terminal c blocked condensate and condensate overflow system Poor Combustion check CO2 or O2 Intermittent igniter failure defective igniter gasket allows igniter base to overheat Occasional failure of blower red PURGE light will be flashing 9600 CB zone control short cycling or voltage problem Operate thermostats in various sequences to create suspect problem Note Three wire zone valves such as Taco or Watts must have isolating relay between end switch and HeatMaker 9600 CB parts4iWheating 800 536 1582 Fax 866 448 9304 infoGparts4heating com 800 900 9276 Fax 800 559 1583 Customer Service Service Advisors 20 Industrial Way Rochester NH 03867 603 335 6300 Fax 603 335 3355 Applications Engineering Heating Systems Company 1869 Sismet Road Mississauga Ontario Canada LAW 1W8 905 238 0100 Fax 905 366 0130 A subsidiary of BRADFORD WHITE Corporation www Laars com Litho in U S A Laars Heating Systems 0810 Document 2109
28. otor type pump which operates whenever there is a call for heat or hot water If a pump change is required for any reason valve off the boiler and drain approximately 1 or 2 gallons of water 3 79 to 7 58L from the unit through the drain under the chamber Drain is accessed by removing lower front panel Turn off the main disconnect switch and unplug the pump wires remove the pump motor The pump housing need not be removed The replacement pump motor should be installed in the reverse order from which the old pump motor was removed After filling the system be sure to bleed air from the diverting valve petcock 1L Blower The combustion air blower is a high head centrifugal blower It is designed to provide about 4 W C of suction at 43 CFM This performance is necessary to operate the gas valve reliably to overcome induction system friction losses and to eliminate any sensitivity to wind striking the vent terminal It is powered by a 120 volt motor which draws about 1 65 amps at rated load It is controlled by the boiler control Whenever there is a call for heat and 30 seconds after the blower should be energized If a blower change is required turn off the 120 volt power and unplug the power wires from the blower motor Disconnect intake exhaust vents and remove top jacket Remove the six bolts and nuts from the blower discharge flange and the four nuts from the blower inlet flange The blower may now be deflected enough to pe
29. r burner adjustment see Burner Adjustment 9600 CB amp HWG Service Manual Page 13 Boiling noises can occur because of air in the secondary loop of a heating system 9600 CB applications or because of pump failures in either the 9600 CB or 9600 HWG Another boiling noise which occurs primarily on 9600 HWG units can result from liming of the primary heat exchanger This noise is more pronounced and may occur at any temperature If the pump appears to be operating properly and the unit continues to run normally except for the knocking sound then liming should be suspected and the unit should be de limed according to the Routine De liming Procedure If the knocking is very sever de liming may not stop the noise and the primary heat exchanger will need to be replaced The knocking sound may also exist on 9600 CB and 9600 HWG units for a very short time followed by a safety limit trip out The generally results from total pump failure impeller sheared off or motor not running at all 1V Short Cycling There are two different types of short cycling 1 System related 2 Combustion related The most common cause of system related short cycling is boiler oversizing 9600 CB Because the 9600 CB is a low mass boiler with high output it will short cycle if system load or water flow are insufficient to accept all of its output This situation may also occur with a properly sized boiler when it is installed in a zoned system a
30. ressure results from improper second stage regulator selection or a faulty regulator It can be detected by measuring the gas supply pressure to the unit at the inlet pressure tap on the gas valve Use a water manometer or pressure gage with a scale reading of at least 25 in W C or 1 oz in 2 Install the pressure tap in the 1 8 NPTF plugged port located above the gas inlet port on the gas valve The gas supply to the boiler must be shut off before making this connection The Heatmaker boiler is designed to operate with supply pressures of 4 14 in W C 8 1 oz in2 with the boiler not operating it is likely that this is the cause of the delayed ignition Lock up pressures must be measured when the boiler is not operating and preferably immediately after boiler shutdown Gas valve regulation problems can also cause delayed ignitions To detect gas valve regulation problems it is necessary to have an inclined manometer or a Magnehelic pressure gage The normal gas valve regulator setting is 0 2 IN W C This should happen smoothly without allowing pressure spikes positive when the solenoid opens then the gas valve regulator is faulty and may be the cause of the delayed ignition A defective burner flameholder can cause a delayed ignition however not often If the gas supply pressure and the gas valve are functioning properly and the air and gas orifices are correct the burner should be inspected To inspect remove the mixer tube and the
31. rmit its removal Replace the new blower using new gaskets in the reverse order from which the old blower was removed The four Inlet flange nuts however should only be finger tight initially and then tightened with a wrench after all other operations have been completed The combustion should be checked for correct air fueled ration whenever the blower is replaced see Burner Adjustment 1M Gas Valve The gas valve is a solenoid operated negative pressure regulated valve The outlet pressure is regulated at minus 2 inches W C It is designed to operate with supply pressures of 4 14 inches W C Within that range of supply pressures the regulated discharge pressure may vary from minus 05 to minus 35 inches W C The regulator is not adjustable and the effect of this variation in discharge pressure is not significant Because of the fixed regulator setting gas flow must only be adjusted by changing the gas orifice To remove the gas valve shut off the 120 volt power and the master gas cock in gas line loosen the nut on the gas orifice union and remove the orifice union plus piping to the gas valve Disconnect the wires from the gas valve the valve may now be unscrewed from the inlet piping It may be necessary to deflect the inlet piping somewhat in order to clear the boiler jacket After the valve has been removed replace with a new valve in the reverse order in which the old valve was removed Do not overtighten the fittings into
32. t pump It provides blower prepurge as well as burner flame sensing When replacing the boiler control all plugs are color coded and it is not possible to miswire the control See sequence of operation for operating details 9600 CB amp HWG Service Manual 11 Stack Switch The Stack Switch is a normally open single pole switch which is operated by the pressure difference across the air orifice It is set to close when a static pressure difference of 1 in W C is generated by the combustion air blower Its function is to prove airflow and to inhibit burner operation in the event of flue stoppage The switch is wired directly to the boiler control It is located on the inside of the jacket back panel 11 Igniter The Igniter is a glow bar type silicone carbide unit It is energized whenever there is a call for heat and the red IGNITER light on the boiler control is lit After the igniter is switched off and boiler continues to run the igniter functions as a flame sensor for the boiler control If the igniter fails and must be replaced always install a new igniter gasket with the replacement igniter 1J Transformer The control transformer accepts 120 VAC power and provides 40 VA of 24 VAC power for the boiler control only It is not capable of supplying control power for external devices such as zone valves They must have their own separate power supply 1K Unit Pump The unit pump is a wetted r
33. tat or storage tank aquastat to call for heat 4 Turn on electrical power to the unit 5 Thegreen light on the boiler control will light and the internal circulator and blower will start After a 15 second prepurge the igniter will come on for 20 seconds and then the gas valve will open and ignition will occur for more details see Sequence of Operation Note Air in new gas lines may prevent ignition The boiler control will make a total of three attempts for ignition before lockout To reset the control switch off the power switch for 10 seconds 1C Checkout Procedures 1 Check burner input rate Allow burner to operate for at least 5 minutes before checking the input On most LP installations it will be impossible to check the input however checking combustion as in step 2 below will guarantee proper burner operation To check the input where possible time the gas meter to determine the time required for 4 cubic feet of gas to pass through it No other equipment supplied by the gas meter should be operating when the timing is done Table 1 can be used to convert the time to input rate Due to the effects of altitude and other minor variances it is possible that the input rate will differ slightly from the rating plate value 2 Check combustion see Figure 7 It is important to check the combustion with a CO2 or O2 tester Bacharach for example to ensure maximum efficiency and reliability Insert
34. the outlet water from the primary H X back to the primary H X inlet so that the minimum temperature required to prevent condensation on the primary H X is maintained at 160 F 71 C The thermostat element is similar to those used in large industrial engines To change the thermostatic element valve off the unit and turn off electrical power Open boiler drain to relieve pressure and close again Remove the cap screws 3 and remove top of valve Remove and replace the element with barrel up spring and sealing disc Place O ring under valve top and replace top Secure with cap screws and tighten Turn on valves and bleed air from the top of the diverting valve Turn on electrical power and restart unit 1F Safety Limit Switch The Safety Limit Switch has a fixed set point of 245 F 118 C It has a manual reset button which may be reset at temperatures below 240 F 116 C To replace the switch shut off the 120 volt power and valve off the unit Drain a gallon of water from the boiler and remove the 3 8 NPTM fitting which seals the capillary Remove the two screws which hold the switch to the side panel remove the switch and unplug the switch wires Install the replacement in the reverse order open isolation valves and bleed air from the diverting valve petcock Switch on 120 volt power and restart unit 1G Boiler Control The boiler control controls the combustion process the gas valve the igniter the blower and the uni
35. ve Flow To Primary Loop Secondary Heat Exchanger Inlet Secondary Heat Exchanger Outlet Primary Heat Exchanger Inlet Primary Heat Exchanger Outlet m Pp B Oo N O Q b Q N 1 1 4 FLOW SYSTEM 60 C THERMOSTAT m t CHECK I VALVE H INTERNAL PUMP A PORTION OF 1 HOT WATER D IS RECYCLED D VU TO MAINTAIN _ N PRIMARY HEAT T EXCHANGER INLET E TEMPERATURE R AT 60 C N _ 5 7 PRIMARY HEAT L 2 EXCHANGER gt lt 1 1 4 RETURN L FROM SYSTEM ud L Figure2b Water Flow through a Heatmaker 9600 HWG After S N 394 067 CB After S N 795 0013 Page 6 LAARS Heating Systems EXHAUST INTAKE TERMINAL gt NN WALL Ma ae NPY N Y EXHAUST AIR N D TERMINAL INTAKE WALL PLATE AIR ORIFICE GAS ORIFICE COMBUSTION p COIL GAS 2 2 7 FLAMEHOLDER EXHAUST c ASSEMBLY REFERENCE PAGE 8 FOR PART NUMBERS CONDENSATE Figure 3 Air Fuel Flow Through Heatmaker 9600 9600 amp HWG Service Manual Page 7 64 Figure 4 Cut Away View of Heatmaker 9600 Figure 5 Control Box Page8 LAARS Heating Systems HIGHLIMIT SAFETY SWITCH BOX
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