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13 functioning parts data & how to check them

1. 52 9 Over Temperature Fuse Sa a i ea aq 55 11 Air Pressure Switch VIRA d s 56 12 SONSON OEM 13 Printed Circuit Board 1 1 eere errore eren reir orante onum aatia nott meno nones 14 Control Panel Base Board Ge Rada 60 15 Electromagnetic Pump Unit Bypass Valve 61 16 e SM 1 BE 17 18 POS FLEET OCIS a 6 19 Fuel Filter a S RARER 64 20 Dismounting amp Dismantling of Parts Components Fa 14 Capacity Data 1 66 69 15 Electric Specifications A Timing Sequence Graph ERR Ne EA A Reed FR A 70 71 FW CHOI pon 72 Winhg DIBDIBm 73 D SS ttr 74 E Voltage Values on PCB Connector 75 F Failure Mode and Effects 76 G Grout BOCK uu q ki Sua aa aaa a 18 Sohema
2. a l Control Panel 70 15 ELECTRIC SPECIFICATIONS TEMPERATURE CONTROL GRAPH AT NORMAL MODE OF OPERATION 1 Power switch pushed to ON position on control panel 2 When faucet is opened the flow sensor senses a min of 45 gal m of flow then the operation sequence starts as long as the set temp is higher than the water temp at thermister sensor 3 Blower motor and ignitors start the operation After completion of T1 electromagnetic pump and valve turn ON low mode 4 Once CDS senses flame the electromagnetic valve turns off and air solenoid releases thus allowing the unit to go to high mode 5 The temp at thermister rises to an OFF point level 1 which turns the unit to low mode 6 Thetemp at thermister rises higher to OFF point level 2 stopping the electromagnetic pump and the burner light turns off 7 a The temp at thermister sensor drops down to ON point level 2 then unit turris onto low mode b Temperature drops further to ON point level 1 then unit goes to high mode 8 When the faucet is closed the burner stops and the unit goes to post purge mode The blower motor stops after passing T4 9 The power switch at the control panel is turned OFF then power lamp turns OFF 71 15 ELECTRIC SPECIFICATIONS Power Switch ON Power Switch ON 3 Power Lamo ON cc Fiow Sensor detected the flow of the water
3. JOJOIN UPS LAO JBIBM 192 Jenno JO SIN3W3T13 11 OPERATING INFORMATION 11 2 PERFORMANCE DATA QUANTITIES AND TEMPERATURES OF HOT WATER SUPPLIED The maximum quantity of hot water that can be supplied is about 220 G H Temp of Outlet Water Outputof Outlet Temp Temp Of Hot Intake Water Hr of Hot Water Increases Water Min 77 204 76G 149 F 341G a x SpringFal sorF 16380G 1499F 90 2736 356 F 12946G tF 1134 zs 11 3 ERROR CODES Error codes on the control panel blink to inform the user of irregular operation Causes Loss of ignition in burner Flame out CDS wiring disconnection False flames or short circuited CDS Thermister wiring disconnection Thermister defective or short circuited Trouble with the lead wire or the terminal Overheat prevention thermostat tripped 194 F Trouble with the lead wire or the terminal Problem between control and main PCB Trouble with the lead wire or the terminal Main PCB has problem Fan motor has problem and fails to turn Trouble with the lead wire or the terminal 11 OPERATING INFORMATION 11 4 RECOMMENDED MAINTENANCE PROCEDURE WARNING mm Disconnect electrical power before proceeding Unit should also be cool ONA YEARLY BASIS Replace fuel filter at storage tank Check for water due to condens
4. Wrap the threads on the right side of the unit with a sealing tape or compound to ensure a tight fit Attach the fuel filter onto the pipe on right side of unit FUEL PIPE 1 2 3 When using copper pipe 3 8 in 9 52mm dia its length should be no more than 50 feet Prevent any debris from entering the fuel line Fuel pipe should be kept straight Bending can hold air bubbles and cause irregular combustion Do not crimp the fuel line Piping should include no inverse U type bends avoid air locks which could block the fuel supply Fuel filter must meet required specifications and should be installed so that it can be removed for maintenance service Be professional Clean up the work area before testing the unit Open fuel supply valve at fuel tank Loosen air purge screw at fuel filter installed on unit and allow air to escape Loosen bowl of fuel filter until it fills itself with kerosene Tighten air purge screw back to its original position Caution Wipe off all kerosene spilled over vessel MATTERS OF SPECIAL IMPORTANCE Fuel Filter 27 8 HOT amp COLD WATER PLUMBING WORK 10 Bi 12 13 A licensed plumber familiar with local codes and ordinances should install the KWH124 A water softener is recommended in regions where hard water may be a concern Do not apply any heat to the unit nipples Use standard copper alloy unions and nipples for the connections to the unit e Copper piping
5. 7039 Electric Outlet Cover Packing Kit Exterior Cover left side 79 18 GAUGE The drawing on the attached sheet can be cut out and used as a gauge DIRECTIONS FOR USE 1 Checking the position of an electrode a Please press a gauge against the nozzle through the hole of a stabilizer 7 STABILIZER ELECTRODE QT N BURNER HEAD UNIT b Check if the position of an electrode A B and C refer to page 48 stays within the range of each marking 18 GAUGE 2 Adjusting the position of electrodes a Check and make sure the center point of the nozzle is centered inside the hole of the stabilzer marked A centered within 5mm After adjusting remove the burner head unit b Adjust the height from surface of nozzle to electrodes marked C 3 3 5mm c Adjust distance from center point of nozzle to electrodes marked B 5 5 6 5mm d Adjust gap between electrode points marked 2 25 2 75mm e Reinstall burner head unit Adjust height from surface of nozzle stabilizer marked E 10mm GAUGE Cut gauge out carefully Reuse if possible bz 21 HMM 39nv9 bz HM O Z T gt H31N32 C m m D
6. If a problem is suspected the recommended procedure is replacing the nozzle rather than trying to check it Only if a nozzle was not readily available it could be checked by removing the burner from the unit Igniting the burner into an open non combustible atmosphere and surroundings Warning The checking procedure is not recommended in a consumer s home since the burner will produce kerosene vapor on pre purge and a long open flame upon ignition which could cause a hazard 13 FUNCTIONING PARTS DATA 8 HOW TO CHECK THEM 18 POWER TRANSFORMER NORMAL HOW TO CHECK 1 Pull the terminal of the transformer from PCB Red Red about 30 37 ohm White White 0 47 0 59 ohm 2 Measure resistance between Red Red White White Red White infinity ohm at 68 F and Red White terminals 19 FUEL FILTER Fuel filter separates impurities water and or dirt from fuel and ensures only clean fuel to be fed into the system When the element gathers a lot of dirt and a lot of impurities fuel does not run properly to the electromagnetic pump thus impeding the burner operation Clean the element at least once a year 13 FUNCTIONING PARTS DATA 8 HOW TO CHECK THEM 20 DISMOUNTING amp DISMANTLING OF PARTS COMPONENTS PROCEDURES AND PRECAUTIONS 1 Before removing any part component fromthe unit or a system close the fuel supply and water intake valves Shut off power supply Special attention must be paid to th
7. TURNING ON 1 Set the hot water temperature adjustment on control panel 2 Press the power switch on control panel to turn unit on Power lamp goes on 3 Fully open hot water faucet and unit will ignite in a few seconds Caution Be careful of scald injury when hot water faucet is open NOTE When the unit is installed at about 3 200 feet or higher please open the air volume control damper 1 Remove the Front Panel and Access Cover 2 Loosen the lower screws and adjust the damper 3 When adjusting the damper please check the state of burner combustion by checking the dratt Lossen this screw 31 11 OPERATING INFORMATION F rrrn f sS a 11 1 WORKING PRINCIPLES 1 Press the power switch on the control panel Power lamp is illuminated and unit is ready for operation 2 Open a hot water outlet valve or tap Opening valve starts the flow of water from the water inlet through the flow sensor heat exchanger and mixing tank When the water flow reaches approximately 45 G min the fan motor turns on When fan motor comes up to speed air pressure is closed and unit is ready for ignition 3 The prepurge lasts about 5 seconds after which the ignitors and fuel pump are energized The unit starts in low mode and as the CDS senses flame intensity building the Combustion lamp comes on As the burn chamber becomes hot the heat is transferred to the heat exchanger and in turn to the water If temperature se
8. 15 6 VENTING INSTALLATION SIDE WALL VENTING FITTING THE FLUE IMPORTANT Extension Limits of the Flue Length of the Number of Bends Note Extension limits do not include pipe adaptor elbow and end cap INSTALLATION EXAMPLE 1 1 BEND AL 3 MIN Clearance se MIN Use Only MPI Venting Kit From Combustible MIN Model MPI KWH Vent Kit Material Clearance Eod can Horizontal Vent Cap 9 MIN N Clearance N n k Wall thimble 7 MIN MN Clearance AST NOTE Maintain 3 min clearance around flue pipe from any combustible material Maintain 9 min clearance around end cap and 6 min clearance outside wall End cap is not considered a bend In the drawing shown above the number of bends is one 16 6 VENTING INSTALLATION INSTALLATION EXAMPLE 2 2 BENDS Vent Cap Horizontal Vent cap Wall Thimble Top View Pipe Adapter Sa Side View NOTE Maintain all min clearances stated in installation example 1 Possible Applications 2 bends 1 Up across and back 2 Up back and across 3 Back and across 4 Across and back Length variation may vary depending on place of installation Length should not exceed extension limits and no more than 2 bends 17 6 VENTING INSTALLATION 6 3 L TYPE VERTICAL VENTING IMPORTANT 1 Use only MPI KWH Vent Kit and Accessories for Side Wall Verti
9. Supply fuel and purge air Clean fuel filter Clean fuel piping Clean fuel tank Clean soot Use right sizes Check and replace Check and replace Check for obstruction a bad capacitor or bad motor Check and clean the flue Drain all bad fuel off Use kerosene only Provide air intake ports or louvers Open the damper at the Blower and check the state of burner combustion see page 31 12 TROUBLE SHOOTING 5 SMOKE IS COMING OFF THE UNIT PAINT ON THE EXTERIOR HAS BURNED DUE TO EXCESS HEAT Power Source Lamp and Combustion Lamp ON Causes of Troubles Countermeasures 1 Burner is not installed properly Screws are loose Check and repair burner packings are not in place 2 Silencer is not installed properly Screws need Check and repair tightening burner gaskets are not in place 3 Heat exchanger has warped resuhing in leaking gas Check and repair Heat exchanger has a hole 13 FUNCTIONING PARTS DATA amp HOW TO CHECK THEM 1 BURNER amp BURNER HEAD The unit is equipped with a newly developed one nozzle two stage combustion burner This burner is capable of creating two different levels of combustion high and low by changing the output pressure of the electromagnetic pump The burner controls the air damper so that the right amount of air is fed into the combustion chamber in accordance with change in the output pressure of the electromagnetic pump BURNER HEAD UNIT In orde
10. 10 Sec Passed 7 Lock out Code LED P ag Water Temperature Contro 2 ON Fan Motor ON Igniter ON Air Solenoid ON Prepurge Finished Electromagnetic Pump ON Electromagnetic Valve ON Flame Establised 7 Safety Time Over 7 Run Lamp ON _ Lock out x Cord LED a Hot Water Temperature Control 1 _ Solenoid OFF Electromagnetic Valve OFF Hot Water Temperature Control 2 ON Air Solenoid ON Electromagnetic Valve ON Post ignition Finished Igniter OFF 72 Power Lamp OFF Electromagnetic Pump OFF Electromagnetic Valve OFF Air Solenoid OFF igniter OFF Hun Lamp OFF Post Purge Finished Lockout Code LED x X Maltunction Indicator 3 6 7 9 9 HE GM GG Electromagnetic Pump OFF Electromagnetic Valve OFF Air Solenoid ON Run Lamp OFF Post Purge Finished Fan Motor OFF Igniter OFF 15 ELECTRIC SPECIFICATIONS C WIRING DIAGRAM Power Electromagnetic Pump Blower Solenoid Igniter Temp on mp Fuse T Junction Box Ora fa ll 5 e i li EQUIPMENT MN a GROUND IRE ETT erhea 5055 JSS 5 CILA 1 Prevention QODIE lt XASS ol YEL 1LLI T X d Cc m gt 5 gt gt 0 Fuse Pressure a Switch Printed circuit board RED imr RED WHT
11. 13 FUNCTIONING PARTS DATA 8 HOW TO CHECK THEM 14 CONTROL PANEL BASE BOARD This circuit board starts stops the burner and controls the temperature of hot water to be supplied through the user s operation of ON OFF switch and the temperature control knob on control panel This circuit board also incorporates circuits to operate monitor lamps including the emergency code lamp which blinks in case of a failure HOW TO ADJUST TEMPERATURE OF HOT WATER TO BE SUPPLIED e Power Source Lamp is lighted when the switch is turned ON e Operation Lamp is lit while the electromagnetic pump is working Monitor Indicators blink in case of trouble 2 4 8 E H P Press the switch on control panel off and then back on for resetting HOW TO ADJUST TEMPERATURE OF HOT WATER TO BE SUPPLIED Thermostat has been set at the factory to about 104 F to reduce the risk of scald injury Temperature of hot water rises as the hot water temperature control knob is turned to High and decreases as it is turned to Low Temperature range is about 167 F for High 130 F for Med and 104 F for Low NOTE When reinstalling a control panel circuit board make sure the thermostat slide is lined up with the panel cover so that knob can be installed back on correctly Knob Printed Circuit Board 13 FUNCTIONING PARTS DATA amp HOW TO CHECK THEM 15 ELECTROMAGNETIC PUMP UNIT BYPASS VALVE Electromagne
12. blue terminal 45 grey Tester around 2 3V O ring turbine shaft bearing bearing plate Screw cover terminal magnet case permanent magnet Hall Ic intake port thermister NORMAL TROUBLE Tester needle moves Tester needle stands still at OV or 12V Tester needie moves around 2 3V Tester needle moves Tester needle stands still at OV or 12V needle moves 13 FUNCTIONING PARTS DATA 8 HOW TO CHECK THEM HOW TO CHECK ee NORMAL 2 Checking built in thermister a Pullthe terminal of the flow sensor from the PCB Check on resistance by bringing the probe of a multi meter to come in contact with the terminal When the thermister is operating property its resistance should correspond with the specific characteristics shown the graph Method of Measuring Resistance E a Adjustthe tester to the resistance range Dis connect from PCB b Touch the two grey terminals with the probe as illustrated here AQ B0 BO 100 120 740 Temperature of Thermister Sensor Note If incoming water temperature is above 104 F the thermister will now allow the unit to come on 13 FUNCTIONING PARTS DATA amp HOW TO CHECK THEM 13 PRINTED CIRCUIT BOARD CONTROL CIRCUIT part component to ensure the safe operation of the unit SER Communications technology using a micro computer is 225 i Sum
13. oH f wm RED Power 5 lt lt X lt EE 4 Transformer BRN 222050 zz C i BRN amp Controller sou QU T Cds Thermistor Flow Sensor 73 15 ELECTRIC SPECIFICATIONS D Thermister in the flow sensor Electromagnetic Valve BLUE YELLOW 700 15 ohm RESISTANCE VALUES Component m mE Approx OHMS Blower Motor 33 ohm 38 5 ohm at 68 F Electromagnetic Pump RED RED 47 0 15 ohm 154 15 K ohm at 68 F 8 485 1096 K ohm at 122 F Air Solenoid Thermister for temperature control Less than 500m ohm Less than 50m ohm 18 4 8 K ohm at 59 F Less than 1 5m ohm 30 ohm 37 ohm at 68 F Power Transformer 047 ohm 059 ohm at 68 F av ohms Pressure Switch Overheat Prevention Thermostat Temp Fuse WARNING DISCONNECT POWER BEFORE MAKING ANY RESISTANCE TESTS 74 15 ELECTRIC SPECIFICATIONS E VOLTAGE VALUES ON PCB CONNECTOR Reading Taken at Voltage Reading Component m PCB Connectors DC Electromagnetic Pump _ 120VAC half wave rectified Electromagnetic Valve non Air Solenoid 120 VAC full wave rectified DC 108V Thermistor for temperature control 5V Pressure Switch RED RED gt w Overheat Prevention Thermostat YE ORN 5 Thermistor in the Flow Sensor o o 5V 75 15 ELECTRIC SPECIFICATIONS F FAIL
14. used to properly operate various circuits for safe operation EI of the unit Also various self diagnostic functions have been co built into this PCB ee PCB plays the role of controlling the performance of each The following are the circuits built in PCB PCB also provides connections for terminals of various functioning parts components e False flame detection circuit amp prevention of bumer from operating when there is no flow of water Pre purge circuit and post purge circuit Post ignition circuit Temperature control circuit and lost flames circuit Ignition failure and lost flames alarms circuits Broken thermister wire detection circuit Broken wire of temperature control resistance detection circuit Prevention of overheating circuit hi limit Over current prevention device fuse 6A Over voltage prevention device Monitor indicators circuit HOW TO CHECK NORMAL TROUBLE Printed Circuit Board 1 Make certain that monitor indicator H is blinking PCB is malfunctioning Fuse 2 Look through the glass tube to find out ifthe fuse inside Not blown is blown out either visually or by using a multi meter When the fuse is blown check out unit for pos sible short causing short The PCB which should be checked for shorted burnt or There is conductivity circuit cracked components or a shorted component outside the 1 Remove the fuse cover PCB such as a motor or coil 59
15. CHECK THEM 4 FAN MOTOR UNIT Fan motor sends compressed air necessary for combustion to combustion chamber Air damper is fitted at the air intake port of fan motor so that proper combustion air has been adopted for this system There is high and low automatically changed in accordance with the quantity of fuel being burned An air volume control a delicate control is attached by a screw on the damper casing This control may need to be adjusted for altitudes above 3 000 ft see page 31 This adjust ment would be determined by exhaust draft readings Fan blades must be kept clean Dirty fan blades may not produce enough air for effective combustion Dirty blades need cleaning Clean the blades once a year The fan motor is of a condenser type A double turbo is used for the blades The motor has a built in overload prevention system which comes into play when the motor has trouble or when the temperature in the inside ofthe unit rises excessively The overload protector will reset automatically when motorcools to normal operating temperatures HOW TO CHECK STANDARD VALUE MOTOR u 1 Pulloffthe fan motor terminal from the printed circuit board pip 33 ohm 2 Using a multi meter measure resistance at the terminals ds coming from the fan motor SOLENOID 1 Pull off the solenoid terminal from the printed circuit board M Value 1 5k ohm 15 a e 2 Using a muiti meter measure resistance at the terminals c
16. High to raise water temperature Slide knob down toward Low to reduce temperature c When adjusting hot water temperature with hot cold water mixing valve control the amount of cold water from main supply without changing the amount of hot water being supplied k Knob at position HIGH provides hot water at a temper ature around 167 F Knob at position MED provides hot water at a temper ature around 130 F Knob at position LOW provides hot water at a temper ature around 104 F WARNING w High temperature setting increases the risk of SCALD injury Households with small children or invalids may require a 120 F or lower thermostat setting to prevent accidental contact with HOT water NOTE Seasonal change in temperature of water from main water supply results in different hot water temperatures supplied Use hot water supply tap to control hot water temperature or readjust thermostat setting UNIT SHUT OFF 1 Shut off hot water supply tap and burner will automatically extinguish Post purge fan will run approximately 150 seconds after shut off 2 Press and turn off Power when unit is not going to be used for an extended time Power lamp goe 3 OPERATIONAL PROCEDURES 3 4 WARNINGS BURNS Don t touch the flue The flue reaches a high temperature Protect yourself from potential burns WATER FOR DRINKING The quality of water from unit may change depending o
17. MODEL KWH 124 Instantaneous Kerosene Fired Water Heater D N 10 11 CONTENTS Specifications I n u usu M Special Precautions n Operational Procedure Fuel Installation Operation nennen 5 9 Freeze Proofing of the Piping nennen Maintenance Cheellial 11 12 Venting Installation 6 1 Chimney Installation TR 13 14 6 2 Side Wall Installation wau E E E GS SCARIER OSL 15 16 6 3 L Type Vertical Venting 17 20 6 4 MPI Venting Kit amp Accessories 21 25 Installation of Fuel Pipe UMEN 26 27 Hot amp Cold Water Plumbing Work A ea RN s 28 29 Elpotiio WI kata ES 30 POSE 31 Operating Information 11 1 Working Principles SARI ER EE sa KI Ran de 11 2 Performance Data e M IPC 11 3 Zip uo A Y assi No NAYA RA 34 11 4 Recommended Maintenance Procedur
18. is recommended for the hot water supply line Refer to local codes when considering piping materials e Steel piping is not recommended as it may cause rust in the piping e Use NPT for piping of hot and cold water Connecting plumbing to the unit hold unit fittings securely with a wrench to prevent damage to the unit Provide a shut off valve and a check valve on the cold water supply An ANSI listed pressure relief valve should be installed at the hot water outlet connection of the heater at the time of installation Local codes should govem the installation of the relief devices For safe operation of the heater be sure that a No valve is placed between the relief valve and the heater b Discharge from the relief device is routed to a suitable place for disposal when relief occurs c No reducing coupling or other restrictions are installed in discharge line d Discharge line is installed to allow complete drainage of the device and line Note Manual operation of pressure relief valves should be done at least once a year Connection between the heater and places where hot water is used should be as short and direct as possible and a uniform pipe size of sufficient diameter to carry the full capacity of hot water should be used Be sure to connect the water inlet and the hot water outlet as shown on the heater Reversing the two connections will damage the unit When hot water flows through the supply line there is an inevitable heat l
19. ohm Pull off the terminal of CDS from the main board Use a tester to measure the pre operation resistance value of 2 CDS detects false flames CDS If the value measured is less than 80k ohm check a CDS is not fitted properly in place a through c b Front panel doors are left open when the unit was turned on c stabilizer gathered so much soot that flames do not go out when the unit is shut off 6 BROKEN WIRE OF THERMISTER Causes of Trouble Countermeasures 1 Broken wire of thermister or thermister terminal has Pull off the thermister terminal from the main board come off the PCB or a defective connector a tester to measure its resistance value If the va measured is more than above 30k ohm at 32 F check the connections at the terminal If the connections are good then replace the thermister 12 TROUBLE SHOOTING a uwa n 7 1 THERMAL OVERHEAT PROTECTOR WAS ACTIVATED 2 THERMISTER VALUE IS TOO LOW Causes of Troubles Countermeasures 1 Thermal overheat protector Troubie with the printed Replace with another printed circuit board and see if the circuit board cause of the trouble has been removed 2 Thermister value is too low Thermister resistance Use a tester to measure the resistance value of the value is low compared to the temperature of water in the thermister If the value measure is less than 800 ohm heat exchanger Refer to chart further in this manual on replace the thermi
20. valve is shut The fan motor continues run awhile in order to drive exhaust gas out of the combustion chamber even after the hot water valve is shut off Fan motor will stop in about 150 seconds 36 12 TROUBLE SHOOTING ERROR CODES THEIR POSSIBLE CAUSES AND POSSIBLE SOLUTIONS B 4 Causes of Troubles 1 Defective flow of fuel e aoe m d B f No fuel in the fuel tank The fuel valve on the fuel tank is in the off position The fue line is broken Water and or dust in the fuel line Fuel filter is clogged with dust and debris insufficient fuel filter air purge Irregular sparking at igniter rods a b C Improper fitting of igniter terminal Soot or carbon has gathered on igniter rods Improper positioning spacing and contact of igniter rods Voltage is low sparks are weak Defective igniter does not spark Crack in insulator of electrode 3 No fuel running from nozzle or vaporizing trouble a b Defective electromagnetic pump Clogged nozzle 4 CDS is not working properly a b C d 6 Insufficient air supply Accumulation of soot on CDS light reception surface Accumulation of soot on Bumer Head CDS is not properly fitted in place CDS has wiring problem or CDS has too high a resistance value 5 Exhaust gas recycles inside the unit 7 Trouble with the printed circuit board 37 DETECTION OF BURNER IGNITION FAILURE AN
21. ARD VALUE UNACCEPTABLE VALUE Resistance Varies Hesistance does not change with changes in light levels During good combustion reads less than 30k ohms Loss of flame detected at more than 85k ohms After unit shutdown no combustion more than 100k ohms 13 FUNCTIONING PARTS DATA amp HOW TO CHECK THEM 17 NOZZLE The fuel compressed to the required level by the electromagnetic pump is injected as vapor from the little hole of the nozzle into the combustion chamber The nozzle changes the compressed fuel into vapor that atomizes faster than liquid Nozzles come in a variety of sizes Do not attempt to change the size as fuel consumption and clean efficient com bustion depends on nozzle size Nozzles allegedly of the same size in fact are not exactly identical Fuel consumption could sometimes change by merely changing the nozzle to one that is claimed to be of the same size NOZZLE TO BE USED Size 0 85 GPH Vapor Injection Angle 60 Vapor Type A Pattern Service Parts No 7011 HOW TO CHECK Filter Distributor Orifice E LY Sit LA _ Circulator Remove the burner from the unit Ignite the burner in the atmosphere streak Normal Vaporization a uniform distribution lt _ of particles nozze vaporization 60 70 stabilizer stabilizer DEFECTIVE VAPORIZATION 1 Vapor is not uniform 2 Vapor angle is wrong 3 Streaks are visible instead of mist
22. D LOSS OF FLAME Countermeasures Loosen the air purge screw at the fuel filter and see if fuel comes out If no fuel comes out check 1 through 3 again Remove the burner Pull and disconnect the terminal of the electromagnetic pump from the baseboard Turn on hot water supply switch and see whether or not the igniter rods spark If not check 1 through 3 again Caution Igniter rods operate at high voltages Be careful to avoid electric shock hazard Remove the burner Place metal box with burner head facing away from source With igniter leads disconnected open up a hot water outlet Unit will start at which time the spray pattern is observed for even spray If no spray pump is bad funeven nozzle is clogged Dealer should do this at his shop to avoid fuel spray damage Pull and disconnectthe terminalof CDS fromthe base Use a tester to check the resistance of CDS While doing so turn on hot water supply switch and measure the resis tance value immediately after the electromagnetic pump was activated If the value is more than 60K ohm check a through d above Check the flue and its installation Check air intake grill and air damper for blockage Check 1 through 6 If nothingis wrong after having checked 1 through 6 replace the printed circuit board 12 TROUBLE SHOOTING I sss 5 DETECTION OF FALSE FLAMES CDS SHORT CIRCUIT Causes of Troubles Countermeasures 1 CDS short circuit resistance 0
23. IES Straight Length Pipe 1 length length 8505 _ h 3 length 8506 S length 8507 Carries a 3 clearance to combustibles and can be used i n both vertical and horizontal applications Inner Liner is 012 stainless steel type 430 Out side casing is 018 aluminized steel Adjustable Length Vent Kits are not appropriate be cause of interior obstructions 45 Elbow 6 VENTING INSTALLATION C T Adjustable Roof Flashing A Z 5 Accommodates roof pitches from lg B 0 12 6 12 Tall cone flashing allows 0 12 12 12 Tall Cone Roof Flashing 4 Rain Cap ka A Storm Collar The storm collar slips around the pipe just above the flashing Sealthe inner edge to the chimney with mastic 24 6 VENTING INSTALLATION Tea Support Bracket Top View Side View pi House Shield For blower discharge protection in E horizontal venting situations ds 7 INSTALLATION OF FUEL PIPES Use only fresh crystal clear 1 K Kerosene usually referred to simply as kerosene Avoid using deteriorated kerosene INSTALLATION OF FUEL TANK 1 Fuel tank must be equipped with a shut off valve that can effectively cut supply of fuel in case of emergency and with a UL listed fuel filter and drain valve 2 Fuel tank must be installed in a well ventila
24. NG FUEL FILTER To be done by authorized service person Check at least every six months to see if debris and or water has gathered in fuel filter 1 Shut fuel supply valve on fuel tank Turn cup counterclockwise to remove it from the assembly Dump water and debris from cup 2 Pull off element Clean it with kerosene 3 Reassemble fuel filter Purge air from fuel filter EXCESSIVE PRESSURE RELIEF VALVE Once a year make sure that the pressure relief valve installed on water supply piping is functioning 6 VENTING INSTALLATION say acannon 6 1 CHIMNEY INSTALLATION FITTING THE FLUE IMPORTANT THIS UNIT REQUIRES A DRAFT AT FLUE CONNECTION OF THE UNIT OF 2mmH O to SmmH O TO OPERATE NORMALLY Use flue pipes of 4 inside diameter Note tmay be necessary to install a Draft Regulator in the flue to obtain the recommended operating draft gt SA t E From Combustible Material Pitch Flue 1 4 Per Foot Upward Overall Length Of Flue Pipe ELE BD Chimney Installation Example 13 6 VENTING INSTALLATION GUIDELINE FOR ATTACHING THE FLUE NU Do not make any changes to the diameter of the flue piping Use durable materials for the flue such as double wall pipes with stainless steel Seal the connections of the flue Ensure that minimum distances are met between flue piping and walls and ceiling Double wall L type flue pipes are recommended to preve
25. STANTLY IMPROVING OUR PRODUCTS ALL SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE 1 SPECIFICATION 1 2 PARTS DESCRIPTION APPEARANCE _ Cold Water Intake Outlet Hot Water Filter Maintenance Cover Control Panel Fuel Filter Connection Front Door Drain Junction Box CONTROL PANEL Power Lam Run Lamp P Code LED Power Switch Temperature Adjusting Knob CONSTRUCTION Cold Water Intake Hot Water Outlet Air Damper Fan Motor 0 Mixing Tank Printed circuit Overheat Protector Thermo Heat Exchanger Hot Water Thermistor Temperature Fuse 1 SPECIFICATION 1 3 UNPACKING Unpack unit carefully The following parts are contained in the package Locate fuel filter and set aside to use when connecting the fuel line P Fuel Filter Water Intake Insulator Hot Water Outlet Insulator NOTE These parts are located inside the styrofoam packing at the top of the unit 1 4 SECTION DESIGNATIONS amp MAIN DIMENSIONS Dimensional Outline Drawing Unit Inches Hot Water Outlet Cold Water Intake Oil Filter Connection Vent Connector 2 SPECIAL PRECAUTIONS WARNING B Useonly crystal clear 1 K kerosene Neveruse gasoline white gas camp fuel or other flammable liquids Use of such fuels can result in an explosion and cause severe injury Adamaged or malfunctioning part should be di
26. Tes Exchanger relied Was i8 7013 Heat Exch winsulated wrap gasket 53 7102 Heal Exchanger Base Gasket f 7014 Water niet Connector 54 7103 Exhaust Stack Gasket 15 Fite 7104 Fan Motor Gasket 16 _ Water Governor __ 7105 Flange Gasket 17 inlet Pipe Bumer Heat Gasket 18 a ri Water Inlet Gasket _ 19 7019 FlowSensorBracet 59 7108 Water Outlet Gasket 2 7020 Mixing Tank 1 1 60 7109 Water Governor Gasket u 21 7o21 Water i 7110 Damper Cushion 22 Exhaust Stack Outlet Insulator _ 7028 Printed Cirout Board 63 7201 O Ring Thermister P6 40 T 7024 ContolPanelAesy 64 7202 O Ring Water Filter P10A 1A 25 Control Panel Circuit Board 65 7203 O Ring Multiple Use P14 4C 26 7026 Thermo Overheat Protector 86 7204 _ O Ring Flow Sensor Inlet P18 4C 27 _ Over Temperature Fuse Set 7205 O Ring Water Governor P22A 1A 28 7028 MenFustA 709 Fuel Fitter Element 29 Power Transformer GLUE for burner head gasket 7030 Terminal Block 7207 GLUE heat exch base amp exhaust stack gasket 7031 PCB Spacer Clip 7208 Lead Wire fan motor Lead Wire flow sensor 33 NET TI CHEE SE S Lead Wire air pressure switch 34 Lead Wire power supply 35 7212 Lead Wire control panel 36 Owner s Manual 37 Exterio PET 7214 Installation Manual 38 7215 Carton Box
27. URE MODE AND EFFECTS Component Blower Motor ignitor Electromagnetic Pump Electromagnetic Valve Air Solenoid Thermistor sensor in the flow sensor _ Thermistor Sensor CDS Air Pressure Switch Overheat Prevention Flow Sensor Power Transformer Controller Failure Mode Open Shot Open Short Open Open en 9 9 Short en 9 ho Open a Open Open o 2 mi Open Effect on system operation When blower motor starts the main fuse cuts off Blower Motor does not start Code LED blink P and system lockout When ignitor starts the main fuse cuts off Ignitor does not start Code LED blink 4 and system lockout When electromagnetic pump starts main fuse cuts off Electromagnetic Pump does not start Code LED blink 4 and system lockout When electromagnetic valve starts the main fuse cuts off Electromagnetic Valve does not start When Air Solenoid starts main fuse cuts off Air Solenoid does not start System does not start System does not start Code LED blink 7 and system lockout Code LED blink 6 and system lockout Code LED blink 5 and system lockout Code LED blink 4 and system lockout Code LED blink P and system lockout Code LED blink and system lockout _ NO Change Code LED blink 8 and system lockout System does not star
28. agnetic pump is defective gets insufficient pressure Either solenoid or damper is defective solenoid does not work Burner gets ignited but flames are not normal Electromagnetic pump is defective NOTE If the fuel pipe has been disconnected for atmospheric combustion the stability of flames will not be achieved if air inside the fuel pipe is not completely purged out Installing Direction of Burner Head Unit Please adjust the notch of Burner Head Unit to the dowel which will set position and then fasten 4 screws Burner Head Unit Adjust the notch to the dowel 46 13 FUNCTIONING PARTS DATA amp HOW TO CHECK THEM 2 IGNITER TRANSFORMER To ignite vaporized kerosene from the nozzle two ignition rods are placed close to the nozzle and high voltage is applied to the tips of these rods to create sparks Kerosene is ignited by these sparks The igniter transformer increases the incoming voltage of 120 volts up to 17 000 volts The igniter transformer for this unit is of the electronic type HOW TO CHECK NORMAL TROUBLE 1 Disconnect the connector of the electromagnetic pump lead wire from the PCB 2 Turn the unit on and listen for the sound of the Thereis audible sparking Sparksoundis inaudible electrodes to be audible sound PRECAUTION e Handle igniter carefully as high voltage runs through igniter e Grounding the lgnitor Transformer Make sure the two transformer mounting scr
29. ater flow and quantity of flow The sensor used for this unit is of the impact turbine type The turbine has a spiral shape with two wings Both water intake port and outlet port are shaped to have a 90 degree angle The opening of the intake port has a semi circle shape Water coming into the turbine from this opening turns the turbine that is the turbine s rotation is in propor tion to the speed and quantity of water that comes in A magnet installed in the turbine rotates in conjunction with the turbine and helps tap signals to take advantage of hall effect Hall IC is separated from water current by a plate The temperature of water coming into the heat exchanger is measured by a thermister _ HOW TO CHECK 1 A simple way to check on flow signals It takes an oscilloscope for a precise reading of the flow signals lt wave pattern The following is a simpler alternative a Turn ON OFF switch ON Open the hot water dispenser valve slowly until hot water running from it reaches slightly over the minimum quantity re quired to start the unit burner that is about 45 gal min b While keeping the terminal of the flow sensor on PCB touch it the terminal with the probe of a multi meter and measure voltage Measuring Method a Adjust the tester to the DC voltage range 10V b Bring the negative side probe of the tester to come in contact with the white terminal and the positive side probe with the
30. ation Drain if necessary Check and clean fuel filter at unit Check fuel lines and all connections for leaks kinks or obstructions Tighten or replace if necessary Inspect electrical wiring for cracks signs of deterioration bare wires and or loose connections COMBUSTION BLOWER ASSEMBLY Remove combustion blower assembly for cleaning and inspection Remove CDS Check and clean If heavy dust build up clean out combustion blower Note gasket is damaged replace it Check air pressure switch hose for blockage Wire brush and vacuum burner head ring and stabilizer Inspect for cracks and deterioration Inspect igniter rods for cracks in the ceramics or distortion Also check rod spacing Vacuum inside of burn chamber Caution Be careful not to distort heat exchanger fins located at bottom of bum chamber and be careful not to scratch burn chamber B ADDITIONAL PROCEDURES On a two to three year basis Note Before proceeding shut off water supply and drain unit Change nozzle Remove flow sensor and thermistor Check for scale mineral deposits or corrosion Clean or replace if necessary Inspect the water passages of heat exchanger for scale or deposits Flush and clean if necessary FOUR TO FIVE YEAR BASIS Remove burn chamber heat exchanger and clean thoroughly all carbon and soot deposits Clean and vacuum silencer assembly Note Gaskets should be replaced Check O Ring seals for cracks or deteri
31. cal L Type Venting 2 This unit must be installed in accordance with these instructions local code ordinance and or in the absence of local codes the latest edition of The National Fire Protection Association NFPA 31 code 3 Overall length of the flue system is governed by the necessary draft This system requires a draft at flue connection of the unit of 2mmH O to SmmH O to operate normally may be necessary to install a draft regulator GUIDELINES FOR ATTACHING THE FLUE 1 Do not make any changes to the diameter of the flue piping 2 Seal and lock the connections of the flue 3 Use a rain cap to protect the flue from rain and wind coming in 4 An insulated wall thimble is required for inserting the flue through any combustible material 5 Ensure that minimum distances are met between flue pipes and walls and ceilings 6 Flue piping used through the wall should be pitched down 1 4 per foot toward outside Side Wall Venting 18 6 VENTING INSTALLATION INSTALLATION EXAMPLE 1 L TYPE VENTING OUTSIDE OR STRUCTURE Vent Cap Rain Cap Storm Collar _ Roof Flashing W 3 MIN Clearance to Combustibles Tee Support Bracket Every 4 MIN H 3 MIN Clearance to Combustibles Wall Thimble Tee with Tee Cap 90 Elbow P4 7 a Pipe Adapter To check draft drill hole large enough to insert pro be of Monometer or Bacar ach Meter to m
32. dicate a leak and must be corrected B FUEL PIPES REPLACEMENT Check fuel pipes at least one a year for distortions and or cracks Contact authorized service dealer for re placement of defective pipes WATER IN FUEL TANK Water and dust can easily go into fuel tank After accumulating in the tank they may flow into burner and cause imperfect combustion Check if there is any water in the tank at least every six months by checking the fuel filter canister at tank Have any water removed by an authorized service person FLUE AND ITS VICINITY Periodically make sure that there are no flammables around and above flue Also make sure flue is properly installed and maintained CLEANING HEAT EXCHANGER Drain water from heat exchanger at least one a year 1 Shut water supply valve at main 2 Open hot water supply faucet 3 Open drain valve at heat exchanger Also open inlet water filter and pressure release valve Then drain water from heat exchanger CLEANING INLET WATER FILTER Check once every three months and remove debris gathered in the inlet water filter 1 Shut water supply valve at main 2 Open hot water supply faucet 3 Open drain valve at heat exchanger Then remove inlet water filter and wash and clean it CAUTION If lime has accumulated remove it with a commercial compound for dissolving lime Check water soften ing equipment if lime is found in the filter 5 MAINTENANCE CHECKLIST CLEANI
33. e 35 Trouble Shooting A B j Guideline 8 Corrective Measures ANE P A S filao 36 Error Code their possible causes and possible solutions 37 40 A 5 ie bad H P Causes of troubles and irregularities which are not reflected in Monitor Indicator Lamp 1 Desirable temperature of hot water is unobtainable 41 2 NO hot water Burner does not ignite GSS kas Gs 42 3 Fowertamp does not BONNE eke 42 4 Strange sound in Combustion Burner soot is produced smell of kerosene 43 5 Smoke is coming off the unit Paint the exterior has burned due to excess heat NACE asas 44 13 Functioning Parts Data amp How to Check Them 1 Somer amp Burner Head a s uuu sua quas a 45 46 2 ignitor Transformer H kl 3 Electrodes I ao UR FR SARUM M 4o 4 Ban Motor Ll iuuenes tore to oon o euro a 49 9 Water Governol 6 Mixing s 7 Heat RTI aN 91 8 Thermostat For Prevention of Overheating
34. e e b ITE LI LIII ITI F mo LET 110 2 Water Temperature at Intake Time min 105 6G H Quantity of Hot Water Dispensed ui A477 nnn ini 160 Position of Knob 1 HIGH 150 1407 120 ol so L ft sol li _ 1 1 l o LLL 60 110 Water Temperature at Intake Time min 14 CAPACITY DATA GRAPH 158 5G H Quantity of Hot Water Dispensed TI Position of Knob T HIGH D MED Water Temperature at Intake Temperature of Hot Water Dispensed Time min 211 3G H Quantity of Hot Water Dispensed Position of Knob Water Temperature at Intake Temperture of Hot Water Dispensed 2 10 Time min 69 15 ELECTRIC SPECIFICATIONS NNNM M R A TIMING SEQUENCE GRAPH m SEQUENCE OF MOTIONS Variable Timing of Sequence T1 Preignition Prepurge 5 1 sec T2 Post Ignition 10 2 sec T3 Ignition Trial 15 3 sec T4 Post Purge 150 30 sec T5 Flame Response 15 MAX sec T6 Pre Air Solenoid 15 0 5 sec T7 Air Pressure Switch ON Delay 12 3 sec T8 Air Pressure Switch OFF Delay 58 12 sec Normal Mode D rower Switch ON B Water supply tap 2 Water supply tap ON 9 Power Switch OFF Electromagne tic Pump _ Electromagne tic Valve CdS Temperature at Thermister Sensor ar VZZZA L Burner State pi
35. e number of and the order in which these parts have been dismantled Re assembling must follow the reverse order and should leave nothing unassembled Once reassembling is completed first check for the possibility of leaking water fuel and or exhaust gas Also make certain that the state of combustion is normal 65 14 CAPACITY DATA GRAPH 1 QUANTITY OF HOT WATER DISPENSED HOT WATER TEMPERATURE CHARACTERISTICS PARAMETER WATER TEMPERATURE Position of Temperature Controller High 180 Ahhh LL prs UNT LI Wwe gt pasak ama san IN 60 100 1 200 220 250 Temperature of Hot Water Dispensed 50 Quantity of Hot Water Dispensed ds 14 CAPACITY DATA GRAPH 2 HOT WATER OUTLET MAXIMUM DEGREE RISE Maximum hot water supplied by this unit is about 220 Gal HR II _ 85GalMin 3 TIME HOT WATER TEMPERATURE CHARACTERISTICS PARAMETER POSITION OF TEMPERATURE CONTROLLER Position of Temperature Controller Knob THERMOSTAT 00 1969 5mm HIGH Position 2 0 7874 20mm MED Position 31 1811in 30mm Water Temperature at Intake was measured at the Cold Water Intake Temperature of Hot Water Dispensed was measured at the Hot Water Outlet 67 14 CAPACITY DATA GRAPH Temperature of Hot Water Dispensed 2 Temperature of Hot Water Dispensed 52 8G H Quantity of Hot Water Dispensed Position of Knob 170 S I eee e
36. easure draft Note Reseal hole to pre vent exhaust leaks after draft measurement w ba Tee Support Bracket 19 6 VENTING INSTALLATION INSTALLATION EXAMPLE 2 INSTALLATION EXAMPLE 3 L TYPE INSTALLATION VERTICAL VENTING Inside of Structure Vent Cap Rain Vent yo Rain 3 MIN Clearance Pipe Sections As Required Storm Collar z yo Roof Flashing SS FI 3 MIN Clearance to Combustibles or Wall Thimble 3 MIN to Combustibles I 3 MIN to Combustibles or Wall Thimble 6 VENTING INSTALLATION 6 4 MPI VENTING KIT amp ACCESSORIES 1 MPI KWH VENT KITS amp ACCESSORIES LIST Ali MPI S W V Kit parts can be purchased separately as needed PART NAME u 90 Elbow 8518 wa Thimble 8519 aa im K NENNEN r Straight Length Pipe 3 Length Tee Wih Tes Cap 8512 Rain in Cap Storm Cola EN 8514 Tee Support Bracket esis Howe shies E TEE Horizontal Vent 21 6 VENTING INSTALLATION 2 MPI KWH VENT KITS MPIS W V KIT 8501 INCLUDES THE FOLLOWING Pipe Adapter 90 Elbow Wall Thimble Horizontal Vent Cap Pipe Adapter SIZE 4 Unpainted Stock 8517 90 Elbow Wall Thimble 6 VENTING INSTALLATION ACCESSOR
37. ed RUNNING WATER This method will help to prevent water from freezing throughout unit s systems including pipes for inlet water and hot water supplies as well as valves 1 Turn Power switch on control panel to off position 2 Open a hot watertap and allow a stream to flow continuously at about 1 gal min Be sure to check that water continues to run during the period that freezing may occur PURGING WATER This method is useful when unit is not going to be used for extended periods of time 1 Shut off electrical power Turn off water supply valve at unit 2 Open fully all hot water faucets including the shower 3 Open drain valve of heat exchanger Open inlet water screen and release the pressure relief valve Allow water to drain from inside heat exchanger CAUTION When tuming on unit in cold weather open water faucet and make sure that water comes out If water does not run smoothly or does not come out at all chances are water is frozen Wait until water starts running smoothly and then turn unit on 10 5 MAINTENANCE CHECKLIST en It is recommended that the unit is inspected and cleaned once or so a year to ensure its long life FLAMMABLES OR DUST Keep the top and vicinity of unit clean Keep flammables and dangerous items away from unit FUEL LEAKAGE SPILLS AND STAINS Make sure all fuel connections are tight and are not leaking Any spills or stains by unit in
38. ews are tight and secure so that they provide a good ground g Igniter 2 AOU A 2 di gt i a z R xt e 2 Screws 47 13 FUNCTIONING PARTS DATA amp HOW TO CHECK THEM 3 ELECTRODES Electrode is the instrument used to ignite vaporized fuel When the electrode gathers soot current leaks occur causing weak dis charge at the top end of electrode If ignition does not occur even after cleaning the electrode it must be replaced If correct distance is not maintained between electrode and nozzle ignition may not occur even if there is discharge at the tope end of electrode This situation can be corrected by adjusting the distance between the two Check the resistance of Flame Sensor CDS and the electrodes positioning first if there are frequent ignition failures HOW TO CHECK See Pages 80 and 81 Check if there are any cracks in the ceramics Check if carbon has accumulated which could cause possible voltage leaks Relative position of electrodes UNIT mm ELECTRODE BURNERHEAD _ STABILIZER D 1 ES d z e NW L Ta M IN C NOZZLE MN E A Center of Stabilizer to Nozzle within 0 5 mm B Center of Nozzle to Electrode Rod Tip 6 0 6 5 mm C Surface of Nozzle to Electrode Rod Tip 3 0 3 5mm D Distance between Electrode Rods 2 25 2 75 mm E Distance from Surface of Nozzle to Stabilizer 10 mm 13 FUNCTIONING PARTS DATA amp HOW TO
39. following manner a Refill kerosene tank b Allow 30 minutes after refilling to activate KWH124 This allows fuel to settle c Make sure tank vent is open Fuel purge d Open shut off valve on fuel tank screw Loosen air purge screw at fuel filter Discharge air out of all channels through which fuel runs e Fill the bowl of the unit fuel filter with kerosene Fasten fuel purge screw back in original position Handle O Ring of fuel purge screw carefully A damaged O Ring can cause fuel leakage and render unit inoperative Don t misplace O Ring f Wipe all fuel spills off thoroughly 3 OPERATIONAL PROCEDURES 3 2 INSTALLATION THIS UNIT MUST BE INSTALLED IN ACCORDANCE WITH THESE INSTRUCTIONS LOCAL CODE OR DINANCE AND OR IN THE ABSENCE OF LOCAL CODES THE LATEST EDITION OF THE NATIONAL FIRE PROTECTION ASSOCIATION NFPA31 CODE SELECTION OF THE INSTALLATION SITE Choose a suitable site with water and electrical connections readily accessible The following should be taken into consideration in selecting the installation site An indoor place sheltered trom weather A well ventilated place air intake openings should be provided Side bottom and top clearance comply with instructions and local codes A place where there are no combustible materials near the unit Suitable and non combustible floor The fuel tank is installed according to local codes The exhaust pipe is installed in accordance wit
40. h instructions If water starts leaking measures must be taken so that it does not affect other parts in the same area recommended that a drain pan is placed underneath the leaking point until it can be repaired A place accessible for maintenance after the installation 10 Noise prevention the unit does produce some low noise when operating Carefully consider the location for the installation if this is objectionable PN oat sa i 11 Unit must always be electrically grounded 12 If unit is to be installed in an alcove or a closet its clearance should comply with instructions 13 Unit must be level Unit performance is maintained only when it is installed level E PROHIBITED INSTALLATIONS Do not install the heater in the following locations a In small poorly ventilated rooms b In airtight rooms c Near vents for heating or cooling d In places where special chemicals are used e In bathrooms bedrooms or any occupied rooms normally kept closed f In a location where it may be exposed to freezing temperatures g In a location where heater is subject to vibration Note Check local codes for any special requirements concerning the location of a water heater in a garage 3 OPERATIONAL PROCEDURES BEFORE THE INSTALLATION Important safety 1 Unit should be raised off floor two to four inches to prevent contact with combustible material and moisture damage in case of wet basements Use prope
41. he electromagnetic pump Fuel nozzle has clogged 4 Trouble with temperature controller 5 Trouble with the thermister sensor 6 The unit has exhaust gas cycling in it 7 Scaling in heat exchanger 41 Countermeasures Correct Piping arrangement Clean Clean Purge air from fuel filter Repair fuel line Clean soot Check and replace Check and replace Check and replace the printed circuit board for control panel Check and replace Check the flue and make sure that exhaust gas does not come back into the unit Flush or replace heat exchanger 12 TROUBLE SHOOTING 2 Causes of Troubles 1 Flow sensor does not sense running water a Flow sensor has clogged b Lead wire of flow sensor has been discon nected c Thermister of flow sensor has a broken wire NO HOT WATER BURNER DOES NOT IGNITE Power Source Lamp ON Combustion Lamp OFF Countermeasures Dismantle and clean the flow sensor Check the lead wire Measure resistance value 3 POWER LAMP DOES NOT LIGHT Power Source Lamp and Combustion Lamp OFF Causes of Troubles 1 Circuit breaker has tripped 2 Trouble with control panel circuit board A defective transformer 3 Improper connection on control panel PCB printed circuit board corrosion or poor contact at terminal block of incoming power supply 4 The control cord is broken 5 The fuse 6A of PCB has blown 6 Over temperature fuse ha
42. lie DISAREOMDIY IILI uuu 78 17 Service Parts List O C 0o E ENI m 80 81 1 SPECIFICATION 1 1 SPECIFICATION Heating Instantaneous Direct Connection of Main Supply High Voltage Discharge Spark Crystal Clean 1 K Kerosene Hot Water OUT PUT Fuel Consumption _ Efficiency Maximum Pressure Applied Minimum Water Flow to Activate Burner Area of Heat Transmission 8mm sree Voltage Frequency Combustion 1 004 110W Quantity of Vapor 0 85 GPH M __ wa SpayPaten 1 Paten CC O 4J0D8 rD A Electric Current Fuse Safety Devices Safe ignition Flame Sensor Over Heat Protector Air Pressure Switch BEEN Surge Absorber 34 Male ao Drain B 1 2 NPT Male Accessories supplied Fuel Filter uM Water Intake Insulator Hot Water Outlet insulator Hot Water Outlet Maximum 70 F Rise 210GAUH 35 _ 90 F 164 2 73 Maximum hot water supplied by this unit is about 221 GAL H x This represents efficiency under laboratory conditions This rating can vary up to 4 SINCE WE ARE CON
43. n sealant Handling Heat Exchanger The Heat Exchanger Burn Chamber is constructed primarily of copper be careful not to scratch or dent since it is soft The area to heat up Silencer 51 13 FUNCTIONING PARTS DATA amp HOW TO CHECK THEM 8 THERMOSTAT FOR PREVENTION OF OVERHEATING This thermostat will be activated when the burner operations stays on due to trouble with the temperature controller orthermister The thermostat overheat protector is located on the hot water outlet line under the mixing tank When the temperature of the heat exchanger rises to about 190 F the contact point of the thermostat is cut and stops the unit while triggering the alarm When the temperature gets down to the normal level below 174 F the user is required to press the orvoff switch on control panel to restart the unit HOW TO CHECK NORMAL 1 Pull off the thermostat from PCB Less than 50m ohm 2 Bring the probe of a multi meter to the terminal of the thermostat and measure resistance NOTE Thermostat for Prevention of Overheating Please attach the Thermostat securely to the Mounting Bracket so that it makes good contact Thermostat Mounting Bracket 13 FUNCTIONING PARTS DATA amp HOW TO CHECK THEM The temperature control system for this unit is made of 1 thermis ter sensor temperature detector 2 temperature adjuster for presetting of a desirable temperature and 3 PCB printed ci
44. n water being supplied from main and deterioration of piping material scale etc Never use water that has remained stagnant in heat exchanger and pipes for long periods as drinking water Turn water on for a couple of minutes before drinking SHOWER Feel temperature of hot water with your hand before entering shower stall KEEP DRAIN VALVE SHUT WHILE UNIT IS OPERATING Opening drain valve while unit is in operation will overheat unit and can result in possible heat exchanger damage and blown temperature fuses LIGHTNING Lightning may Cause a temporary power surge which may damage some electronic parts Where there is thunderstorm activity install a surge protector in power circuit WHEN UNIT WILL NOT BE USED FOR AN EXTENDED PERIOD OF TIME TAKE THE FOLLOWING MEASURES 1 Close fuel supply valve at fuel tank 2 Turn Power switch off 3 Purge water from unit See instructions on Page 10 4 FREEZE PROOFING OF THE PIPING Freezing must be anticipated not only inthe northern states but in other areas as well Therefore care must be taken to ensure the lines valves and unit do not freeze Water should not be allowed to freeze in the supply or hot water pipes in winter If water freezes in the supply and hot water supply pipes in winter frozen pipes could rupture and leak Repairs to unit with ruptured pipes could be costly Such damages are not covered by the warranty The following preventive measures should be follow
45. nt injury or burns if there is contact with flue Check local codes and ordinances IMPORTANT GUIDELINE The flue piping of the unit should be as short as possible and pitch 1 4 per foot up toward chimney Do not exceed 10 feet overall length of flue pipe Do not use more than two bends in the piping Chimney penetration is not considered a bend The piping when inserted into the chimney should not extend 1 2 beyond the inside surface of the chimne The area around of flue piping should be sealed where it enters the chimney Refer to the drawing Seal 14 6 VENTING INSTALLATION 6 2 SIDE WALL INSTALLATION IMPORTANT 1 Use only MPI KWH Vent Kit and Accessories for Side Wall Vertical L Type Venting 2 This unit must be installed in accordance with these instructions local code ordinance and or in the absence of local codes the latest edition of The National Fire Protection Association NFPA 31 code GUIDELINES FOR ATTACHING THE FLUE Do not make any changes to the diameter of the flue piping Seal and lock the connections of the flue Use an end cap to protect the flue from rain and wind coming in An insulated wall thimble is required for inserting the flue through any combustible material Ensure that minimum distances are met between flue pipes and walls and ceilings Flue piping used through the wall should be pitched down 1 4 per foot toward outside Side Wall Venting
46. oming from the fan motor NOTE e When changing a solenoid position rubber washers correctly Don t forget to install the restrictive plate 49 13 FUNCTIONING PARTS DATA amp HOW TO CHECK THEM 5 WATER GOVERNOR The water governor ensures a constant quantity of water to flow into the unit irrespective of change in tap water pressure Maximum water flow approx 220 gal hr G min Water Pressure Discharge Characteristics 4 5 Quantity of Flow no Li 1 5 1 0 0 5 0 40 60 80 100 120 140 160 Pressure Ib in 6 MIXING TANK Hot water from the heat exchanger is mixed here to obtain an even temperature at the outlet 13 FUNCTIONING PARTS DATA amp HOW TO CHECK THEM HEAT EXCHANGER BURN CHAMBER The heat exchanger transfers heat from the burning process to the water The heat exchanger used for the unit has copper fins It is small and light but has a high thermal efficiency This heat exchanger s capacity for water holding is only 0 264G Water therefore is heated quickly This heat exchanger is equipped with a thermister for hot water temperature control and a set of over temperature fuses NOTE e Removal of Heat Exchanger I Heat Exch s You may experience difficulty in trying to remove the Heat Ex 2 changer from the silencer This may be due to hardening of the 2 Gas Torch sealant which can be heated with a propane gas torch to soften and loose
47. oration and replace if necessary Inspect burner head replace if cracked or distorted 35 12 TROUBLE SHOOTING A TROUBLE SHOOTING GUIDELINE amp CORRECTIVE MEASURES The following information is submitted for you to better understand the operation of the KWH124 Minimum water flow is required This unit does not ignite the bumer unless there is a flow of water running through the unit at 45G min Change in hot water temperature when a multiple of hot water valves are opened When more than two hot water valves are opened concurrently the volume and temperature of water from each of these outlets can differ depending on the piping layout and to the extend at which valve is opened Especially change in the temperature and flow of water from the shower is likely to occur when hot water is tapped from another outlet s concurrently Opaque hot water Hot water may look opaque immediately after it is dispensed The opaqueness goes away eventually and hot water becomes transparent The reason for this is that the heated air mixed in the water is compressed and expands to the atmospheric level once it is out of the outlet turning into minute bubbles Nothing is wrong with this White smoke off the exhaust of the flue In winter the vapor in the exhaust gas can turn into water drops and come off from the exhaust port in the form of white steam Nothing is wrong with this Sound of fan motor is audible awhile after the hot water dispenser
48. oss regardless of type of heater Thus insulation or protection of hot water piping is encouraged Flush the piping before connecting to the unit Water flow of 0 45 G min or greater is required for igniting the burner Note To obtain full capacity the unit should have 20PSI min of water flow NOTE Hardness is defined as a characteristic of water which represents the total concentration of calciun 8 HOT amp COLD WATER PLUMBING WORK magnesium expressed as their calcium carbonate equivalent When other polyvalent metal ions are present in significant amounts they also are determined and reported as hardness The hardness of water originally was defined in terms of its ability to precipitate soap Calcium and magnesium ions are the principle causes although iron aluminum manganese strontium zinc and hydrogen ions are capable of producing the same effect Hardness concentrations originally were expressed as grains per gallon Now they are reported commonly as milligrams per liter 1 grain PER GALLON 17 2 mg L Levels above 500mg L hardness are undesirable for domestic use and most drinking water supplies average about 250 mg L TYPICAL INSTALLATION Pressure relief valve Relief valve discharge line to suitable open drain Hot water supply j Check valve Union G Shut off valve Vent connector to chimney _ Union old water supply Drain valve hw k
49. ou CAUTION e Do not allow pipes or valve to freeze Refer to FREEZE PROOFING OF THE PIPING on Page 10 and see owner s manual not use this unit as an auxiliary heat source for a solar hot water system nor hydronic heating 9 ELECTRIC WIRING The KWH124 is designed to be permanently connected on the installation site Power source 120 volts 60 Hz single phase A licensed electrician should make all electrical power connections Make certain electrical grounding is provided for the unit Maximum fuse size for electrical supply should be 15 amp CONNECTING POWER SUPPLY 1 Unfasten 4 screws holding the Electric Outlet Cover at the Right Side Exterior cover Electric Outlet Cover 2 Unfasten the 2 screws holding the plastic cover over the Terminal 3 Please connect the power supply Hot and Neutral wires BLACK to the Terminal Block and connect the Ground wire with WHITE FACTORY WIRING the Earth or E position TERMINAL BLOCK EQUIPEMENT GROUND A VS Y j FIELD WIRING N 30 10 TEST RUN PREPARATION Has the flue been installed properly Adequate clearances Air intake Is fuel in fuel tank Has air been purged from fuel supply pipe Make sure there is no fuel leakage Open hot water faucet and see if water comes out Make sure there is no water leaking from piping Have electrical connections and grounding been wired properly 2 69 OPERATION
50. r and suitable patio block brick concrete block or similar non combustible material Combustible or Non combustible Bad non combustible floor floor only PA gt 2 Clearance from wail ceiling shall be shown as Standard clearance for installations 3 Install an exhaust pipe in accordance with the instructions 4 Make sure proper air intake and ventilation openings are provided a Indoor air intake 2 air intake openings should be provided each 150 sq in at minimum NOTE Air openings would be needed if unit is drawing air out of an area smaller then 775 square feet STANDARD CLEARANCE FOR INSTALLATION Make sure to keep a distance from walls of combustible material From Left Side 7 in 180 mm From Right Side 19 in 505 mm From Back of Heater B in 205 mm Heater to Closet Door 29 in 735 mm Flue pipe to Combustible Surface Vertically Chimney Installation 9 in 229 mm Flue pipe to Combustible Surface Horizontally Chimney Installation 9 in 229 mm Refer to page 16 for minimum clearance of Flue Pipe on Side Wall Venting Pages 19 and 20 for L Type and vertical installations Note Larger space makes service and maintenance easier Space for service and maintenance should be reserved 3 OPERATIONAL PROCEDURES 3 3 OPERATION ADJUSTMENT OF HOT WATER TEMPERATURES a Thermostat has been set at factory to about 104 F LOW b Slide Hot Water Temperature Adjuster knob up toward
51. r to create combustion in the most efficient way something else in addition to vaporized kerosene from the nozzle ignition and air from the fan motor is needed This is the stabilizer The stabilizer combined with the burner head make up a component stabilizer is also called flame securing system The stabilizer can gather carbon and may cause the burner to malfunction One of these symptoms is called vibrating combustion It is therefore important to clean the stabilizer on a regular basis BURNER UNIT BURNER HEAD UNIT HOW TO CHECK The best method to check the state of burner combustion is to ignite it in the atmosphere and check the condition of ignition and flames Major checkpoints are 1 There is no electric discharge at the tip of the ignition rods Igniter transformer is defective Ignition rods are defective Soot has gathered on ignition rods 45 13 FUNCTIONING PARTS DATA amp HOW TO CHECK THEM HOW TO CHECK 2 Burner gets ignited but flames do not hold up Nozzle is defective Stabilizer is defective Electromagnetic pump unit is defective Flames stretch out perpendicularly Long Lazy Flame Rectifier tube which is a can shaped perforated cylinder through which combustion air passes is clogged Fan motor is malfunctioning Delayed ignition or bumer cannot be ignited Position and size of ignition rods are incorrect Nozzle is defective does not vaporize properly Electrom
52. r whole PCB and safety Governed in microprocessor P FAN MOTOR STOPS WHEN IT SHOULD NOT TROUBLE WITH AIR PRESSURE SWITCH Causes of Troubles Countermeasures 1 The combustion blower gathered dust and or foreign Clean the fan and motor blade substance therefore the fan cannot turn 2 Temperature inside the unit has risen excessively Check if there is any leaking exhaust gas from the packing tripping thermal overheat protector on blower motor of the combustion chamber silencer etc Also check if there is trouble with the heat exchanger If this is the case replace it 3 Trouble with the fan motor capacitor Change to a new capacitor 4 In extremely windy conditions operation may stop Wait for wind to diminish then reset 40 12 TROUBLE SHOOTING C CAUSES OF TROUBLES AND IRREGULARITIES WHICH ARE NOT REFLECTED IN MONITOR INDICATOR LAMPS 1 DESIRABLE TEMPERATURE OF HOT WATER IS UNOBTAINABLE Power Source amp Combustion Lamps Are ON Causes 1 Piping for water intake and supply of hot water have been installed in reverse order 2 Trouble with fuel line Fuel is not running through adequately a There is water and or dust in the fuel line b Fuel filter is clogged with debris c Inadequate fuel filter air purge d Fuelline is broken 3 Burner related troubles a Combustion area has gathered soot and carbon b Quantity of fuel has been reduced due to trouble with t
53. rcuit board The thermister sensor is fitted in the heat exchanger and senses the current temperature of hot water Thermister sensor unit has a copper casing containing a thermister Thermister s resistance changes to a great extent as shown in the graph subject to the prevailing temperature of hot water The temperature control circuit in PCB detects thermister resistance and controls the temperature of hot water to be supplied Checking thermister sensor can be made by measuring its resis tance before the unit goes into operation before water is heated and its resistance after the unit goes into operation when water is heated and then compare these resistance values measured with the specific values shown on the graph Note If scale or mineral deposits form on sensor its sensitivity may be impaired and sensor may need to be cleaned or replaced Thermister Hesistance 40 60 80 100 120 140 160 180 Temperature of Thermister Sensor F 13 FUNCTIONING PARTS DATA amp HOW TO CHECK THEM HOW TO CHECK NORMAL TROUBLE To check thermister resistance 1 While keeping ON OFF switch on control panel in the off position open the hot water dis Correspondstothegraphon Does not correspond to the penser valve When cold water starts running page 53 graph on page 53 out of the faucet close the valve 2 Disconnect the thermister terminal from PCB 3 485k ohm 10 Measure its resistance with a m
54. rightness of its surroundings Sensitivity of CDS deteriorates when its light reception surface becomes dusty or sooted needs regular clean ing once a year When CDS continues to stay with a high or low level of resistance it triggers the safety and stops operation Checking on CDS is possible by measuring its resistance with a multi meter during combustion and immediately after the suspension of combustion HOW TO CHECK CHECKING OUT CDS 1 Turn power switch off Open the front panel of the unit and pull off CDS terminal from PCB Then pull CDS out from the fan motor 2 Ifthe light reception surface of CDS is dirty clean it with a soft cloth 3 Use a multi meter across CDS terminal and measure resistance Resistance value changes depending on d dm L IILI CHECKING OUT CDS WHILE OPERATING UNIT 1 Set temperature control at position high 2 While keepingthe hot water dispenservalve fully open pull CDS terminal off from PCB and turn ON OFF switch on control panel on 3 When the burner has ignited and combustion starts measure resistance between terminals of CDS witha multi meter NOTE Measure resistance after the five second pre purge but within 15 seconds after the unit was started After 15 seconds the code No 4 will start blinking f resistance Could not be measured in time then turn ON OFF switch once again and measure resistance r3 STAND
55. s a broken wire or has tripped 42 Countermeasures Check the circuit breaker Change control panel Take out the transformer Check resistance between terminals Check all connectors for proper connections Discon nect clean and re tighten all connections Check the control cord Correct the problem that caused the fuse to blow Then replace the 6A fuse if fuse blows again replace PCB Check transformer for resistance or short Correct the problem that caused the over temperature to blow Then replace the over temperature fuse 12 TROUBLE SHOOTING 4 STRANGE SOUND IN COMBUSTION SOOT IS PRODUCED SMELL OF KEROSENE Power Source Lamp amp Combustion Lamp is ON Causes of Troubles 1 Fuel fuel pipe related problems a Fuelhas run out b Clogged fuel fitter c Dust and or water in pipe d There is moisture in fuel tank 2 Burner related problems a Combustion chamber gathered soot b Wrong size of nozzle ignition amp stabilizer c Trouble with electromagnetic pump bypass solenoid return pipe accumulator d Clogged nozzle e Fan motor is unable to turn 3 The flue is not installed connected properly or it has clogged 4 Other fuels such as light oil other than kerosene was used 5 The unit is not receiving sufficient air There is no intake louvers in the room where the unit is located 6 The unit is installed at high altitudes 3 200 feet or higher Countermeasures
56. scarded and be replaced with a new genuine service part All repairs should be left to professionals Contact your local authorized service dealer CAUTION B DO NOT STORE flammable liquids or materials such as gasoline near the unit Make sure that the flue is properly installed and connected A separation in the flue during the operation of the unit can cause the release of exhaust gas into the room The consequences could be dangerous gm Turn off the unit in case of an accident or an emergency Stay calm and do not panic Just turn off the unit B incase of a fuel leak exhaust fumes in home no hot water Turn off unit Call an authorized service person When using a shower feel the temperature of hot water with your hand first before moving yourself under the hot water Avoid the use of hard water In regions where hard water is the only source take advantage of a water softener This unit is only for indoor use Avoid its exposure to rain or moisture 3 OPERATIONAL PROCEDURES A a a 3 1 FUEL FUEL TYPE Use only crystal clear Type 1 K Kerosene FUEL SUPPLY Precaution No water or debris should be allowed to enter the fuel tank When these two are mixed with fuel imperfect combustion can result thereby shortening the life of the burner 1 Keep the tank filter cap tight 2 Do not allow tank to run empty If the KWH124 is allowed to operate without fuel air must be purged in the
57. ster page 54 8 OVERHEAT SENSOR WAS ACTIVATED 190 F Causes of Troubles Countermeasures 1 Trouble with the thermister is the cause of overheating Measure the resistance value of the thermister Compare the value measured with the specific characteristics graph on page 53 Ifthe comparison shows that the measured resistance of the thermister is not up to par replace the thermister 2 Trouble with the printed circuit board Replace with another printed circuit board and see if the cause of the trouble has been eliminated 3 Broken wire of the thermostat Use a tester to see if there is continuity 39 12 TROUBLE SHOOTING 9 TEMPERATURE CONTROL SLIDE REOSTAT Causes of Troubles Countermeasures 1 Temperature control reostat is corroded has a burnt Slide control up and down several times if burnt or broken spot or broken wire Replace the printed circuit board of control panel E TROUBLE WITH COMMUNICATION CIRCUIT Causes of Troubles Countermeasures 1 Trouble with connections and or wiring of either the Check the continuity of the cord with a tester Check the printed circuit board of the unit or of control panel connections onthe and also the screw connection on control panel H DETECTION OF IRREGULAR PERFORMANCE OF PRINTED CIRCUIT BOARD Causes of Troubles Countermeasures 1 Irregular performance of the printed circuit board of the Replace the printed circuit board unit Diagnose fo
58. t System does not start No Change System does not start Primary side main fuse cuts off Secondary side Main fuse cuts off Primary Secondary leakage System does not start System lockout System does not start 15 ELECTRIC SPECIFICATIONS G CIRCUIT BLOCK DIAGRAM Las Temp Fuse Fuse 6A fF 1 Controller x Operation Signal Generator and Receiver Circuit Power Circuit Electromagnetic Pump Pg Igniter Overheat Prevention Cds Thermistor K1 Relay Circuit x Segence Check Circuit Flow Sensor KIZ 8 a gt Micro Computer Pressure Switch 1E 5 lii Power Watch Circuit 16 SCHEMATIC DISASSEMBLY 45 62 AN a y Z j 78 17 MPI KWH124 SERVICE PARTS LIST kan Part No Description Fuel Pump Ass y Drain Cover a onon Solenoid al 7042 Front Cover 1 2 __ 3 7008 r 8 Top Cover 4 Sensor CDS u 44 7044 Front Cover Screws Collar 5 6 Combustion Blower Ass y 45 7045 Air Pressure Sensor 46 7046 FrontCover Bracke 7 PCB Mounting Bracket 8 7008 ee e fatra Burner Retaining Bracket Ass y 3 L9 _ Air Pressure Swich Water Inlet Insulation Set 7050 Junction Box T 7051 Drain Retainer s 7012 artien Rod Sa Gh Lah SZ
59. ted location Avoid excessive exposure to sun 3 When installing fuel tank indoors check local codes ordinances and or 1 4 When installing fuel tank indoors a 3 ft or more open space must be provided around it and a 6 ft or more open space must be kept from a source of heat 5 KWH124 is fed by gravity from the fuel tank The inlet fuel pressure must not exceed 2 5PSI If the inlet pressure exceeds 2 5 P S I a pressure reducer must be used 6 Insure the top of the tank is no more then 8 1 2 ft high and the bottom of the tank is the same level as the bottom of the unit mom Sy AN N ae aive EN N A N 3 8 Flare 8 1 2ft AJ Connection TI Maximum N EN x Minimum sa Fuel nite level as konton N __ N UL Listed J of unit k Af P x Fusible link valve connection is recommended 3 8 O D Copper Tubing CAUTION When locating the KWH124 below the level of the fuel tank i e in basement a pressure reducer must be used to prevent the fuel inlet pressure from exceeding 2 5PSI 26 7 INSTALLATION OF FUEL PIPES m INSTALLATION OF FUEL FILTER Install a UL listed fuel filter at the tank outlet Specifications required of this fuel fitter are as follows Type of Fuel Type 1 K Kerosene Rated Filtering Capacity 2 G H Minimum 1 6 HOW INSTALL FUEL FILTER A Standard Accessory
60. temperature fuse comes as a set and thus has to be replaced as a set e Check the position of Over Temperature Fuse l w A Drum pipe 1 Remove the temp fuse from temp fuse holders which are set at left and right side of the Heat Exchanger 2 Set the new one into the temp fuse holders Please make sure to line up the insulation tube of temp fuse and the surface of drum pipe Temp fuse holder Drum pipe Temp fuse holder Detail A 55 13 FUNCTIONING PARTS DATA amp HOW TO CHECK THEM 11 AIR PRESSURE SWITCH This is a safety device which is tripped when fan motor stops for some reason When this switch is activated the indicator P starts blinking HOW TO CHECK NORMAL TROUBLE 1 Disconnect this switch from PCB Bring the probes of Before blowing air infinity No change in needle a multi meter in contact with the terminal of the switch ohmreading Afterblow position 2 Blow air lightly into the pressure sensing side of the ing air lightly less than switch and see if the needle changes its position 500m ohm Note e Extremely strong gusts of wind blowing into flue pipe or chimney may cause this switch to trip e The vinyl hose plugs into the high side of the switch which is marked with an arrow for easy identification KWH 124 ch Front Cover Bracket Vinyl hose 13 FUNCTIONING PARTS DATA amp HOW TO CHECK THEM 12 FLOW SENSOR The flow sensor measures w
61. tic pump unit consists of 1 a high pulsating voltage electromagnetic pump 2 a pressure control valve to keep output pressure constant and 3 an electromag netic bypass valve which changes output pressure in two stages high to low or visa versa When the electromagnetic bypass valve is ON output pressure is low about 92 4 Ib in and when OFF output pressure is high about 213 3 Ib in There is lock out valve which interlocks with the plunger inside electromag netic pump This valve prevents fuel from leaking during suspended operation HOW TO CHECK PUMP NORMAL ABNORMAL 1 Check pump resistance across blue yellow wiring 47 0 15 ohm connector to pump 2 Remove flair nut on the outlet side of the electromag netic pump Kerosene gushes out Kerosene does not come 3 Run the burner while covering the outlet so that fuel out does not splash out HOW TO CHECK BYPASS VALVE NORMAL ABNORMAL 700 15 ohm 1 Check valve resistance across red red wiring connec tor to valve 2 Connect 120V AC to the two red terminals feeding the valve and listen for noise Click Sound Working No sound defective 61 13 FUNCTIONING PARTS DATA amp HOW TO CHECK THEM 16 FLAME SENSOR CDS Flame sensor watches out for ignition failure or loss of flames and if necessary activates proper circuitry on PCB to stop the burner CDS undergoes significant change in its resistance depending onthe b
62. tting and water flow is high enough the unit will operate at the high burn rate The thermister senses the temperature of the water as it s being heated keeping it at a constant level by controlling the high and low buming rate on cycling the unit on and off 4 Hot water tap is closed As water flow drops below 32G min the flow sensor sends a signal to stop the electromagnetic pump and thus the flame extinguishes inside the burn chamber At this point the combus tion lamp goes off followed by a post purge of approximately 150 seconds After the post purge the unit will shut off completely unless the hot water tap is opened again in which case the unit will go into prepurge and restart E PATTERNS OF BURNER OPERATION O ON OFF o o o OuSSOBIUM Wm e e i 32 11 OPERATING INFORMATION JOQUBIIS jeBueuyox3 yeay OlSlui U J asn4 ainjesedwe YIBIS isneyxy ns Hp l pr on O lt Jaqweyp uvonsnqwoj 10SU 8S MO L vey poH 8po429 3 A KO T 8 i L J UNOJSUEJ I u m AT Jay jany je1souuau UONUBABIJ JauJanon J PAA gay dung av Spo M yams anssalg iv
63. ulti meter at 122 F 3 While keeping the tester in contact with the terminal swing and pull lightly the lead wire of Resistance does not change Resistance changes the thermister Watch if the tester needle swings includes momentary swings NOTE If the overheating prevention device turns OFF when hot water is tapped in small quantity it is possible that thermister has become insensitive and has ceased to change resistance In this case check thermister resistance also check sensor itself for build up 13 FUNCTIONING PARTS DATA amp HOW TO CHECK THEM 10 OVER TEMPERATURE FUSE There are two temperature fuses wired in series and mounted one on each side of Heat Exchanger These fuses activate when the temperature of the heat exchanger rises extremely high Primary reasons being burst heat exchanger or drain valve opened with unit turned on When either fuse is blown out power will be suspended turning off all lamps on control panel The over temperature fuse will be blown when the temperature of the heat exchanger reaches 302 F When either fuse is blown replace both trouble shoot and repair the unit then replace the biown out over temperature fuses with a new one HOW TO CHECK NORMAL 1 Pull off the terminal of the temperature fuse from PCB Resistance Value 2 Bring the probe of a multi meter to contact with the terminal of the fuse Less than 1 5m ohm and measure resistance Note e The

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13 functioning parts data & how to check them