HydroTherm MultiPulse AM Series Troubleshooting Manual
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HydroTherm MultiPulse AM Series Troubleshooting Manual

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AM SERIES PULSE BOILER
TROUBLESHOOTING GUIDE
FOR CERTIFIED CONTRACTORS ONLY
260 NORTH ELM STREET
WESTFIELD, MA 01085
(413) 568-9571 • FAX (413) 568-9613
Attachment G
Building 86 (Albert T. Summers Center)
Charleston, WV
AMP8-1203
®
5211 CREEKBANK ROAD
MISSISSAUGA, ONTARIO L4W 1R3 CANADA
(905) 625-2991 • FAX (905) 625-6610

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  • Page 1 Attachment G Building 86 (Albert T. Summers Center) Charleston, WV AMP8-1203 ® AM SERIES PULSE BOILER TROUBLESHOOTING GUIDE FOR CERTIFIED CONTRACTORS ONLY 260 NORTH ELM STREET 5211 CREEKBANK ROAD WESTFIELD, MA 01085 MISSISSAUGA, ONTARIO L4W 1R3 CANADA (413) 568-9571 • FAX (413) 568-9613 (905) 625-2991 •...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS SECTION 1: OPERATION Boiler Operating Lights - Location and function ....................3 Sequence of Operation (with lights) ........................3 Wiring Diagrams (AM-100/-150/-300) ........................ 5 Lighting and Operating Instructions ........................8 SECTION 2: TROUBLE SHOOTING Preliminary Operational Check ...........................9 - Boiler is not running: Condition GC-4A Light Red Light...

  • Page 3: Section 1: Operation

    SECTION 1: OPERATION BOILER OPERATING LIGHTS GC-4A On GC-4A ignition control - visible thru a AMBER Part of 115V ON-OFF rocker switch LIGHT cutout in control cover near the 6-pin LIGHT (SW1). Side of electric box (AM-100 and Molex connector. OFF when no 24V to AM-150).
  • Page 4 5. The ignition sequence (8 sec. duration) is controlled AUTOMATIC RESTART FEATURE: The GC-4A ignition by the module which provides a spark at the spark control is equipped with an automatic reset feature. If plug & energizes the gas valve (Green Light “ON). the control completes an ignition sequence (5 attempts The pre-purge blower continues to operate during for ignition) without sustaining or proving gas ignition,...

  • Page 8: Lighting And Operating Instructions

    LIGHTING AND OPERATING INSTRUCTIONS (Honeywell VR-8305M Gas Valve) WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing properly damage, personal injury or loss of life. C. Use only your hand to turn gas control knob. Never A.

  • Page 9: Section 2: Trouble Shooting

    SECTION 2: TROUBLE SHOOTING CAUTION: Label all wires prior to disconnection 2. If the boiler is running, but exhibits one of the when servicing controls. Wiring errors can cause following conditions, observe the operating improper and dangerous operation. light conditions and use the procedure(s) under Verify proper operation after servicing.

  • Page 10: B Off Off On

    CONDITION B GC-4A LIGHT OFF, RED LIGHT OFF, AMBER LIGHT ON Turn Rocker Switch OFF and ON. If, within 10 seconds, the GC-4A light comes ON proceed to “CONDITION “E”. Replace Red Light (if OFF). If GC- 4A light remains OFF, proceed with check. POSSIBLE CAUSE VERIFICATION SOLUTION...
  • Page 11 CONDITION C GC-4A LIGHT OFF, RED LIGHT ON Turn Rocker Switch OFF and ON. If, within 10 seconds, the GC-4A light come ON, proceed to CONDITION “E”. If after the toggle switch is turned “OFF” and “ON”: - GC-4A light remains “OFF”. - Red light is “ON”...
  • Page 12 CONDITION D GC-4A LIGHT ON (If Red or Amber lights are OFF, replace lamp or switch.) Boiler may be in an ignition seqence - wait 40 seconds for an attempt at ignition (Green Light ON). If there is no attempt at ignition: turn Rocker Switch on boiler OFF and ON. Observe and clock the time the GC-4A light is ON.

  • Page 13: E Blinking

    CONDITION E GC-4 LIGHT BLINKING Turn the Rocker Switch OFF and ON. Observe GC-4 light and clock ON time before it begins to blink. If Red or Amber Lights OFF, replace lamp or switch. If the boiler starts and runs, a temporary problem may have corrected itself, (I.E., low gas pressure or a blockage of the inlet, etc).
  • Page 14 CONDITION “E” continued… 2. If measured fan pressure is at or below the minimum for Fan Prove Switch (PS2) operation. POSSIBLE CAUSE VERIFICATION SOLUTION Fan Motor Turn Rocker Switch and Gas Valve If you read 115V, proceed with top knob OFF. Remove air cushion verification.

  • Page 15: Condition 1. Boiler Ignites: Runs For 8 Seconds Then Shuts Off

    CONDITION “E” continued … POSSIBLE CAUSE VERIFICATION SOLUTION Wiring to GC-4A (115V) Turn Rocker Switch OFF. With an If no continuity on any wire, replace ohmmeter, check continuity of red & or repair as required. black wires of the 3-conductor Molex connector.

  • Page 16: Condition 2. Boiler Attempts Ignition (8 Seconds) - Shuts Off With A "Cough" Or No Ignition

    CONDITION #2 - BOILER ATTEMPTS IGNITION (8 SECONDS) WITH ONLY A “COUGH” OR NO IGNITION: THEN SHUTS OFF GC-4A Light is “ON”; Red Light “ON”; Green Light “ON”; - during each 8 sec. ignition trial (5 attempts). Unit does not run after 3 min. 45 sec. The GC-4 light then blinks. NOTE: ON A START-UP, BOILER MAY LOCK OUT SEVERAL TIMES BEFORE ALL AIR IS PURGED FROM GAS LINE.
  • Page 17 CONDITION #2 continued … POSSIBLE CAUSE VERIFICATION SOLUTION Ignition Lead Turn Rocker Switch “OFF.” Remove If no continuity or damaged lead - cover from ACC. Remove the fan then replace wire harness assembly. assembly on the AM-100 & -150. (See “Procedures” section). With an ohmmeter, check lead for Reseal “ACC”...
  • Page 18 CONDITION #2 continued..B. IF FAN PRESSURE MEASURES “ABOVE - NORMAL” CONDITIONS: +2.4" W.C. OR HIGHER ON AM-100 & -150 +1.6" W.C. OR HIGHER ON AM-300 POSSIBLE CAUSE VERIFICATION SOLUTION Blocked Condensate Drain Remove condensate drain tube at If condensate begins to flow rear base of boiler.

  • Page 19: Condition 3. Boiler Is "Short Cycling

    CONDITION #2 continued..C. IF FAN PRESSURE MEASURES “BELOW-NORMAL” CONDITIONS: • LESS THAN 1.45" W.C. ON AM-100 & -150 • LESS THAN 1.0" W.C. ON AM-300 POSSIBLE CAUSE VERIFICATION SOLUTION Air Inlet Pipes/Fan Assembly Turn “OFF” Rocker Switch. Turn gas If fan pressure increases to normal (AM-100 &...
  • Page 20 CONDITION 3A - BOILER SHORT CYCLES BUT AUTOMATICALLY RESTARTS POSSIBLE CAUSE VERIFICATION SOLUTION Recirculation of Exhaust Visually check air inlet terminal(s) for If there is recirculation, temporarily at Inlet Terminals exhaust recirculation (vapor path). extend exhaust vent. If this eliminates problem, proceed with NOTE: On thru-the-wall installations permanent fix.
  • Page 21 CONDITION #3A continued … POSSIBLE CAUSE VERIFICATION SOLUTION Overfire Reassemble boiler. Check input to If overfired-adjust input - see boiler using one of the prescribed “Procedures” Section. If obtaining methods under “Procedures” section rate is difficult or starts are adversely of the manual.

  • Page 22: Condition 4. Boiler And Condensate Water Leaks

    CONDITION 4 - BOILER AND CONDENSATE WATER LEAKS • WATER IN BASE PAN (AM-100 & -150) POSSIBLE CAUSE VERIFICATION SOLUTION Condensate Drain Fitting Check for moisture at bottom side If wet, remove tubing and fitting. and Tubing of fitting and tubing. Inspect and repair or replace as required.
  • Page 23 CONDITION #4 continued … • WATER ON FLOOR AT REAR OF BOILER (AM-300) POSSIBLE CAUSE VERIFICATION SOLUTION Condensate Fitting & Tubing Check condensate fitting & tubing. Tighten,or replace fitting/tubing. Flue Box Gasket Check for moisture at flue box If wet, replace gasket following attachment to rear plate on packaged instructions.

  • Page 24: Condition 5. Boiler Noise (Control And Adjustment)

    CONDITION 5 - BOILER NOISE - CONTROL AND ADJUSTMENTS A certain amount of operational noise is to be considered “NORMAL” when operating a PULSE BOILER. Most “objectionable” noise occurs on start-up and is correctable by the procedures outlined in this section. NORMAL OPERATION: START-UP CHARACTERISTICS: •...

  • Page 25: A) Prolonged Stutter On Start-Up

    CONDITION 5a - PROLONGED “STUTTER” ON START-UP (AM-300) • An occasional stutter when starting can be expected (i.e. - cold water/initial start-up.) POSSIBLE CAUSE VERIFICATION SOLUTION Incorrect Gas Supply Check Gas Supply Pressure and Adjust Gas Supply Pressure as Pressure (should be gas input rate as outlined under necessary.

  • Page 26: B) Combustion/Operating Noise

    CONDITION 5b - COMBUSTION / OPERATING NOISE (STEADY-STATE) POSSIBLE CAUSE VERIFICATION SOLUTION Boiler Overfired Check gas supply pressure and Adjust supply pressure and/or input gas input rate as described in rate as necessary. If boiler is in “Procedures” section of this operation more than 5 years - it is manual.

  • Page 27: C) Vibration Noise

    CONDITION 5c - VIBRATION NOISE (IN-HOUSE) BUT, REMOTE FROM BOILER (STEADY-STATE) POSSIBLE CAUSE VERIFICATION SOLUTION Air Intake & Exhaust Lines Visually check that the lines are If pipes are rigidly supported or in supported with vibration isolator direct contact with the building supports &...

  • Page 28: E) Objectionable (Localized)

    CONDITION 5e - OBJECTIONABLE (LOCALIZED) NOISE - STEADY-STATE POSSIBLE CAUSE VERIFICATION SOLUTION Exhaust Line Leak Check exhaust vent line, joints & Repair or replace as necessary with connections to boiler. “SCH-40” CPVC parts. “O” Ring between Boiler & With the boiler running for 5-minutes; If a leak is suspect, remove lower Exhaust Cushion Chamber feel around the jacket about 3"...

  • Page 29: Section 3: Servicing/Repair Procedures

    SECTION 3: SERVICING & REPAIR PROCEDURES 2. Locate the plastic tube connecting the Fan Prove SERVICING TOOLS LIST: • Volt/OHM/Continuity Meter Pressure Switch (PS2) to the 3/16" barb tee on the boiler. Disconnect the plastic tubing from either • 15/16" Deep Socket •...

  • Page 30: Gas Input Rate Check (Metered And Differential Methods)

    7. Turn the gas supply “OFF” at the up-stream 4. Turn Rocker Switch and Gas Valve top knob to service valve before replacing the line pressure ON. Approximately 30 seconds after combustion test plug on the combination gas valve. starts, manometer should read according to TABLE 1 below.

  • Page 31: Fan Inlet Gasket Replacement (Am-300)

    4. Apply a 1/4" wide bead of silicone at the edge and 5. Secure orifice in place with PVC cement. Replace completely around the 3-1/2" diameter hole in the fan assembly in boiler. Reassemble boiler lid and top of the flue box. Allow silicone to skim. panel and turn gas “ON”.
  • Page 32 GAS VALVE TOP KNOB EXTENDED REGULATOR ADJUSTMENT CAP GAS VALVE OUTLET PRESSURE TAP 1/8" OD TUBING GAS VALVE NOT SHOWN IN REGULATOR VENT OPENING MOUNTED POSITION FOR CLARITY PURPOSES. LINE PRESS. TEST PLUG FIGURE 4: GAS VALVE DETAIL MANIFOLD MANIFOLD PRESS.

  • Page 33: Exhaust Cushion Chamber (Ecc) And/Or "O" Ring Replacement (Am-100 And 150)

    4. Remove jacket top and insulation from the boiler. 4. Check the bottom head of the boiler and remove Remove the Air Cushion Chamber (ACC) lid and any remnants of the gasket that may be adhering lift out the fan assembly, taking care when to it.
  • Page 34 1. Turn gas “OFF” at supply (upstream) valve. Turn 4. Remove the boiler from the installation and locate it electrical power to boiler “OFF” at disconnect switch. for further disassembly. Disconnect gas piping and power to boiler. Isolate boiler from hydronic system and drain boiler. 5.

  • Page 35: Leak Check (Am-300)

    7. Remove the heat exchanger as follows: (3) Lay an approximately 4" piece of the 1/4" Carefully remove the insulation from the top square braided gasket next to and overlapping (front and rear) and sides of the heat the butt joint. Use high temperature silicone exchanger.

  • Page 36: Reposition Boiler In Its Location [Am-300]

    3. Assemble Gas Cushion Chamber (GCC) to the Combustion Chamber Inlet. Replace the GCC BACK UP STRIP gasket. Locate clamp ring and secure with 1/4" washers and nuts. GASKET w/ 45° MITER 4. Attach the gas supply tube from the GCC to the gas 1/4"...

  • Page 37: Heat Exchanger Replacement (Am-100 And 150)

    8. Remove the Air Cushion Chamber (ACC) 3. Reinstall boiler water, gas and electric connections. Remove the 4-1/4" nuts securing the top lid. Lift off the lid and the spring and set them aside. 4. Thoroughly purge the air from the boiler and system. Lift the fan assembly, disconnect the motor Only after system is purged of air and filled with water leads.
  • Page 38 6. Apply an anti-sieze compound to the threads of the 12. Mount the electric box and secure it to the jacket with spark plug and screw it into the Combustion the four screws. Chamber. Place bushing over end of wire harness. Inside the electric box: exiting the wire harness 7.

  • Page 39: Quick-Check Trouble Shooting Guide - Gc-4A

    GC-4A "QUICK CHECK" TROUBLESHOOTING GUIDE MPTS-44 ELECTRICAL SYSTEM CHECK FOR BOILERS EQUIPPED WITH THE GC-4A IGNITION CONTROL ON AM SERIES AMBER LIGHT ON FLIP SW. - IT MAY BE OFF BOILER ONLY BOILER ON/OFF SW. CHECK FOR 115V TO BOILER AT TERM. STRIP CHECK FOR 115V TO TERM.

  • Page 40: Section 4: Replacement Parts List

    When ordering replacement parts, provide the model and serial number shown on the unit rating plate as well as the part number and name as shown in parts list Parts may be obtained from your local Hydrotherm heating contractor NAME OF PART PART NO.
  • Page 41 NAME OF PART PART NO. AM-100 AM-150 AM-300 — Gas Cushion Chamber Kit - NG (Has Items 17, 18, 20) BM-7236 Gas Cushion Chamber Kit - NG (Has Items 17, 18, 20) BM-7238 Gas Cushion Chamber Kit - NG (Has Items 17, 18, 20) BM-7240 Gas Cushion Chamber Kit - LP (Has Items 17, 18, 20) BM-7237...
  • Page 42 NAME OF PART PART NO. AM-100 AM-150 AM-300 Flue Box Gasket Only - Old 3 Hole Style BM-7201 Flue Box Gasket Only - New 3 Hole Style 59-1046 Repl Control Box - NG/LP BM-7128 Repl Control Box - NG/LP BM-7210 Combustion Prove Pressure Switch 02-4851 Bracket Ass’y - Pressure Switch...
  • Page 43 NAME OF PART PART NO. AM-100 AM-150 AM-300 FOLLOWING COMMON “STREET” PARTS MAY BE AVAILABLE FROM YOUR LOCAL WHOLESALER Hose Clamp 57-4907 Hose Clamp 57-4906 Cross - 1" 56-5101 Cross - 1-1/4" 56-5103 Cross - 1-1/2" 56-5104 Nipple - 1" x 16" LG 53-1206 Nipple - 1-1/4"...
  • Page 44 JACKET PARTS AND ACCESSORY KITS (Quantity: 1 each) PART NO. NAME OF PART AM-100 AM-150 AM-300 Jacket Top Cover BM-7039 BM-7040 Jacket Upper Panel BM-7260 BM-7263 Jacket Lower Panel BM-7261 BM-7264 Jacket Bottom Cover BM-7144 BM-7048 Jacket Access Panel BM-7262 BM-7265 Jacket Lower Front Panel BM-7166...
  • Page 45 81/82 FIGURE 9: GENERAL ASSEMBLY MODEL AM-100, AM-150...
  • Page 46 61/62 FIGURE 10: MODEL AM-100 CONTROL PANEL 61/62 1 2 3 4 5 FIGURE 11: MODEL AM-150 CONTROL PANEL...
  • Page 47 JACKET ASSEMBLY MODEL AM-300 SIDE PANEL 86/15 BRACKETS 24 83 32 & 33 FIGURE12: GENERAL ASSEMBLY AM-300...
  • Page 48 260 NORTH ELM STREET 5211 CREEKBANK ROAD WESTFIELD, MA 01085 MISSISSAUGA, ONTARIO L4W 1R3 CANADA (413) 568-9571 • FAX (413) 568-9613 (905) 625-2991 • FAX (905) 625-6610...

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