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13 functioning parts data & how to check them | Manualzz
TM
n> MODEL
Instantaneous Kerosene Fired Water Heater
Service Manual
M O N I T O R
P R O D U C T S
N C
#1123;,:
4/9f
CONTENTS
1
1.
Specifications
'3
2.
Special Precautions
3.
Operational Procedure. Fuel/lnstallation/Operation
4.
Freeze-Proofing of the Piping
5.
Maintenance Checklist
6.
Venting Installation
4
5-9
10
11-12
6-1
Chimney Installation
13-14
6-2
Side Wall Installation
15-16
6-3
L Type/Vertical Venting
17-20
6-4
MPI Venting Kit & Accessories
21-25
7.
Installation of Fuel Pipe
26-27
8.
Hot & Cold Water Plumbing Work
28-29
9.
Electric Wiring
30
10.
Test Run
11.
Operating Information
12.
,
31
11-1
Working Principles
32-33
11-2
Performance Data
34
11-3
Error Code
34
11-4
Recommended Maintenance Procedure
35
Troubleshooting
A.)
Guideline & Corrective Measures
B.)
Error Code - their possible causes and possible solutions
36
37-40
"4"/"5"/"67"7"/"8"/"9"/"H"/"P"
C.)
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
42
3.)
Powerlamp does not light
42
4.)
Strange sound in Combustion Burner/soot is produced/smell of kerosene ...... 43
5.)
Smoke is coming off the unit. Paint on the exterior
has burned due to excess heat.
... 44
13.
Functioning Parts Data & How to Check Them
1.)
Burner & Burner Head
2.)
Ignitor Transformer
3.)
Electrodes
4o
4.)
Fan Motor Unit
49
5.)
Water Governor
50
6.)
Mixing Tank
50
7.)
Heat Exchanger
51
8.)
Thermostat For Prevention of Overheating
52
9.)
Over Temperature Fuse
55
11.)
Air Pressure Switch
56
12.)
Flow Sensor
13.)
Printed Circuit Board
59
14.)
Control Panel Base Board
60
15.)
Electromagnetic Pump Unit. Bypass Valve
61
16.)
Flame Sensor
62
17.)
Nozzle
18.)
Power Transformer
6t
19.)
Fuel Filter
64
20.)
Dismounting & Dismantling of Parts/Components
65
14.
Capacity Data Graph
15.
Electric Specifications
45-46
,
57-58
66-69
A.)
Timing Sequence Graph
B.)
Flowchart
72
C.)
Wiring Diagram
73
D.)
Resistance Values
74
E.)
Voltage Values on PCB Connector
75
F.)
Failure Mode and Effects
76
G.)
Circuit Block Diagram
77
16.
Schematic Disassembly
17.
Service Parts List
18.
Gauge
70-71
78
80-81
1
1-1
SPECIFICATION
SPECIFICATION
KWH124
Model
Typ«
Pressure Vapor
Indoor/Forced Exhaust
Instantaneous
Direct Connection of Main Supply
Combustion Type
Air Intake/Exhaust
Heating
Source of Water
High Voltage Discharge Spark
Crystal Clean 1-K Kerosene
Ignition
Fuel
123.000 BTU/H
Hot Water OUT PUT
Fuel Consumption (Max)
Efficiency
Capacity of Heat Exchanger
Maximum Pressure Applied
Minimum Water Flow to Activate Burner
Area of Heat Transmission
1.1GAL/H
86%*
1.057QT(1.0L)
150PSI
0.45 QAL/MIN
620 in2
35in(H) X 1 1 .8ln(W) X 20.9 in(D)
Exterior Dimensions
88 Ibs.
Weight
Voltage/Frequency
AC 120V/60HZ
Ignition: 1.05A(127W)
Rated: Ampere
(Rated Power Consumption)
Combustion: 1.00A(110W)
4 In.
482°F
Flue Size (Diameter)
Exhaust Air Temperature
Nozzle
0.85 GPH
Quantity of Vapor
Spray Pattern
Spraying Angle
Pattern A
60"
Temperature Fuse
302°F
Electric Current Fuse
6A
Safety Devices
* Safe Ignition * Flame Sensor
* Over Heat Protector
' Air Pressure Switch
* Surge Absorber
Pipe Connection
Water Intake
3/4 NPT Male
3/4 NPT Male
Hot Water Outlet
1/2 NPT Mate
Fuel Filter
Drain
Accessories (supplied)
Water Intake Insulator
Hot Water Outlet Insulator
Hot Water Outlet (Maximum)
70° F Rise
210 GALTH
3.5 GA17MIN
Degree Rise
80° F
184
3.07
90° F
164
2.73
100° F
147
2.45
110°F
134
(Maximum hot water supplied by this
2.23
unit Is about 221 GAL/H.)
if This represents efficiency under laboratory conditions. This efficiency rating can vary up to 4%.
"SINCE WE ARE CONSTANTLY IMPROVING OUR PRODUCTS, ALL SPECiRCATIONS ARE SUBJECT TO
CHANGE WITHOUT NOTICE"
1
1
SPECIFICATION
1-2
PARTS DESCRIPTION
•
APPEARANCE
Cold Water Intake
Hot Water Outlet
-Filter
Maintenance
Cover
Control Panel
Fuel Filter
Connection
Front Door
Drain
Junction
Box
CONTROL PANEL
Power Lamp
Power Switch
Temperature
Adjusting Knob
CONSTRUCTION
Cold Water Intake
Hot Water Outlet
Air Damper
Fan Motor
Mixing Tank
Printed circuit
Board
Burner
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.
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 & MAIN DIMENSIONS
Dimensional Outline Drawing (Unit: Inches)
6.1
3.1
Oil Filter Connection
Cold Water Intake
Hot Water Outlet
=,
Vent Connector
16.9
Drain
10.6
j_ 10.2
20.8
1.7
I
11,
2
SPECIAL PRECAUTIONS
WARNING
Use only crystal clear 1 -K kerosene. Never use gasoline, white gas, camp fuel orother flammable liquids.
Use of such fuels can result in an explosion and cause severe injury.
A damaged or malfunctioning part should be discarded and be replaced with a new genuine service part.
All repairs should be left to professionals. Contact your local authorized service dealer.
- CAUTION 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 causethe release of exhaust gas into the room.
The consequences could be dangerous.
Turn off the unit in case of an accident or an emergency. Stay calm and do not panic. Just turn off the
unit.
In case 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
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 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.
d. Open shut-off valve on fuel tank.
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 0-Ring of fuel purge screw carefully. A damaged 0-Ring can cause
fuel leakage and render unit inoperative. Don't misplace 0-Ring.
f.
Wipe all fuel spills off thoroughly.
Fuel purge
screw
3
OPERATIONAL PROCEDURES
3-2
INSTALLATION
.
THISUNITMUSTBE 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 (NFPA31) CODE.
J
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:
1.
2.
3.
4.
5.
6.
7.
8.
An indoor place sheltered from 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 with 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.
9. 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.
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.
•
PROHIBITED INSTALLATIONS
Do not install the heater in the following locations:
(a)
(b)
(c)
(d)
(e)
(f)
(g)
In small, poorly ventilated rooms.
In airtight rooms.
Near vents for heating or cooling.
In places where special chemicals are used.
In bathrooms, bedrooms or any occupied rooms normally kept closed.
In a location where it may be exposed to freezing temperatures.
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.
6
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 proper and suitable patio block, brick, concrete block or similar non-combustible material.
Combustible or
non-combustible floor
Non-combustible
floor only
Bad
'/,
FT-
\
2. Clearance from wall, 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
8 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
"High" to raise water temperature. Slide knob down
toward "Low" to reduce temperature.
c. When adjusting hot water temperature with not-cold water
mixing valve, control the amount of cold water from main
supply without changing the amount of hot water being supplied.
if
Knob at position "HIGH" provides hot water at a temperature around 167°F.
Knob at position "MED" provides hot water at a temperature around 130° F.
Knob at position "LOW" provides hot water at a temperature around 104°F.
HIGH n
MED.
LOW LJ
WARNING
* 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 gof
8
3
3-4
OPERATIONAL PROCEDURES
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 on 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.)
9
4
FREEZE-PROOFING OF THE PIPING
Freezing must be anticipated, not only in the 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 followed:
•
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 water tap 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.
"CAUTIONWhen turning 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
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 indicate a leak and must be corrected.
•
FUEL PIPES REPLACEMENT
Check fuel pipes at least one a year for distortions and/or cracks. Contact authorized service dealer for replacement 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.
\y/ Cold water intake
[Q/
inlet Water Filter
S^T^"?^
CAUTION
If lime has accumulated, remove it with a commercial compound for dissolving lime. Check water softening equipment if lime is found in the filter.
11
5
MAINTENANCE CHECKLIST
CLEANING 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 fitter.
EXCESSIVE PRESSURE RELIEF VALVE
Once a year, make sure that the pressure relief valve (installed on water supply piping) is functioning.
12
6
VENTING INSTALLATION
6-1
CHIMNEY INSTALLATION
•
FITTING THE FLUE
IMPORTANT'
THIS UNIT REQUIRES A DRAFT (AT FLUE CONNECTION OF THE UNIT) OF -2mmH20 to -5mmH20 TO
OPERATE NORMALLY.
Use flue pipes of 4" inside diameter.
Note: It may be necessary to install a Draft Regulator in the flue to obtain the recommended operating draft.
\ \ \ \ \ \ \ \ \ \ v \ \ \ \ \ \ \ \ V \_ \ A A
9" MIN
From Combustible
Material
Pitch Flue 1/4"
Per Foot Upward
9" MIN
10' MAX _
Overall Length
1 1 O f Flue Pipe
1/2'
MAX
Chimney Installation Example.
13
6
VENTING INSTALLATION
•
GUIDELINE FOR ATTACHING THE FLUE
1.
2.
3.
4.
5.
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 prevent injury or bums, if there is contact with flue.
Chimney Connection
Check local codes and ordinances.
IMPORTANT GUIDELINE>
1. 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.
2. Do not use more than two bends in the piping.
Chimney penetration is not considered a bend.
3. The piping, when inserted into the chimney should not extend 1/2" beyond the inside surface of the chimnr
The area around of flue piping should be sealed where it enters the chimney. Refer to the drawing belt
Seal
1/2"
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:
1.
2.
3.
4.
5.
6.
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.)
15
6
VENTING INSTALLATION
SIDE WALL VENTING-FITTING THE FLUE
IMPORTANT
Extension Limits of the Rue
Length of the Rue
Number of Bends
10 feet
2
16 feet
1
Note: Extension limits do not include pipe adaptor elbow and end cap.
INSTALLATION EXAMPLE (1) - 1 BEND
Use Only MPI Venting Kit
(Model MPI-KWH Vent Kit)
3" (MIN)Clearance
From Combustible
9" (MIN)
Clearance
Material
9" (MIN)
Clearance
End cap
(Horizontal Vent Cap)
Wall thimble
7" (MIN) __
Clearance
-6"(MIN)Clearance
Pitch Flue 1/4"
downward per foot
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
Elbow
Elbow
Top View
Elbow
Elbow
Wall Thimble
Pipe Adapter
D
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
IMPORT ANT 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.
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 -2mmH20 to -5mmH20 to operate normally. It may be necessary to install a
draft regulator.
GUIDELINES FOR ATTACHING THE FLUE:
(1)
(2)
(3)
(4)
(5)
(6)
Do not make any changes to the diameter of the flue piping.
Seal and lock the connections of the flue.
Use a rain 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).
18
6
VENTING INSTALLATION
INSTALLATION EXAMPLE (1)
"L"-TYPE VENTING OUTSIDE OR STRUCTURE
Vent Cap
(Rain Cap)
Storm Collar
Roof Flashing
3" MIN Clearance to-4
Combustibles
Tee Support Bracket
Every 4' (MIN)
3" MIN Clearance to
Combustibles
Wall Thimble
Tee with Tee Cap
90' Elbow
Pipe Adapter
To check draft drill hole
large enough to insert probe of Monometer or Bacarach Meter to measure draft
Note: Reseal hole to prevent exhaust leaks after
draft measurement
Tee Support Bracket
19
6
VENTING INSTALLATION
INSTALLATION EXAMPLE (2)
INSTALLATION EXAMPLE (3)
"L"-TYPE INSTALLATION
Inside of Structure
VERTICAL VENTING
Vent Cap
(Rain Cap)
Storm Collar
Vent Cap
Cap)
Roof Flashing,
3" MIN Clearance
Storm Collar
Pipe Sections
As Required
Roof Flashing
3" MIN Clearance
to Combustibles or Wall Thimble
—3" MIN to
Combustibles
or Wall Thimble
Tee with Tee Cap
D
20
6
VENTING INSTALLATION
6-4
MPI VENTING KIT & ACCESSORIES
1. MPI-KWH VENT KITS & ACCESSORIES LIST.
All MPI S.W.V. Kit parts can be purchased separately as needed.
KIT No.
PART NAME
Pipe Adapter
#8517
#8501
90° Elbow
#8518
S.W.V. Kit
Wall Thimble
#8519
Horizontal Vent Cap
#8520
#8503
Straight Length Pipe
V Length
#8504
Adjustable Length
1' Length
#8505
Straight Length Pipe
2' Length
#8506
Straight Length Pipe
3' Length
#8507
Straight Length Pipe
5' Length
#8508
45° Elbow
#8509
Tee With Tee Cap
#8510
Adjustable Roof Flashing
#8511
Tall Cone Roof Flashing
#8512
Rain Cap
#8513
Storm Collar
#8514
Tee Support Bracket
#8515
House Shield
#8517
Pipe Adaptor
#8518
90° Elbow
#8519
Wall Thimble
#8520
Horizontal Vent Cap
21
6
VENTING INSTALLATION
2. MPI-KWH VENT KITS
•
MPI S.W.V. KIT #8501 INCLUDES THE FOLLOWING:
1 - Pipe Adapter
1 - 90° Elbow
1 - Wall Thimble
1 - Horizontal Vent Cap
Pipe Adapter
SIZE
A
Unpainted Stock #
4"
23/8
8517
90° Elbow
SIZE
A
B
Stock*
4"
63/4
51/4
8518
Wall Thimble
11/2
SIZE
A
Wall Hole Required
Stock #
4"
43/4
9"
8519
4/ 2 TO 7 ADJ.
_L
Horizontal Vent Cap
SIZE
45/8
6%
Stock*
22
8520
6
VENTING INSTALLATION
ACCESSORIES
Straight Length Pipe
SIZE
1' length
2' length
3' length
5' length
4"
8503
8505
8506
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. Outside casing is .018 aluminized steel.
Adjustable Length
SIZE
A
1' length
4"
101/2
8504
Used whenever fixed lengths on MPI
Vent Kits are not appropriate because of interior obstructions.
45° Elbow
SIZE
A
B
Stock #
L
4"
33/4
2
8508
Straight Length Pipe
SIZE
A
B
C
Stock*
23
4"
91/2
59/16
51/2
8509
6
VENTING INSTALLATION
Adjustable Roof Flashing
4"
SIZE
41/4"
A
9"
B
8510
Stock*
Accommodates roof pitches from
0/12-6/12. Tall cone flashing allows
0/12-12/12.
Tall Cone Roof Flashing
SIZE
A
B
Stock #
4"
11"
91/4"
8511
B
Rain Cap
SIZE
A
B
Stock*
0
1
h — H
4"
45/8"
83/8"
8512
1
Storm Collar
SIZE
45/8"
Stock*
8513
The storm collar slips around the pipe
just above the flashing. Seal the inner
edge to the chimney with mastic.
24
6
VENTING INSTALLATION
Tea Support Bracket
SIZE
Stock*
Top View
4 3/4"
8514
Side View
12"
House Shield
SIZE
4 3/4"
12"
Stock #
8515
For blower discharge protection in
horizontal venting situations.
25
INSTALLATION OF FUEL PIPES
Use only fresh, crystal clear Type 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,
2.
3.
4.
5.
6.
and with a UL listed fuel filter and drain valve.
Fuel tank must be installed in a well-ventilated location. Avoid excessive exposure to sun.
When installing fuel tank indoors, check local codes, ordinances and/or NFPA31.
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.
The 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.
Insure the top of the tank is no more then 81/2 ft. high and the bottom of the tank is the same level as the
bottom of the unit.
8-l/2ft.
Maximum
(Minimum, same
level as bottom
of unit.)
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
INSTALLATION OF FUEL FILTER
Install a UL listed fuel filter at the tank outlet.
Specifications required of this fuel filter are as follows:
Type of Fuel: Type 1-K Kerosene
Rated Filtering Capacity: 2 G/H (Minimum)
HOW TO INSTALL FUEL FILTER (A Standard Accessory)
1. Wrap the threads (on the right side of the unit) with a sealing tape, or compound to ensure a tight fit.
2. Attach the fuel filter onto the pipe on right side of unit.
FUEL PIPE
1. When using copper pipe 3/8 in. (9.52mm dia.), its length should be no more than 50 feet.
2. Prevent any debris from entering the fuel line.
3. 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).
4. Fuel filter must meet required specifications, and should be installed so that it can be removed for maintenance
service.
5. Be professional. Clean up the work area before testing the unit.
HOW TO PURGE AIR (Note: Place a drain pan under filter before purging air)
1. Open fuel supply valve at fuel tank.
2. Loosen air purge screw at fuel filter installed on unit
and allow air to escape.
3. 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
27
Air Purge Screw
Fuel Filter
8
HOT & COLD WATER PLUMBING WORK
1.
A licensed plumber familiar with local codes and ordinances should install the KWH124.
2.
A water softener is recommended in regions where hard water may be a concern.
3.
Do not apply any heat to the unit nipples.
4.
Use standard copper alloy unions and nipples for the connections to the unit.
5.
• Copper piping is recommended for the hot water supply line.
Refer to local codes when considering piping materials.
• Steel piping is not recommended as it may cause rust in the piping.
• Use NPT for piping of hot and cold water.
6.
Connecting plumbing to the unit, hold unit fittings securely with a wrench to prevent damage to the unit.
7.
Provide a shut-off valve and a check valve on the cold water supply.
8.
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 govern 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.
9.
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.
10.
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.
11.
When hot water flows through the supply line there is an inevitable heat loss, regardless of type of heater.
Thus, insulation or protection of hot water piping is encouraged.
12.
Flush the piping before connecting to the unit.
13.
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.
28
8
HOT & COLD WATER PLUMBINGWORK
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
Check valve
Union
Shut-off valve
Vent connector
to chimney
Union
Cold water supply
Drain valve
Typical Installation
CAUTION
Do not allow pipes or valve to freeze.
Refer to FREEZE-PROOFING OF THE PIPING on Page 10 and see owner's manual.
Do not use this unit as an auxiliary heat source for a solar hot water system, nor hydronic heating.
29
9
ELECTRIC WIRING
The KWH124 is designed to be permanently connected on the installation site.
1.
2.
3.
4.
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
to the Terminal Block and connect the Ground wire with
the Earth or "E" position.
BLACK
FACTORY WIRIN.
TERMINAL BLOCK
EQUIPEMENT
GROUND
FIELD WIRING
30
10 TEST RUN
PREPARATION
1.
2.
3.
4.
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?
OPERATION
•
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.
NOTEWhen 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 draft.
| CLOSE
OPEN
Lessen this screw
31
11
OPERATING INFORMATION
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 a 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
setting and water flow is high enough, the unit will operate at the high burn rate. The thermistor senses the
temperature of the water as it's being heated, keeping it at a constant level by controlling the high and tow
burning 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 bum chamber. At this point, the combustion 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.
PATTERNS OF BURNER OPERATION
(O = ON
Pattern Load
• - OFF)
Electromagnetic Pump Pump Pressure
Low Bum
O
High Burn
O
Post-Purge
•
•
Extinguishment
Damper Solenoid
Remarks
O
0
Output 79,360 BTU/H
•
•
O
•
•
32
•
Output 1 24,000 BTU/H
Ready for Operation
Suspension of Operation
11 OPERATING INFORMATION
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.)
Season
Temp of
Water
Intake
Output of
Water/Hr.
Outlet Temp,
of Hot Water
Temp.
Increases
Outlet
Of Hot
Water/Min
Summer
77° F
204.76 G
149° F
72
3.41 G
Spring/Fall
59° F
1 63.80 G
149° F
90
2.73 G
Winter
35.6° F
1 29.46 G
149°F
113.4
2.16 G
11-3 ERROR CODES
Error codes on the control panel blink to inform the user of irregular operation:
Code Indicators
Cause(s)
4
Loss of ignition in burner. Flame out.
CDS wiring disconnection.
5
False flames or short-circuited CDS.
6
Thermistor wiring disconnection.
7
Thermistor defective or short-circuited.
Trouble with the lead wire or the terminal.
8
Overheat prevention thermostat tripped 194° F.
Trouble with the lead wire or the terminal.
9
Error in control panel.
E
Problem between control and main PCB.
Trouble with the lead wire or the terminal.
H
Main PCB has problem.
P
Fan motor has problem and fails to turn.
Trouble with the lead wire or the terminal.
34
11 OPERATING INFORMATION
11-4 RECOMMENDED MAINTENANCE PROCEDURE
WARNING
Disconnect electrical power before proceeding. Unit should also be cool.
ON A YEARLY BASIS
Replace fuel filter at storage tank.
Check for water due to condensation. 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: If gasket is damaged, replace it.
•
•
•
•
4
•
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.
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 0-Ring seals for cracks or deterioration and replace if necessary. Inspect burner head replace if
cracked or distorted.
35
12 TROUBLESHOOTING
A.)
TROUBLE SHOOTING: GUIDELINE & 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 burner 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.
•
Opaqu e 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 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 TROUBLESHOOTING
B.) ERROR CODES - THEIR POSSIBLE CAUSES AND POSSIBLE SOLUTIONS
[4]
DETECTION OF BURNER IGNITION FAILURE AND LOSS OF FLAME
Causes of Troubles
Counter-measures
(1) Defective flow of fuel
a. No fuel in the fuel tank
b. The fuel valve on the fuel tank is in the off position.
c. The fuel line is broken.
d. Water and/or dust in the fuel line.
e. Fuel filter is clogged with dust and debris.
f. Insufficient fuel filter air purge.
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.
(2) Irregular sparking at igniter rods
a. Improper fitting of igniter terminal
b. Soot or carbon has gathered on igniter rods.
c. Improper positioning, spacing and contact of
igniter rods.
d. Voltage is low (sparks are weak).
e. Defective igniter (does not spark.)
f. Crack in insulator of electrode.
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.
(3) No fuel running from nozzle or vaporizing trouble.
a. Defective electromagnetic pump.
b. Clogged nozzle.
Remove the burner. Place on a 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
isbad. If uneven, nozzle is clogged. (Dealer should do this
at his shop to avoid fuel spray damage.)
(4) CDS is not working properly.
a. Accumulation of soot on CDS light reception
surface.
b. Accumulation of soot on Burner Head.
c. CDS is not properly fitted in place.
d. CDS has wiring problem or CDS has too high a
resistance value.
PullanddisconnecttheterminalofCDSfromthebase. Use
a tester to check the resistance of CDS. While doing so,
turn on hot water supply switch, and measure the resistance value immediately after the electromagnetic pump
was activated. If the value is more than 60K ohm, check a
through d above.
(5) Exhaust gas recycles inside the unit.
Check the flue and its installation.
(6) Insufficient air supply.
Check air intake grill and air damper for blockage.
(7) Trouble with the printed circuit board.
Check 1 through 6. If nothing is wrong after having checked
1 through 6, replace the printed circuit board.
37
12 TROUBLESHOOTING
[5]
DETECTION OF FALSE FLAMES CDS SHORT-CIRCUIT
Counter-measures
Causes of Troubles
Pull off the terminal of CDS from the main board. Use a
tester to measure the pre-ope/ation resistance value of
CDS. If the value measured is less than 80k ohm, check
a through c.
(1) CDS short-circuit (resistance 0 ohm).
(2) CDS detects false flames.
a. CDS is not fitted properly in place.
b. Front panel doors are left open when the unit was
turned on.
c. Burner 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
come off the PCS or a defective connector.
Pull off the thermister terminal from the main board. ''
a tester to measure its resistance value. If the Vc.
measured is morethan above 30kohm(at 32° F), check the
connections at the terminal. If the connections are good,
then replace the thermister.
38
12 TROUBLESHOOTING
[ 7]
(1) THERMAL OVERHEAT PROTECTOR WAS ACTIVATED
(2) THERMISTER VALUE IS TOO LOW
Causes of Troubles
Countermeasures
(1) Thermal overheat protector. Trouble with the printed
circuit board.
Replace with another printed circuit board , and see if the
cause of the trouble has been removed.
(2) Thermistor value is too tow. Thermistor resistance
value is low compared to the temperature of water in the
heat exchanger. (Refer to chart further in this manual on
page 54.)
Use a tester to measure the resistance value of the
thermister. If the value measure is less than 800 ohm,
replace the thermister.
[81
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). If the 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 TROUBLESHOOTING
[9]
TEMPERATURE CONTROL SLIDE REOSTAT
Causes of Troubles
Countermeasures
(1) Temperature control reostat is corroded, has a burnt
spot or broken wire.
Slide control up and down several times if burnt or broken
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
printed circuit board of the unit or of control panel.
Check the continuity of the cord with a tester. Check the
connections on the PCB, and also the screw connection on
control panel.
[ H]
DETECTION OF IRREGULAR PERFORMANCE OF PRINTED CIRCUIT BOARD
Countermeasures
Causes of Troubles
Replace the printed circuit board.
( 1 ) Irregular performance of the printed circu it board of the
unit. Diagnose for 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
substance, therefore, the fan cannot turn.
Clean the fan and motor blade.
(2) Temperature inside the unit has risen excessively
tripping thermal overheat protector on blower motor.
Check if there is any leaking exhaust gas from the packing
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 TROUBLESHOOTING
(C)
[ 1]
CAUSES OF TROUBLES AND IRREGULARITIES WHICH ARE NOT
REFLECTED IN MONITOR INDICATOR LAMPS.
DESIRABLE TEMPERATURE OF HOT WATER IS UNOBTAINABLE - (Power Source & Combustion Lamps An ON)
Countertneasures
Causes
Correct Piping arrangement.
(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. Fuel line is broken.
Clean.
Clean.
Purge air from fuel filter.
Repair fuel line.
(3) Burner-related troubles,
a. Combustion area has gathered soot and carbon,
b. Quantity of fuel has been reduced due to trouble
with the electromagnetic pump.
c. Fuel nozzle has clogged.
Clean soot.
Check and replace.
Check and replace.
(4) Trouble with temperature controller.
Check and replace the printed circuit board for
control panel.
(5) Trouble with the thermister sensor.
Check and replace.
(6) The unit has exhaust gas cycling in it.
Check the flue, and make sure that exhaust gas does not
come back into the unit.
(7) Scaling in heat exchanger.
Flush or replace heat exchanger.
41
12 TROUBLESHOOTING
[2]
NO HOT WATER/BURNER DOES NOT IGNITE - (PowirSoun* Lamp ON- Combustion Lamp OFF)
Countermeasures
Causes of Troubles
(1) Flow sensor does not sense running water.
a. Flow sensor has clogged.
b. Lead wire of flow sensor has been disconnected.
c. Thermistor of flow sensor has a broken wire.
[3]
Dismantle and clean the flow sensor.
Check the lead wire.
Measure resistance value.
POWER LAMP DOES NOT LIGHT • (Powtr Score* Lamp and Combustion Lamp OFF)
Causes of Troubles
Countermeasures
(1) Circuit breaker has tripped.
Check the circuit breaker.
(2) Trouble with control panel circuit board. A defective
transformer.
Change control panel. Take out the transformer. Check
resistance between terminals.
(3) Improper connection on control panel PCB (printed
circuit board) corrosion or poor contact at terminal
block of incoming power supply.
Check all connectors for proper connections. Disconnect, clean and re-tighten all connections.
(4) The control cord is broken.
Check the control cord.
(5) The fuse (6A) of PCB has blown.
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.
(6) Over temperature fuse has a broken wire or has
tripped.
Correct the problem that caused the over temperature to
blow. Then replace the over temperature fuse.
42
12 TROUBLESHOOTING
[4]
STRANGE SOUND IN COMBUSTION/SOOT IS PRODUCED/SMELL OF KEROSENE
(Powor Sourc* Lamp 4 Combustion Lamp la ON)
Countermeasures
Causes of Troubles
(1) Fuel/fuel pipe-related problems.
a. Fuel has run out.
b. Clogged fuel fitter.
c. Dust and/or water in pipe.
d. There is moisture in fuel tank.
Supply fuel and purge air.
Clean fuel filter.
Clean fuel piping.
Clean fuel tank.
(2) Burner-related problems.
a. Combustion chamber gathered soot.
b. Wrong size of nozzle, ignition & stabilizer.
c. Trouble with electromagnetic pump (bypass
solenoid, return-pipe, accumulator).
d. Clogged nozzle.
e. Fan motor is unable to turn.
Clean soot.
Use right sizes.
Check and replace.
Check and replace.
Check for obstruction , a bad capacitor or bad motor.
(3) The flue is not installed/connected properly or it has
clogged.
Check and clean the flue.
(4) Other fuels (such as light oil) other than kerosene
was used.
Drain all bad fuel off. Use kerosene only.
(5) The unit is not receiving sufficient air. There is no
intake louvers in the room where the unit is located.
Provide air intake ports or louvers.
(6) The unit is installed at high altitudes (3,200 feet or
higher).
Open the damper at the Blower and check the state of
burner combustion (see page 31).
43
12 TROUBLESHOOTING
[5]
SMOKE IS COMING OFF THE UNIT/PAINT ON THE EXTERIOR HAS BURNED DUE TO EXCESS HEAT
(Power Sourc* Lamp and Combust/on Lamp ON)
Causes of Troubles
Counter-measures
(1) Burner is not installed properly. (Screws are loose,
burner packings are not in place.)
Check and repair.
(2) Silencer is not installed properly. (Screws need
tightening, burner gaskets are not in place.)
Check and repair.
(3) Heat exchanger has warped resulting in leaking gas.
Heat exchanger has a hole.
Check and repair.
44
13 FUNCTIONING PARTS DATA & HOW TO CHECK THEM
1) BURNER & 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 order 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 & 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.
3.
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.
4.
Delayed ignition or burner cannot be ignited.
Position and size of ignition rods are incorrect.
Nozzle is defective (does not vaporize properly).
Electromagnetic pump is defective (gets insufficient pressure).
Either solenoid or damper is defective (solenoid does not work).
5. 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 & 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 votts up
to 17,000 volts. The igniter transformer for this unit is of the
electronic type.
NORMAL
TROUBLE
There is audible sparking
sound.
Spark sound is inaudible.
HOW TO CHECK
1. Disconnect the connector of the electromagnetic
pump lead wire from the PCS.
2. Turn the unit on and listen for the sound of the
electrodes to be audible
PRECAUTION
Handle igniter carefully as high voltage runs through igniter.
Grounding the Ignitor Transformer.
Make sure the two transformer mounting screws are tight and secure so that they provide a good ground.
Igniter
2 Screws
47
13 FUNCTIONING PARTS DATA & 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 discharge 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.
(UNITimm)
ELECTRODE
BURNER HEAD
A:
B:
C:
D:
E:
Center of Stabilizer to Nozzle
Center of Nozzle to Electrode Rod Tip
Surface of Nozzle to Electrode Rod Tip
Distance between Electrode Rods
Distance from Surface of Nozzle to Stabilizer
48
within 0.5 mm
6.0 - 6.5 mm
3.0-3.5 mm
2.25 - 2.75 mm
10 mm
13 FUNCTIONING PARTS DATA & HOW TO 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
tow, 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 adjustment 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 of the unit rises excessively. The overload protector will reset automatically when motorcools
to normal operating temperatures.
STANDARD VALUE
HOW TO CHECK
MOTOR
(1) Pull off the fan motorterminal from the printed circuit board.
(2) Using a multi-meter, measure resistance at the terminals
coming from the fan motor.
Resistance Value About 33 ohm •
38.5 ohm (at 68° F)
SOLENOID
(1) Pull off the solenoid terminal from the printed circuit board.
(2) Using a multi-meter, measure resistance at the terminals
coming from the fan motor.
Resistance Value 1.5k ohm 15%
(at 68° F)
NOTE:
When changing a solenoid, position rubber washers
correctly.
Solenoid
Steel washer
Don't forget to install the restrictive plate.
Rubber washer
Shaft
49
13 FUNCTIONING PARTS DATA & 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.
Water Pressure-Discharge Characteristics
(G/min)
4. 5
4. 0
/
3. 5
o
U-
>> 2 - 5
(5
—•
.
1
—
/
3. 0
"o
\^_
/
7^
2. 0
3
0
1. 5
1. 0
0. 5
20
40
60
80
100
120
140
160
< lb/in2 >
Pressure
6) MIXING TANK
Hot water from the heat exchanger is mixed here, to obtain an even temperature at the outlet.
50
13 FUNCTIONING PARTS DATA & HOW TO CHECK THEM
/) HEAT EXCHANGER (BURN CHAMBER)
The heat exchanger transfers heat Irom 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:
Removal of Heat Exchanger
You may experience difficulty in trying to remove the Heat Exchanger from the silencer. This may be due to hardening of the
sealant which can be heated with a propane gas torch to soften
and loosen sealant.
Gas Torch
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 & 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 on/off switch on
control panel to restart the unit.
NORMAL
HOW TO CHECK
Less than 50m ohm
(1) Pull off the thermostat from PCB
(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.
o
_L
Overheat Prevention
Thermostat
Mounting Bracket
52
13 FUNCTIONING PARTS DATA & HOW TO CHECK THEM
9) THERMISTER SENSOR (TEMPERATURE DETECTOR)
The temperature control system for this unit is made of (1) thermister sensor (temperature detector), (2) temperature adjuster (for
presetting of a desirable temperature), and (3) PCB (printed circuit
board).
The thermistor 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 resistance 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.
40
60
80
100
120
140
160
180
Temperature of Thermister Sensor (°H
53
13 FUNCTIONING PARTS DATA & HOW TO CHECK THEM
HOW TO CHECK
To check thermister resistance:
(1) While keeping "ON-OFF" switch on control
panel in the off position, open the hot water dispenser valve. When cold water starts running
out of the faucet, close the valve.
(2) Disconnect the thermister terminal from PCS.
Measure its resistance with a multi-meter.
(3) While keeping the tester in contact with the
terminal, swing and pull lightly the lead wire of
the thermister. Watch if the tester needle
swings (includes momentary swings).
NORMAL
TROUBLE
Corresponds to the graph on
page 53.
Does not correspond to the
graph on page 53.
3.485k ohm ±10%
(at122°F)
Resistance does not change.
Resistance changes.
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.
54
13 FUNCTIONING PARTS DATA & 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 blown out over temperature fuses with a new one.
HOW TO CHECK
NORMAL
(1) Pull off the terminal of the temperature fuse from PCB.
(2) Bring the probe of a multi-meter to contact with the terminal of the fuse
and measure resistance.
Resistance Value.
Less than 1.5m ohm.
Note:
The temperature fuse comes as a set and thus has to be replaced as
a set.
Check the position of Over Temperature Fuse.
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
Detail A
55
13 FUNCTIONING PARTS DATA & 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
a multi-meter in contact with the terminal of the switch.
(2) Blow air lightly into the pressure sensing side of the
switch, and see if the needle changes its position.
Before blowing air infinity
ohm reading. After blowing air lightly less than
500m ohm.
No change in needle
position.
Note:
•
Extremely strong gusts of wind blowing into flue pipe or chimney may cause this switch to trip.
•
The vinyl hose plugs into the high side of the switch which is marked with an arrow for easy identification.
KWH 124
Front Cover Bracket
Vinyl hose
56
13 FUNCTIONING PARTS DATA & HOW TO CHECK THEM
12)
FLOW SENSOR
The flow sensor measures water 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 proportion 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 1C is separated from water current by a plate.
The temperature of water coming into the heat exchanger
is measured by a thermistor.
HOW TO CHECK
0 ring
turbine
shaft bearing
bearing
terminal
magnet case
permanent magnet
casing
intake port
NORMAL
(1) A simple way to check on flow signals:
It takes an oscilloscope for a precise reading of the flow
signals (<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 required to start the unit (burner), that is about .45
gaUmin.
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.
plate
screw
cover
Hall Ic
thermister
TROUBLE
Tester needle moves.
Tester needle stands still
at 0V or 12V.
Tester needle
around 2.3V.
moves
(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
"blue" terminal.
Tester needle moves.
Tester needle
around 2.3V
12345
1 pink
2 white
3 blue
4.5 grey
57
moves
Tester needle stands still
at 0V or 12V
13 FUNCTIONING PARTS DATA & HOW TO CHECK THEM
NORMAL
fj
HOW TO CHECK
a. Adjust the tester to the resistance range.
Dis connect from PCB
b. Touch the two grey
I /
terminals with the
;
u //
probe as illustrated here.
r~
\"
\
\\
o
\\
o
(Method of Measuring Resistance)
[\
Thermister Resistance
a. Pull the terminal of the flow sensor from the PCB.
Check on resistance by bringing the probe of a multimeter to come in contact with the terminal. When the
thermister is operating properly, its resistance should
correspond with the specific characteristics shown
on the graph.
o
(2) Checking built-in thermister:
\
^^Ji
I
~rJt
r
'i
f^\
40
60
80
100
120
Temperature of Thermister Sensor
Noto:
If incoming water temperature is above 104° F the thermister will now allow the unit to come on.
58
'40
('F
13 FUNCTIONING PARTS DATA & HOW TO CHECK THEM
13)
PRINTED CIRCUIT BOARD (CONTROL CIRCUIT)
PCS plays the role of controlling the performance of each
part/component to ensure the safe operation of the unit.
Communications technology using a micro-computer is
used to properly operate various circuits for safe operation
of the unit. Also, various self-diagnostic functions have been
built into this PCS.
The following are the circuits built in PCB. PCB also
provides connections for terminals of various functioning
parts/components.
False flame detection circuit & prevention of burner
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:
(1) Remove the fuse cover.
(2) Look through the glass tube to find out if the fuse inside
is blown out either visually or by using a multi-meter.
* The PCB which should be checked for shorted, burnt or
cracked components, or a shorted component outside the
PCB such as a motor or coil.
59
Not blown.
There is conductivity.
When the fuse is blown,
check out unit for possible short-causing short
circuit.
13 FUNCTIONING PARTS DATA & 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
•
•
•
Power Source Lamp:
Operation Lamp:
Monitor Indicators:
is lighted when the switch is turned ON.
is lit while the electromagnetic pump is working.
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 ft 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
60
13 FUNCTIONING PARTS DATA & HOW TO CHECK THEM
15)
ELECTROMAGNETIC PUMP UNIT
BYPASS VALVE
Electromagnetic pump unit consists of (1) a high pulsating
voltage electromagnetic pump (2) a pressure control valve
to keep output pressure constant, and (3) an electromagnetic 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/in2) and when OFF, output
pressure is high (about 213.3 Ik/in2). There is lock-out
valve which interlocks with the plunger inside electromagnetic pump. This valve prevents fuel from leaking during
suspended operation.
HOW TO CHECK PUMP
NORMAL
(1) Check pump resistance across blue yellow wiring
connector to pump.
ABNORMAL
47.0 +-15% ohm
(2) Remove flair nut on the outlet side of the electromagnetic pump.
Kerosene gushes out.
(3) Run the burner while covering the outlet so that fuel
does not splash out.
HOW TO CHECK BYPASS VALVE
NORMAL
(1 ) Check valve resistance across red-red wiring connector to valve.
700 +-15% ohm
(2) Connect 1 20V AC to the two red terminals feeding the
valve and listen for noise.
Click Sound Working.
61
Kerosene does not come
out.
ABNORMAL
No sound defective.
13 FUNCTIONING PARTS DATA & 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
tostopthe burner. CDS undergoes significant change in its
resistance depending on the brightness of its surroundings.
Sensitivity of CDS deteriorates when its light reception
surface becomes dusty or sooted. It needs regular cleaning (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
STANDARD VALUE
UNACCEPTABLE
VALUE
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) If the 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
surrounding brightness.
CHECKING OUT CDS WHILE OPERATING UNIT
(1) Set temperature control at position "high."
(2) While keeping the hot water dispenser valve 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 with a
multi-meter.
NOTE: Measure resistance after the five-second prepurge, but within 15 seconds after the unit was started.
After 15 seconds, the code No. 4 will start blinking. If
resistance could not be measured in time, then turn "ONOFF" switch once again and measure resistance.
62
Resistance Varies
Resistance 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 & 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 combustion 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.
Distributor
NOZZLE TO BE USED:
Size:
Vapor Injection Angle:
Vapor Type:
Service Parts No.:
Filter
0.85 GPH
60
A Pattern
7011
HOW TO CHECK
Remove the burner from the unit. Ignite the burner in the atmosphere.
(Normal Vaporization)
streak
^- a uniform distribution
of particles
1. Vapor is not uniform.
2. Vapor angle is wrong.
3. Streaks are visible instead of mist.
nozzle
vaporization 6CT~70:
stabilizer
DEFECTIVE VAPORIZATION
stabilizer
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.
63
13
FUNCTIONING PARTS DATA & HOW TO CHECK THEM
18)
POWER TRANSFORMER
HOW TO CHECK
NORMAL
(1) Pull the terminal of the transformer from PCS.
Red-Red about 30-37 ohm
White-White 0.47 - 0.59 ohm
Red-White infinity ohm (at 68 F)
(2) Measure resistance between Red-Red, White-White,
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.)
64
13 FUNCTIONING PARTS DATA & HOW TO CHECK THEM
20)
DISMOUNTING & DISMANTLING OF PARTS/COMPONENTS
PROCEDURES AND PRECAUTIONS
1. Before removing any part/component from the unit or a system, close the fuel supply and water intake valves. Shut
off power supply.
2. Special attention must be paid to the number of and the order in which these parts have been dismantled. Re
assembling must follow the reverse order and should leave nothing unassembled.
3. 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
(PARAMETERiWATER TEMPERATURE)
(T)
Position of Temperature Controller :High
200
180
0)
CO
<=
Q.
160
co
Q)
\
140
to
68° F
120
SOT
0
3
37.4° F
100
I
CD
Q.
<D
80
60
40
(26.4)
50
100
150
Quantity of Hot Water Dispensed
66
200
(220)
250
(G/H)
14 CAPACITY DATA GRAPH
2)
HOT WATER OUTLET (MAXIMUM) DEGREE RISE
(Maximum hot water supplied by this unit is about 220 Gal./HR.)
3)
70° F
210Gal./HR.
3.5 Gal./Min.
80° F
184
3.07
90° F
164
2.73
100 °F
147
2.45
110° F
134
2.23
TIME - HOT WATER TEMPERATURE CHARACTERISTICS
(PARAMETERrPOSITION OF TEMPERATURE CONTROLLER)
Position of Temperature Controller (Knob)
THERMOSTAT
1
HIGH
1
i— i
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LOW
®0,1969in (5mm) -HIGH Position
(D0,7874in (20mm) -MED. Position
(S)1,1811in (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
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Temperature of Hot Water Dispensed
Temperature of Hot Water Dispensed
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CAPACITY DATA GRAPH
Temperature of Hot Water Dispensed TI
Temperture of Hot Water Dispensed
15 ELECTRIC SPECIFICATIONS
A)
TIMING SEQUENCE GRAPH
SEQUENCE OF MOTIONS
Variable Timing of Sequence
5
10
15
150
1.5
1.5
12
58
T1 : Preignrtion Prepurge
T2: Post Ignition
T3: Ignition Trial
T4: Post Purge
T5: Flame Response
T6: Pre-Air Solenoid
T7: Air Pressure Switch ON Delay
T8: Air Pressure Switch OFF Delay
Normal Mode
S
Components
^
>
N. Relay
\
Blower-Motor
K4
Ignitor
K3
Air Solenoid
K5
Electromagne
tic
Pump
K1
Electromagne
tic
Valve
K2
' \
+++-
1 sec.
2 sec.
3 sec.
30 sec.
MAX sec.
0.5 sec.
3 sec.
12 sec.
(J) Water sup ply tap OFF
'
'
(D Power Swilch OFF
1)Pow er Switch ON
i
++++-
) Water supply tap ON
i
1r
1
a--
— T1
I
i
i
r
i
—t— T6
~l
CdS
i
I
II
1
1
1
1
1
•s
y
1
Sensors
Flow Sensor
i
Air Pressure Switch
HIGH
Temperature at
Thermister
Sensor
o-m
31 g ON
»
T
iS
i/'
OFF
•-§
ft
ON
^^
LOW
*
Burner State
OFF
LOW
| Control Panel
HIGH
////
3S
^^^.
;
iN
u.
^
^
•*"
/
\
IV
T jf^~~^
rr
Orr
7
/ //
////
// / / /
/////////
/////////
///
Power Switch
Power Lamp
Run Lamp
i
1
70
///
15 ELECTRIC SPECIFICATIONS
TEMPERATURE CONTROL GRAPH AT NORMAL MODE OF OPERATION
1. Power switch pushed to "ON" position on control panel.
2. When a 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 igniters 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. The temp, 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 turns 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 Lamo OFF
Electromagnetic Pump OFF
Electromagnetic Valve OFF
Air Solenoid OFF
Igniter OFF
Run Lamp OFF
Fan Motor OFF
Lockout
Code LED "X"
X : Malfuncti
•4" "5- "6
-E- -H- ..,
.•"•"•
Fan Motor ON
Igniter
ON
Air Solenoid ON
>
Electromagnetic Pump ON
Electromagnetic Valve ON
:>
Hot Water TemperatureControl (1) ON ?
Air Solenoid ON
Electromagnetic Valve ON
:=»
Air Solenoid OFF
Electromagnetic Valve OFF
•Hot Water Temperature• Control (2) ON ?
•^w.
>
\
Igniter OFF
Electromagnetic Pump OFF
Electromagnetic Valve OFF
Air Solenoid ON
Run Lamp OFF
Fan Motor OFF
Igniter OFF
72
15 ELECTRIC SPECIFICATIONS
C)
WIRING DIAGRAM
Electromagnetic Pump Blower
Solenoid Igniter
Temp.
Fuse
Power Source
Junction Box
^EQUIPMENT
GROUND
Overheat
Prevention
/it
±
QQD-l H
QDZI
_l LU _J _l
CD CC CD QQ
U_ILU_JLU I L_
QCCrDQ> § O
tUORN
Pressure
Switch
Printed circuit board
iRED
Power
Transformer
B
™ *$Btt
o_§moo
BRN
Controller
Thermistor
Flow Sensor
73
15 ELECTRIC SPECIFICATIONS
D)
RESISTANCE VALUES
Component
Approx. OHMS
Blower Motor
33 ohm - 38.5 ohm (at 68° F)
Electromagnetic Pump
RED - RED
47.0 +-15% ohm
Electromagnetic Valve
BLUE -YELLOW
700 +-15% ohm
Air Solenoid
1.5+-15%Kohm(at68°F)
Thermister for temperature control
3.485 + - 10% K ohm (at 122° F)
Pressure Switch
Less than 500m ohm
Overheat Prevention Thermostat
Less than 50m ohm
Thermister in the flow sensor
18.4 +- 8% K ohm (at 59° F)
Temp Fuse
Less than 1.5m ohm
Power Transformer
RED - RED
30 ohm - 37 ohm (at 68 ° F)
WHITE - WHITE
.047 ohm - .059 ohm (at 68° F)
RED - WHITE
OD ohms
WARNING
DISCONNECT POWER BEFORE MAKING ANY RESISTANCE TESTS
74
15 ELECTRIC SPECIFICATIONS
E)
VOLTAGE VALUES ON PCB CONNECTOR
Reading Taken at
Voltage Reading
PCB Connectors
AC
DC
WHT - GRA
120
-
Ignrtor
BLU - BLU
120
-
Electromagnetic Pump
BLU - YEL
Electromagnetic Valve
RED -RED
Air Solenoid
BLK - RED
Component
Blower Motor
120 VAC half-wave rectified
120
-
120 VAC full-wave rectified DC 108V
Thermistor for temperature control
WHT - WHT
-
5V
Pressure Switch
RED -RED
-
5V
Overheat Prevention Thermostat
YEL - ORN
-
5V
Thermistor in the Flow Sensor
GRA - GRA
-
5V
Power Transformer
RED -RED
120
-
75
15 ELECTRIC SPECIFICATIONS
F)
FAILURE MODE AND EFFECTS
Component
Blower Motor
Ignrtor
Short
Open
Electromagnetic Pump
Short
Open
Electromagnetic
Valve
Short
Air Solenoid
Thermistor sensor
in the flow sensor.
Thermistor Sensor
CDS
Air Pressure Switch
Overheat Prevention
Flow Sensor
Temp. Fuse
Power Transformer
Controller
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 "P" and system lockout.
NO Change.
Code LED blink "8" and system lockout.
System does not start.
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.
Failure Mode
Short
Open
Open
Short
Open
Short
Open
Short
Open
Short
Open
Short
Open
Short
Open
Short
Open
Short
Open
Short
Open
Short
Open
76
15 ELECTRIC SPECIFICATIONS
G)
CIRCUIT BLOCK DIAGRAM
Cds
Controller
f
!
_
1
_ .
^'^y
1
|
1
|
|
t
Thermistor
Flow Sensor
Pressure Switch
ra l/tT
)
oo
66
66600
1
1
l
L
O
T
C
j
(0,
i
1
t
Bridge Circuit
f i
Yy?
i
Operation-Signal
Generator and
Receiver Circuit
4
>
£
i
4>
\/
1
Power Circuit
c «-
>
^
Micro Computer
*
—
\/
Electromagnetic
Circuit
1
o f*Yo
J
2
Blower
x^^i^
2
Solenoid
^
2
1
Seqence Check
r.irr,,it
Igniter
\X
0-
I
V
1
@4
rT5
>
>*1
Overheat
Prevention
77
Power
c
Circuit
*
-r
i
J
16 SCHEMATIC DISASSEMBLY
17 MPI KWH124 SERVICE PARTS LIST
Fuel Pump Ass'y
No.
41
Part
No.
7041
Drain Cover
Air Damper Solenoid
42
7042
Front Cover
Ignitor Transformer
43
7043
Top Cover
Photo Sensor (CDS)
44
7044
Front Cover Screws/Collar
Combustion Blower Ass'y
45
7045
Air Pressure Sensor
Burner Ass'y
46
7046
Front Cover Bracket
Burner Base
47
7047
PCB Mounting Bracket
Burner Head Ring
48
7048
Burner Retaining Bracket Ass'y
7009
Air Pressure Switch
49
7049
Water Inlet Insulation Set
7010
Fuel Filter
50
7050
Junction Box
11
7011
Nozzle
51
7051
Drain Retainer
12
7012
Ignition Rod Set (Right & Left)
52
7101
Heat Exchanger Insulated Wrap
13
7013
Heat Exch. Ass'y (w/insulated wrap gasket)
53
7102
Heat Exchanger Base Gasket
14
7014
Water Inlet Connector
54
7103
Exhaust Stack Gasket
15
7015
Filter
55
7104
Fan Motor Gasket
16
7016
Water Governor
56
7105
Flange Gasket
Inlet Pipe Set
Flow Sensor
57
7106
Burner Heat Gasket
58
7107
Water Inlet Gasket
59
7108
Water Outlet Gasket
J --—Item
Part
No.
6
No.
7001
7002
7003
7004
7005
7006
7
7007
8
7008
9
10
1
2
3
4
5
17
7017
18
7018
nern
lljjia
Description
Description
19
7019
20
7020
Flow Sensor Bracket
Mixing Tank
60
7109
Water Governor Gasket
21
7021
Water Outlet Connector
61
7110
Damper Cushion
22
7022
Hot Water Thermister Set
62
7111
Exhaust Stack Outlet Insulator
7201
O-Ring (Thermister P6 4C)
23
7023
Printed Circuit Board
63
24
7024
Control Panel Assy
64
7202
0-Ring (Water Filter P10A 1A)
25
7025
Control Panel Circuit Board
65
7026
Thermo Overheat Protector
66
7203
7204
O-Ring (Multiple Use P14 4C)
26
O-Ring (Water Governor P22A 1A)
Fuel Filter Element
O-Ring (Flow Sensor Inlet P18 4C)
27
7027
7205
7028
Over Temperature Fuse Set
Main Fuse 6A
67
28
68
29
7029
Power Transformer
69
7052
7206
GLUE (for burner head gasket)
30
7030
Terminal Block
70
7207
GLUE ( heat exch. base & exhaust stack gasket)
31
7031
PCB Spacer Clip
71
7208
Lead Wire (fan motor)
32
7032
Fuel Pipe
72
7209
Lead Wire (flow sensor)
33
7033
Fuel Filter Mounting Bracket
73
7210
Lead Wire (air pressure switch)
34
7034
Silencer Ass'y (w/gasket)
74
7211
Lead Wire (power supply)
35
7035
Exhaust Stack Ass'y Base
75
7212
Lead Wire (control panel)
36
7036
Base
76
7213
Owner's Manual
37
7037
7038
Exterior Cover (riaht side)
Access Cover
77
7214
Installation Manual
78
7215
39
7039
Electric Outlet Cover
79
7216
Carton Box
Packing Kit
40
7040
Exterior Cover (left side)
38
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.
STABILIZER
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.
1 .-
C
I
6
r -i
80
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 "D" 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.
t
1
m
1
0
t
t
m
I
m
Q
C
Q
m
m
o
m
81
O
m
m
H

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