HydroTherm MultiPulse AM Series - Default Chapter; Table of Contents

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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 Amber Light
A Off Off Off ....................................9
B Off Off On ..................................10
C Off On ...................................................................11
D On ...................................................................................................12
E Blinking ...............................................................................................13
- Boiler is running:
Condition 1. Boiler ignites: runs for 8 seconds then shuts off .......................................................15
Condition 2. Boiler attempts ignition (8 seconds) - shuts off with a “cough” or no ignition ............16
Condition 3. Boiler is “short cycling” ..............................................................................................19
Condition 4. Boiler and condensate water leaks ...........................................................................22
Condition 5. Boiler noise (control and adjustment) .......................................................................24
a) Prolonged stutter on start-up .......................................................................................25
b) Combustion/operating noise ........................................................................................26
c) Vibration noise .............................................................................................................27
d) Objectionable exhaust noise ........................................................................................27
e) Objectionable (localized)..............................................................................................28
SECTION 3: SERVICING/REPAIR PROCEDURES
Service Tools List .............................................................................................................................................29
Fan Pressure Check .........................................................................................................................................29
Gas Supply Pressure Check ............................................................................................................................29
Gas Input Rate Check (Metered and Differential Methods)..............................................................................30
Adjusting Input Rate .........................................................................................................................................30
Flue Box Adaptor Repair (AM-300) ..................................................................................................................30
Fan Inlet Gasket Replacement (AM-300) .........................................................................................................31
Air Inlet Orifice Repair (AM-300) ......................................................................................................................31
Igntion Wire Check ...........................................................................................................................................31
Wire Harness Assembly Replacement (AM-100 and 150) ...............................................................................31
Exhaust Cushion Chamber (ECC) and/or “O” Ring Replacement (AM-100 and 150)......................................33
Disassembling AM-300 Boiler ......................................................................................................................... 33
Leak Check (AM-300).......................................................................................................................................35
-Reassembly AM-300 Boiler ......................................................................................................................35
-Reposition Boiler in it's location (AM-300) ................................................................................................36
Heat Exchanger Replacement (AM-100 and 150)............................................................................................37
Boiler Reassembly (AM-100 and 150)..............................................................................................................37
Quick-Check Trouble Shooting Guide – GC-4A ...............................................................................................39
SECTION 4: REPLACEMENT PARTS LIST
Part Identification/Figs. 9 thru 12 (AM-100 / -150 / -300) .................................................................................40