Instantaneous Kerosene Fired Water Heater

Transcription

1 MODEL KWH124 Instantaneous Kerosene Fired Water Heater Owner's Manual Thank you for choosing the KWH124 Instantaneous Kerosene Fired Water Heater. We are sure that the modern design and outstanding performance of this unit will meet your highest expectations. Please read this manual and warnings carefully before using your KWH124 Kerosene Fired Water Heater. Please become fully acquainted with all details of its operation so that you can use the KWH124 for many years without problems or malfunctions. Keep this manual handy for reference. 4AP\ M O N I T O R P R O D U C T S I N C

2 INDEX 1. SPECIAL PRECAUTIONS 2. SPECIFICATIONS 2 A. PARTS DESCRIPTION 2 APPEARANCE 2 CONTROL PANEL 2 CONSTRUCTION 2 B. SPECIFICATIONS 3 C. DIMENSIONAL OUTLINE DRAWING 4 3. OPERATIONAL PROCEDURES 5 A. FUEL TYPE '5 B. FUEL SUPPLY 5 C. PRE-OPERATION CHECK LIST 6 D. START UP AND OPERATION 6 E. UNIT SHUT OFF 8 F. FREEZE PREVENTION 8 G. WARNINGS 9 4. SAFETY DEVICES MAINTENANCE CHECK LIST REGULAR CLEANING TROUBLE SHOOTING GUIDE SCHEMATIC DISASSEMBLY 16 The KWH124 is designed for household use for the purpose of supplying hot water. The unit should not be used on a moving vehicle such as a boat or camper. Warranty coverage for commercial application could be voided or limited to 1 year.

3 1. SPECIAL PRECAUTIONS WARNING Use only crystal clear 1-K kerosene. Never use gasoline, white gas, camp fuel or other 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 cause the release of exhaust gas into the room. The consequences could be dangerous. Turn off 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.

4 ( 2. SPECIFICATIONS") A. PARTS DESCRIPTION APPEARANCE Hot Water Outlet Cold Water Intake -Filter - Control Panel Maintenance Cover Fuel Filter Connection Drain Front Door Junction Box CONTROL PANEL Run Lamp ^ Code LED OiSS3 szsm 1 asssf D- ON<fF Power Lamp - Power Switch mm Eza MM Temperature. Adjusting Knob UC-J. LCW MPI CONSTRUCTION Coid Water Intake Hot Water Outlet Fan Motor Air Damper Mixing Tank Printed circuit Board Burner Overheat Protector Thermo Heat Exchanger Hot Water Thermistor Temperature Fuse -2-

5 B. SPECIFICATIONS Model Type Combustion Type Air Intake/Exhaust Heating Source of Water Ignition Fuel 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 Exterior Dimensions Weight Voltage/Frequency Rated: Ampere (Rated Power Consumption) Flue Size (Diameter) Exhaust Air Temperature Nozzle Quantity of Vapor Spray Pattern Spraying Angle Temperature Fuse Electric Current Fuse Safety Devices Pipe Connection Water Intake Hot Water Outlet Drain Accessories (supplied) Hot Water Outlet (Maximum) Degree Rise KWH124 Pressure Vapor Indoor/Forced Exhaust Instantaneous Direct Connection to main supply. High Voltage Discharge Spark Crystal Clean 1-K Kerosene BTU/H 1.1 GAL/H 86% X OT (1.0 L) 150PSI 0.45 GAL/MIN 620 in 2 35 in(h) x 11.8in(W) X 20.9 in(d) 88 Ibs AC 120V/60Hz Ignition: 1.05A (127W) Combustion: 1.00A (HOW) 4 in 482T 0.85GPH Pattern A T 6 A *Safe Ignition * Flame Sensor *Over Heat Protector *Air Pressure Switch * Surge Absorber 3/4 NPT Male 3/4 NPT Male 1/2 NPT Male Fuel Filter Water Intake Insulator Hot Water Outlet Insulator 70F Rise 210 GAL/H 3.5 GAL/MIN 80F F F OF (Maximum hot water supplied by this unit is about 221 GAL/H.) >KThis represents Efficiency under laboratory conditions. This efficiency rating can vary up to 4%. "SINCE WE ARE CONSTANTLY IMPROVING OUR PRODUCTS, ALL SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE." -3-

6 C. DIMENSIONAL OUTLINE DRAWING (Unit-.Inches) Hot Water Outlet Vent Connector Cold Water Intake Fuel Filter Connection ' 0 0 ( I EEC Drain \

7 3. OPERATIONAL PROCEDURES) A. FUEL TYPE: Use only crystal clear Type 1-K Kerosene. B. 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. Fuel purge screw e. Fill the bowl of the unit fuel filter with kerosene. Fasten fuel purge screw back in original position. Handle O Ring of fuel purge screw carefully. A damaged 0 Ring can cause fuel leakage and render unit inoperative. Don't misplace 0 Ring. f. Wipe all fuel spills off thoroughly. -5-

8 C. PRE-OPERATION CHECK LIST 1. Water Leaks Open the valve and run water through unit to see that water runs properly through heat exchanger. No water should be leaking from it, or any fittings. 2. Fuel Leaks Make sure that there is no fuel leaking from fuel tank, filters, valves or from any of the piping connections. 3. Location Make sure proper clearances are kept around unit and there is nothing flammable nearby. 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) From Heater to closet door 29 in (735 mm) Flue pipe to combustible surface, vertically 9 in (229 mm) Flue pipe to combustible surface, horizontally 9 in (229 mm) 4. Flue Connection All flue connections must be air tight and sealed so that no fumes can leak into the room. 5. Unit Wiring The power supply is properly connected and grounded to unit. D. START UP AND OPERATION 1. Readying Safety Device For Action Press and turn off "Power" switch. The "Power" light goes off. Press "Power" switch again, thus turning it on. This procedure readies safety devices for action when necessary. 2. Starting Unit With the "Power" switch in the "ON" position, "Power" lamp should be on. Open hot water faucet and unit will ignite automatically. (While burner has flames, run lamp stays on.) Should run light go off, a code "4" may blink signaling air in fuel supply line. Refer to installation Manual "Test Run" -6-

9 Adjustment of Hot Water Temperatures a. Thermostat has been set at factory to about 104T. (LOW) b. Slide "Hot Water Temperature Adjuster" knob up toward "High" to raise water temperature. Slide knob down toward "Low" to reduce the temperature. c. When adjusting hot water temperature with hot-cold water mixing valve, control the amount of cold water from main without changing the amount of hot water being supplied. > Knob at position "High" provides hot water at a temperature around 167T. 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. KHiimiaa HIGH r MED. LOW 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 results in different hot water temperatures supplied. Use hot water supply tap to control hot water temperature, or readjust thermostat setting. 7

10 G. 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 period 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 results in a "boiling no water" situation, and may result in a blown temperature fuse. LIGHTNING Lightning may cause a temporary power surge, which may damage some electronic parts. Where there is thunder storm activity, install a surge protector in power circuit. WHEN UNIT WILL NOT BE USED FOR AN EXTENDED 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 8.) -9-

11 ( 5. MAINTENANCE CHECK LIST ) Flammables or Dust Keep the top and vicinity of unit, clean. Keep flammables and dangerous items away from unit. Fuel Leakage, Spills, 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 once 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 6 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, sure flue is properly installed and maintained. Also, make Cleaning Heat Exchanger Drain water from heat exchanger at least once a year. l.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. l.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. Cold water intake Inlet Water Filter 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-

12 7. TROUBLE SHOOTING GUIDE ) Use the following chart for detection and correction of problems and their causes. Contact your local dealer for problems beyond your control. (1) Power lamp does not go on. ^ Power is disconnected. % A power failure. ^ Temperature Fuse has been activated. (2) Unit does not start. ^ ^ruwt; lamp UMJ % Temperature adjustment is set too low. % Water inlet filter is clogged. ^ Water supply valve at Main is not open. Reset circuit breaker or safety fuse. Unit operation is suspended until power is restored. Overheat situation. Contact your local dealer. Set temperature Ajuster higher. Remove and clean the filter. Open Water Supply Valve at Main. J V (3) Unit stops during use. - ^ Power connection is loose. : A temporary power failure. ^Temperature Fuse has been activated. fpnwf*i* lirnn nn^ % Hot Water Temperature Adjustment is set on "LOW" side. : Water and/or debris go into Fuel. Filter/Fuel supply pipe. sfcair remains in Fuel Supply pipe. Reset Circuit Braker. Retighten connection. Unit operation will resume shortly. Call your local dealer. Set Temperature Adjustment Higher. Clean, or replace. Purge air from Fuel Supply Pipe. (4) Excessive noise develops while operating. %. Water and/or debris has gone into Fuel. Filter/Fuel supply pipe. ^Air remains in Fuel Supply pipe. >fc Flue has clogged. JjiOil (light oil) other than Kerosene is used. :fc Insufficient air intake for combustion. Clean, or replace. Purge air from Fuel Supply Pipe. Dismantle and clean. Clean and replace with clean kerosene. Contact your local dealer. -13-

13 (5) Water does not flow from hot water outlet. Water supply valve at Main is not open. Open Water Supply Valve at Main. (6) Hot Water temperature is too low. >(c Temperature adjustment is set too low. :fc Hot Water is being used beyond capacity. % Water and/or debris get in Fuel Filter- /Fuel supply pipe. Set Temperatrue Adjustment higher. Partially close the Hot Water outlet. Clean, or replace. (7) Hot Water temperature is too hot. Set Temperature Adjustment is set on high. Set Temperature Adjustment lower. (8) Unit goes into the state of code "4" occasionally. (Unit is shut off.) Water and/or debris get into Fuel Filter/Fuel supply pipe. Air remains in Fuel Supply pipe. Clean, or replace. Purge air from Fuel Supply Pipe. Refer to page 5. The following are conditions that are normal or easily remedied : OPENING HOT WATER SUPPLY VALVE A SMALL AMOUNT WON'T START UNIT : The burner of this unit cannot be ignited unless minimum water flow about 0.45 G/min is maintained. Open up faucet wider. HOT WATER TEMPERATURES CAN VARY WITH MULTIPLE FAUCETS OPEN : When hot water is used from two or more faucets simultaneously, the amount and temperature of hot water from each faucet could vary depending on piping scheme and how much each valve is opened. This tendency could be enhanced when shower and another faucet are put to service simultaneously. HOT WATER APEARS OPAQUE : Hot water might look white and opaque during initial outflow, because air mixes with water in heater, and under pressure is released to atmosphere when faucet is opened. When this happens, air and water come out in the form of bubbles, looking white. There is no harm in this process, and hot water will soon turn transparent. SOUND OF FAN MOTOR STILL AUDIBLE AFTER UNIT IS TURNED OFF : Fan motor continues to run for about 150 seconds after unit is turned off in order to drive exhaust gas out of combustion chamber. -14-

14 BURNER OPERATES IN REPETITIVE RUN/STOP CYCLE : This is normal if flow is low. This unit is being controlled by micro-processor to maintain steady outlet temperature. WHITE VAPOR RISING FROM FLUE (IN WINTER) Vapor in exhaust gas could turn into droplets in winter, which may come out from flue in the form of white vapor. UNIT OCCASIONALLY DISPLAYS AN ERROR CODE "4" AFTER REFILLING FUEL TANK : Error code "4" may start blinking, a sign of air being in fuel supply pipe after filling a empty fuel tank. Follow the procedure provided on page 5 for air purge. Then, set the hot water supply temperature adjustment on the control panel on "High". Fully open the water supply valve, and press "Power" switch once again. Allow unit to run for 10 to 15 minutes after it moves into "Continuous Operation" mode to make sure that there is no air remaining in pipe. Do not allow fuel tank to become empty. ONLY LUKEWARM WATER IS SUPPLIED IN THE BEGINNING : This can happen especially in winter or when the unit that has been installed with a long hot water supply piping arrangement. When standing water in pipe is purged, the temperature of hot water will become constant. DETECTION OF TROUBLES BY READING CODE INDICATOR : 1. Code indicators on control panel can tell where trouble is. 2. If service of your local dealer is needed, provide information on code signs. ( CODE SIGNS ) " 4 " Burner does not ignite. Flames stall occasionally. Cds has a broken wire. (Refer to page 5) " 5 " Faulty flames or shortcircuited Cds. " 6 " A broken wire on detection water thermistor " Hot water supply high limit was activated. (PCS malfunction). Thermistor has electrical short. " 8 " Hot water supply high limit shut off was activated. (194 F Thermo over heat protector) " 9 " Hot water temperature adjustment control has malfunctioned. " E " Communications circuit in trouble. " H " Main PCB has problem " P " Fan motor has problem and fails to turn. (might be caused by extreme windy condition) For all of the above, please contact your local dealer. -15-

15 MONITOR KWH124 SERVICE PARTS LIST ITEM No PART No, DESCRIPTION Fuel Pump Ass'y Air Damper Solenoid Ignitor Transformer Photo Sensor (Cds) Combustion Blower Ass'y Burner Ass'y Burner Base Burner Head Ring ITEM No PART No DESCRIPTION Exhaust Stack Ass'y Base Exterior Cover (Right side) Access cover Electric Outlet Cover Exterior Cover (left side) Drain Cover Front Cover Air Pressure Switch Top Cover Fuel Filter Front Cover Screws/Collar Nozzle Air-Pressure Sensor Ignition Rod Set (Right and left) Front Cover Bracket Heat Exchanger Ass'y (W/lnsulated Wrap, Gasket) PCB Mounting Bracket Water Inlet connector Burner Retaining Bracket Ass'y Filter Water Inlet Insulation Set Water Governor Junction Box Inlet Pipe Set Drain Retainer Flow Sensor Heat Exchanger Insulated Wrap Flow Sensor Bracket Heat Exchanger Base Gasket Mixing Tank Exhaust Stack Gasket Water Outlet Connector Fan Motor Gasket Hot Water Thermistor Set Flange Gasket Printed Circuit Board Burner Heat Gasket Control Panel Ass'y Water Inlet Gasket Control Panel Circuit Board Water Outlet Gasket Thermo Overheat Protector Water Governor Gasket Over Temperature Fuse Set Damper Cushion Main Fuse 6A Exhaust Stack Outlet Insulator Power Transformer Ring (Thermistor P6 4C) Terminal Block Ring (Water Filter P10A 1A) PCS Spacer Clip Ring (Multiple Use P14 4C) Fuel Pipe O-Ring (Flow Sensor Inlet PI 8 4C) Fuel Filter Mounting Bracket Ring (Water Governor P22A 1A) Silencer Ass'y (W/Gasket) -17-

16 KWH124 LIMITED WARRANTY MONITOR PRODUCTS, INC. warrants each KWH124 Instantaneous Water Heater System sold by it to be free from defects in material and workmanship, under normal use and service, for one year after the date of original retail purchase, in a single family dwelling, subject to the term and conditions stated below. An extended warranty period of 48 month is provided for combustion chamber and heat exchanger. The remainder of the unit is subject to the 12 months warranty as provided herein. If the KWH124 is installed in other than a single family dwelling, this warranty is limited to ONE year from date of installation. 1. WARRANTOR: This warranty is granted by MONITOR PRODUCTS, INC., P.O. Box 3408, Princeton, New Jersey PARTIES TO WHOM WARRANTY IS EXTENDED: This warranty shall be extended only to the original retail purcaser. 3. PARTS COVERD: All products and parts manufactured by or for MONITOR PRODUCTS, INC., except as provided for herein. Replacement parts are warranted only for the balance of the original warranty period. 4. PARTS NOT COVERD: The following parts are not coverd by this warranty: fuel filters, venting apparatus, oil lines, fuses and water pipes. 5. REMEDY: if, within the applicable warranty period, any product or part included in this warranty proves to be defective in material and/or workmanship, then MONITOR PRODUCTS, INC., shall repair or replace, at its option, the defective product or part. Service at the point of installation (not including dealer travel time) will be provided at no charge to the customer, but must be performed by a MONITOR PRODUCTS, INC., dealer authorized to sell and service the KWH124 Instantaneous Water Heater system. 6. PROCEDURE FOR OBTAINING PERFORMANCE UNDER THIS WARRANTY : In order to obtain performance of the obligations under this warranty, the original purchaser must promptly (in no event later than thirty (30) days after discovery of the defect) notify the local MONITOR PRO- DUCTS, INC. dealer authorized to sell and service the KWH124 Instantaneous Water Heater system. Service will be provided during normal business hours within a reasonable time after the dealer has been notified of the need for service. If you are unable to locate a local MONITOR PRODUCTS, INC. dealer authorized to sell and service the KWH124 Instantaneous Water Heater System, call or write to : SERVICE DEPARTMENT, MONITOR PRODUCTS, INC., P.O. BOX 3408, PRINCETON, NEW JERSEY 08543, PART NO PRINTED IN JAPAN Any claim made under this warranty must be accompanied by proof of original purchase date sales invoice or cancelled check showing serial number is satisfactory evidence. 7. SOLE REMEDY : The remedy and liability for any breach of warranty, express or implied set forth above is the sole and exclusive remedy and the limit of liability for any such breach. 8. EXCLUSIONS : This warranty does not extend to any defect due to the negligence of others, failure to install, operate or maintain the water heater in accordance with the installation, operation and maintenance instructions furnished with each new water heater, unreasonable use, accidents, alterations, ordinary wear and tear, the use of unauthorized or non-standarized parts, accessories or the use of any fuel other than good quality kerosene, such as Type 1-K grade. This warranty will not apply to parts subject to misuse, abuse, neglect, alteration, accidents, excessive temperature, excessive pressure, lime or sediment accumulation, corrosive atmosphere, noise, odor, rusty water, or installed outside of the United States, or on which the serial numbers have been altered. 9. IMPLIED WARRANTIES : All implied warranties, if any, arising, under state law in connection with the sales by MONITOR PRODUCTS, INC. of any new heater are limited in duration to the duration of this written warranty. There are no warranties, express or implied, of merchantability, fitness for a particular purpose or otherwise which extend beyond this warranty MONITOR PRODUCTS, INC/ shall not be responsible for any incidental or consequential damages. Whether as a result of breach of warranty, negligence, strict liability in tort or otherwise. NOTE: Some states do not allow (A) limitations on how long an implied warranty lasts : or (B) the exclusion or limitation of incidental or consequential damages, so the above limitations or exclusions may not apply to you. 10. NO VARIATION OF TERMS : The parties intend that this warranty be the exclusive and final expression of their agreement. No person has the authority to orally, in writing or in any other way vary the terms, conditions or exclusions, of this warranty or to make any express warranties other than those contained herein. 11. LEGAL RIGHTS : This warranty gives you specific legal rights and you may also have other rights which vary from state to state. MONITOR PRODUCTS, INC. P.O. BOX 3408 PRINCETON, NJ COPYRIGHT 1990 MONITOR PRODUCTS, INC.,