HHW-80 ECOHEAT Operation, Service & Parts Manual CEI Enterprises An Astec Company Albuquerque, New Mexico, U.S.A.
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C18-054, CEI HHW-80 ECOHEAT C18-054, CEI HHW-80 ECOHEAT WARNING! IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE TO THE BURNER CAN CAUSE INJURY OR PROPERTY DAMAGE. Because of the critical nature of burner operations, CEI recommends that you retain the services of a CEI factory trained and licensed burner technician and/or a local licensed burner/boiler technician to check and, if required, adjust the burner prior to commissioning your equipment. iii
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C18-054, CEI HHW-80 ECOHEAT Contents Section 1: Operations... 1 Overview... 3 Safety... 3 IF YOU SMELL GAS...3 WARNING!...3 Safety Symbols...4 HHW-80 Components... 5 Burner...6 Tank...6 Control Panel...7 Installation... 10 Inspection...10 Position...11 Connect Electrical...11 Connect Compressed Air...12 Connect Natural Gas...13 Connect Water...13 Startup...14 UT150 Burner Modulation Controller... 17 Section 2: Maintenance & Troubleshooting... 21 Calcium Clean-Out...23 Cleaning Strainers...25 Freeze Protection...25 Checking Water Level Switches...26 Checking the Flame Scanner...26 Checking the Pilot Gas Pressure Regulator...27 Checking the High Fuel Gas Pressure Switch...27 Checking the Low Fuel Gas Pressure Switch...28 Checking the High Flue Gas Stack Temperature Switch...28 Checking the Auxiliary Contacts For Water Pump Motor...30 Checking Auxiliary Contacts For the Combustion Air Blower Motor...31 Checking the Low Combustion Air Switch...31 Maintenance Schedule... 32 Troubleshooting... 33 Modulation Motor Troubleshooting... 34 What the Modulation Motor Does...35 v
Key Components of Concern...35 Interaction with Fireye Burner Controls...35 Interaction with Modulation Controller...36 Common Problem...36 Other Problems...37 Symptoms of Problems...37 Remedy for Faulty Electrical Connections...37 Checking and Resetting Cams...37 Checking Transformer in the Modulation Motor...38 Checking Terminal Board and Motor...38 HHW Burner Left Side...41 HHW Burner Right Side...42 Burner Internal...43 HHW Water Heater Parts & Assemblies...45 Water Train & Gas Train Components...46 Water Pump & Water Level Indicator Components...47 Electrical...48...49 Specifications...51 Contact Information...55 CEI Service (General Contact)...55 Departmental Contacts...55 vi
C18-054, CEI HHW-80 ECOHEAT Section 1: Operations
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C18-054, CEI HHW-80 ECOHEAT Overview Overview The HHW-80 ECOHEAT is an on-demand heater meaning the burner is fired to heat only the water used, as it is used. Your HHW-80 ECOHEAT heater provide a constant supply of hot water flowing at a rate of up to 1200 gpm while raising the water temperature up to 185 F. A high thermal efficiency (up to 99%) helps keep the exhaust stack temperature near the temperature of the incoming water. The HHW-80 ECOHEAT serial and model number is located on the electrical cabinet door. Note: Please supply the serial number when requesting service support or making reference to the tank for spare parts or operational questions. Safety Safety is of prime concern whenever using an electrically operated, high temperature device. Please use proper safety precautions and follow all company, local, state and federal regulations for operating potentially dangerous equipment. Lock-out/tag-out equipment before performing maintenance. IF YOU SMELL GAS 1. Open windows. 2. Do not touch electrical switches. 3. Extinguish any open flame. 4. Call your gas supplier immediately. Do not store or use gasoline or other flammable liquids and vapors in the vicinity of this or any other appliance. WARNING! Although your HHW-80 ECOHEAT heater provides safe, unattended operation, improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. For assistance or additional information contact CEI. This manual gives basic instructions which must be observed during installation, operation and maintenance of your HHW-80 ECOHEAT. It is imperative that this manual be read by the responsible personnel/operator(s) prior to the commissioning of any liquid media storage system. It must always be kept available at the site of installation. It is not only the general safety instructions contained in this Safety section which must be observed, but also the specific information provided in the following sections and other applicable manuals. 3
Safety Safety Symbols Some symbols shown below may not be used elsewhere in this manual Explosion prevention Spray prevention Fire prevention Lock-Out / Tag-Out Burn prevention Hot surfaces Electrocution prevention Environmental protection Important High pressure Danger and warning messages also appear on decals at appropriate locations on the heater. They identify known hazards, their severity and how you can avoid them. Pay special attention to them. They are shown below to increase your awareness. 4
C18-054, CEI HHW-80 ECOHEAT HHW-80 Components HHW-80 Components a. Stack temperature switch l. Low-low water level switch w. Manual gas leak test valve b. Inlet water pressure switch m. Drain connection x. Pilot gas valve c. Inlet water temperature gauge n. Thermocouple y. Manual gas shut off valve d. Low gas pressure switch (not visible) o. Check valve z. Inlet water Y-strainer e. Gas pressure gauge p. Outlet water Y-strainer 1. Manual inlet water valve f. Control panel q. Automatic outlet water valve 2. Automatic inlet water valve g. Overflow connection r. Outlet water temperature gauge 3. Inlet water pressure regulator h. Water level indicator s. Outlet water pressure gauge 4. Inlet water pressure gauge i. High-high water level switch t. Manual outlet water valve 5. Secondary water connection j. High water level switch u. Burner 6. Exhaust stack connection k. Low water level switch v. High gas pressure switch 5
HHW-80 Components Burner A fully modulated unit running on natural gas (or propane), the burner fires only when heated water is requested. Because it is modulated, the burner only runs at a rate high enough to heat the requested quantity of water thus saving fuel. Tank Cold water is introduced into the tank top as a spray where it migrates down through a bed of stainless steel packing rings. Packing temporarily slows the flow of water and provides surface area for heat transfer. Hot gasses rising from the burner heat the packing and, through contact with the heated packing, heats the water. Low-level switches prevent the burner from firing when there is no flow of water through the heater to ensure the structural walls of the heater are not damaged by overheating. High-level switches shut off the burner and incoming water. Additionally, there is a water overflow and a drain valve. 6
C18-054, CEI HHW-80 ECOHEAT HHW-80 Components Control Panel The control panel is where the system parameters are set and controlled. a EMERGENCY STOP Pushbutton Switch g Low Fuel Gas Pressure Indicator Light b Fireye Burner Control h High Flue Gas Stack Temperature Indicator Light c Burner Modulating Controller i Comb. Air Motor Aux. Contacts Indicator Light d Water Pump Switch j Comb. Air/all Limits Made Indicator Light e Burner Control Switch k Heater Alarm Light f High Fuel Gas Pressure Indicator Light 7
HHW-80 Components Emergency Stop Pushbutton Switch Push in this switch to immediately shut down the heater. Use it only in an emergency. The switch incorporates a light that comes on when the switch is pushed in. Unlike using the BURNER switch to shut down, the emergency stop switch removes electrical power from all other controls and immediately shuts down the heater without a post purge. Burner Modulating Controller The modulating controller, a Yokogawa UT150, provides two functions: Burner modulation control Burner on/off control Burner modulation control. This function of the controller controls heating of the water to maintain a temperature setting that has been preset by the operator. It senses water temperature from a thermocouple. It processes the output voltage of the thermocouple and sends control signals to the Honeywell modulating actuator which either increases or decreases the firing rate as required to maintain water temperature at set point. Burner on-off control. This function of the modulating controller shuts off the burner completely. This happens if system heat demand decreases, allowing water temperature to reach a limit equal to the set point plus a predetermined value. This value is normally set manually at 10. It is known as a floating value since it creates the limit based on the set point. Thus, if its value is 10 and the set point is 140 degrees F, the limit is 150 degrees F (the sum of 140 plus 10). After the water cools down about 20 degrees the controller initiates a new burner cycle. Fireye Burner Controls The Fireye burner controls consist of a Fireye YB110 Burner Management Control and YP100 Programmer Module (inside the panel), and the BV512 Display (indicated). It is a microprocessor based burner management control system. The system provides the proper burner sequencing, ignition and burner monitoring protection. In conjunction with limit and operating controls it sequences the burner/blower motor, ignition transformer and fuel valves to provide for proper and safe burner operation. The system will close all fuel valves within four seconds (maximum) following a flame failure or at the end of the pilot trial for ignition period if no flame is detected. An alarm circuit will be energized following a safety lockout. The system must be reset using a manual reset button on the display after an abnormal condition has been cleared. 8
C18-054, CEI HHW-80 ECOHEAT HHW-80 Components Water Pump Switch This is a manually controlled switch for turning the water pump on and off. The switch is in series with the breaker auxiliary contacts of the motor controller and must be closed for power to reach the motor. When the switch is set to ON, the water pump will run as long as there is an adequate amount of water in the heater reservoir. The controls are designed to allow a signal from a remote tank to start/ stop the heater. The switch must be set to AUTO for this feature to work. Burner Control Switch This is a manually controlled switch for turning the burner on and off. It must be set to ON or AUTO for the heater to operate. The controls are designed to allow a signal from a remote tank to start/stop the heater. The switch must be set to AUTO for this feature to work. When this switch is set to ON the burner will come on and off as needed, independently of external control signals. The burner switch must be set to ON or AUTO for any of the five indicator lights to work. High Fuel Gas Pressure Indicator Light This indicator light denotes the status of the high fuel gas pressure switch. When the light is on the fuel gas pressure is normal and the switch is closed. When the light is off it indicates that the fuel gas pressure exceeded the setpoint. This switch is part of the limit circuit and will shut down the burner when open. The switch has a manual reset button. Note: Not all heaters have a high fuel gas pressure switch. But the panel may still have an indicator light for the switch. In that case the switch is replaced by a jumper wire. Thus, the light will react the same as it would with a switch in its normal pressure state. Low Fuel Gas Pressure Indicator Light This indicator light denotes the status of the low fuel gas pressure switch. When the light is on the fuel gas pressure is normal and the switch is closed. When the light is off it indicates that the fuel gas pressure dropped lower than the setpoint. This switch is part of the limit circuit and will shut down the burner when open. The switch has a manual reset button. Note: Not all heaters have a low fuel gas pressure switch. But the panel may still have an indicator light for the switch. In that case the switch is replaced by a jumper wire. Thus, the light will react the same as it would with a switch in its normal pressure state. High Flue Gas Stack Temperature Indicator Light This indicator light denotes temperature status of gas in the exhaust stack. It is electrically connected to the high flue gas stack temperature switch mounted in the exhaust stack. 9
Installation When the light is on, temperature of the gas is within normal operating range and the switch contacts are closed. When the light is off, gas temperature has exceeded its factory setting of 130 degrees F and the contacts are open. The switch is also part of the limit circuit and will shut down the heater when the switch is opened. The switch must be manually reset. Combination Air Motor Auxillary Contacts Indicator Light This indicator light denotes the status of auxiliary contacts on the motor controller that connects electrical power to the burner blower motor. When the indicator light is on electrical power is connected to the blower motor. When the light is off the contacts are open because electrical power is not connected to the motor. The contacts are also part of the limit circuit and will shut down the heater when opened. The contacts automatically close when power is restored to the motor. Combination Air/all Limits Made Indicator Light This light functions as a low combustion air pressure light in addition to a limits made light. When the light is on it indicates that the combustion air pressure is normal and that the combustion air switch in the burner housing is closed. When the light is on it also indicates that all other limit switches are closed. When the light is out the combustion air pressure is too low and the combustion air switch is open. Heater Alarm Light This light denotes the status of the heater alarm system. When the light is flashing the heater is in an alarm state. The alarm is controlled by the Fireye burner control which turns on the alarm when it detects a variety of abnormal conditions. The Fireye display shows one of several messages to report the condition that caused the alarm. Installation Inspection CEI takes great care in the construction and shipping of each HHW-80 ECO- HEAT so that it will arrive ready for installation and operation. However sometimes the unforeseen happens and damage occurs during loading, shipment and/or delivery. We recommend a full inspection of the unit for any signs of damage and/or missing parts before installing the unit. In the unlikely event that damage has occurred or a part (or parts) is missing, please contact your CEI representative before continuing with installation. 10
C18-054, CEI HHW-80 ECOHEAT Installation Position The HHW-80 ECOHEAT is normally positioned so its heated water can easily be connected to the intended destination equipment and where the burner exhaust gases can safely dissipate. Connect Electrical Verify that there is sufficient electrical power for the HHW-80 ECOHEAT before proceeding. Power requirements are listed on the Electrical Print located within the control box and in the parts drawing section of this manual. Connect the external electrical power while adhering to any applicable codes. Input Power Connections Note: Power is normally supplied through the bottom of the control box. 11
Installation Connect Compressed Air Externally supplied compressed actuates two water flow control solenoids. The air supply can be dry or lubricated filter at 40 to 120 PSI. The air connection is located behind the outlet water connection near the bottom of the unit. Note: CEI tests the air operated water flow control solenoids at 80 psi. Air line to input water control solenoid Connection for externally supplied compressed air Output water control solenoid 12
C18-054, CEI HHW-80 ECOHEAT Installation Connect Natural Gas 1. Verify that there is a sufficient supply of Natural Gas for the HHW-80 ECOHEAT before proceeding (see the Specifications section at the end of this manual). 2. Make sure the heater s gas inlet supply valve is closed then connect the Gas supply to the inlet on the Heater. Open the source gas supply valve and check for leaks. Correct as necessary. Gas Inlet Valve (shown closed) Gas Supply Inlet Connect Water Verify that there is a sufficient supply of water for the HHW-80 ECOHEAT before proceeding (see the Specifications section at the end of this manual). There are two primary water connections, incoming cold and outgoing heated water. The incoming cold water connection is near the top of the unit while the outgoing heater water connection is near the bottom adjacent to the pump/motor assembly. A third connection is for a permanent drain. Connect the plumbing, check for leaks and correct as necessary. 13
Installation Startup Prior to startup The following conditions are required prior to startup: The incoming gas supply line pressure is 0.5 psig. The heater is properly installed, piped, and wired. Water piping should be complete and leak-tested. Air connected to outlet water valve. Preliminary procedure: Power Disconnect Water Pump Switch Burner Switch 1. Make sure the power disconnect switch on the control panel is set to OFF. 2. Make sure the switches marked BURNER and WATER PUMP are set to OFF. 3. Make sure the inlet and outlet water valves are closed (see items t and 1 in the image on page 5). 4. Make sure the two shutoff valves on the water level indicator are open (see item h in the image on page 5). 5. When you drain water from the heater you may wish to drain it to a spot some distance from the heater. If so, install a drain valve and a hose (not supplied) at the drain connection (see item m in the image on page 5). 14
C18-054, CEI HHW-80 ECOHEAT Installation CAUTION! The next 3 steps instruct you to work inside of the heater control panel while its parts are electrically energized with high voltage. You will need a voltmeter suitable for measuring up to 600 volts AC. a. PLC (Programmable Logic Controller) f. Control transformer b. Fireye burner management control g. Blower motor controller c. Main disconnect breaker h. Water pump motor controller d. Grounding lug i. Terminal Strip e. Circuit breakers and fuse blocks j Fused terminals 6. Open the control panel and turn on all breakers except the main disconnect breaker. 7. Note the voltage marked on the voltage label (item a) inside the door. Check that the voltage across the terminals at the top of the main disconnect circuit breaker (item c) is the same as marked on the label. Manually turn on the main 15
Installation circuit breaker and check for the same voltage across the terminals at the bottom of the breaker. Check for 120 VAC across the secondary winding of the control transformer (item f). 8. Make sure that the EMERGENCY STOP switch on the control panel operates properly. While power is on, and the panel door is open check for 120 VAC across terminals 1 and 2 inside the control panel (item c). Push in the EMERGENCY STOP switch. A light should come on inside the stop control. Now check to make sure there is no voltage across terminals 1 and 2. Reset the stop switch and close the panel door. 9. Set the BURNER MODULATION CONTROLLER (see image below) per instructions that follow. The position of the Water Pump and Burner switches for operation depends on whether the unit is operated locally or from a remote location. When operating locally, both the Water Pump and Burner switches are in the ON position. When operating from a remote location the Water Pump and Burner switches are in the AUTO position. Once all connections are made and verified, set the water temperature (aka set temperature) on the digital controller. To adjust the temperature, use the updown arrows on the controller. Press the SET/ENT key to save the setting. CAUTION! Do not exceed 190 F Fireye Flame Monitor Burner Modulation Controller Water Pump & Burner Switches Status Lights 16
C18-054, CEI HHW-80 ECOHEAT UT150 Burner Modulation Controller UT150 Burner Modulation Controller Note: Setup Parameters The Burner Modulation Controller is normally pre-programmed to the values listed in the tables below when ordered from CEI. However, if the display shows that IN is OFF when you first apply power, the controller has not been programmed. Repeatedly press the UP arrow key until the display shows 35 then press the SET/ENT key. 1. To enter Setup Parameters press and hold the key for approximately 3 seconds until the display shows A/M. 2. Repeatedly press the key until the display shows LOC. 3. Press the key to change the display to 1. Note: If the LOC display shows 1, press the down key for a display of 0. Press the SET/ ENT key, press the down arrow key for a display of 1, then press the SET/ENT again to enter Setup Parameters. 4. Use the and keys to change the displayed value to those in the following table then press the key to save the value. 5. Press the key again to move to the next item. 6. Repeat steps 4 and 5 for all items in the following table: Prompt Parameter Type Value Input type Setpoint range maximum value Setpoint range minimum value Setpoint ramp-up rate Setpoint ramp-down rate Setpoint ramp-rate time unit Retransmission maximum value Retransmission minimum value 35 500 25 OFF OFF 1 200 0 17
UT150 Burner Modulation Controller Prompt Parameter Type Value Alarm 1 type a Alarm 2 type Alarm 1 hysteresis Alarm 2 hysteresis SUPER function Direct / reverse action 5 De-energized on deviation high limit 0 15 0 OFF 0 7. When finished entering the Setup Parameters: Operating Parameters Note: a. Set to turn the burner OFF when the water temperature exceeds the set temperature by 5 The controller automatically returns to the Operator mode after 2 minutes if no buttons are pressed. 1. To enter Operating Parameters press and hold the key for approximately 3 seconds until the display shows SP. 2. Use the and to change the displayed value to those in the following table then press the key to save the value. 3. Press the key again to move to the next item. 4. Repeat steps 2 and 3 for all items in the following table: Prompt Parameter Type Value Auto / Manual A1 Value A2 Value Control mode Auto-tuning Proportional band AUT 10 0 PID OFF 24 18
C18-054, CEI HHW-80 ECOHEAT UT150 Burner Modulation Controller Prompt Parameter Type Value Integral time Derivative time PV input filter PV input bias Key lock 256 64 OFF 0 0 5. When finished entering the Operating Parameters: 6. Press and hold the key until the display returns to normal operations 19
UT150 Burner Modulation Controller 20
C18-054, CEI HHW-80 ECOHEAT Section 2: Maintenance & Troubleshooting
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C18-054, CEI HHW-80 ECOHEAT Calcium Clean-Out Build up of calcium inside the heater can be a matter of serious concern. Excessive buildup can lead to heater malfunctions and heater damage. The rate of calcium buildup varies widely depending on the amount of calcium in the water supply and operating conditions. Frequency of checks and down-time The heater should be checked at least once a month while in regular use to make sure calcium buildup has not reached a point that affects operation of the heater. If no adverse signs are found, the checks can be made less frequently. However, if the heater is moved to a new location or if the water supply is changed, revert back to monthly checks. When excessive calcium buildup is found you need to plan down-time for cleanout. You may need to allow a full day for clean-out. Do not delay any longer than absolutely necessary. Symptoms of excessive build-up In due time you should be able to judge when it s time for a clean-out by the appearance of calcium buildup on the packing in the heater. In order to inspect the packing, shutdown the heater and allow it to cool. Then open the lower access door and pull out several pieces of packing from the center of the heater. You will need to remove packing until you are near the bottom center of the packing column. Calcium will build up here first. As you continue to check packing at regular intervals you should also watch for other symptoms of calcium buildup. One symptom is the inability to heat the water to the desired temperature as you have in the past. Another symptom is an abnormally high stack temperature and excessive vapor from the stack. Another symptom is discoloration of the outside of the heater shell. We strongly recommend that you do not wait until these symptoms appear. Instead you should develop your ability to judge buildup by inspecting the packing as indicated earlier. 23
Cleaning methods There are two methods for cleaning calcium from your heater. The first method requires shutting it down and removing all the packing. The packing must be soaked in a chemical intended for dissolving calcium. Once the calcium has been removed from the packing, rinse it and put it back in the heater. The second method is to clean the inside of the heater and packing simultaneously. This is done by introducing a chemical cleaner into the top of the heater. Do this while circulating water from the reservoir through the heater with the burner off. This may take several hours, depending on the amount of calcium buildup. To circulate its water, first fill the reservoir. Then temporarily install a pipe or hose from the water outlet valve to the secondary water connection. Then operate the water pump to circulate the water containing the cleaning chemical. The cleaning chemical will probably work better soon after the heater has been shut down, while it is still warm. The chamber that contains the floats for water level switches should be cleaned separately. Chemicals A variety of chemicals are available for removing calcium deposits. Some contain sulfamic acid. Others contain citric acid. You may wish to use stronger chemicals on the packing while it is out of the heater and milder chemicals inside the heater. Keep in mind that chemicals circulating through the heater will contact non-stainless steel parts, such as circulating pump, bronze valves, seals, etc. We suggest that you contact a chemical supplier to find out what they recommend. Packing (removal & replacement) Dissolving calcium from the packing may take several hours after it is removed from the heater. Consequently your heater will be out of service for an extended period unless you could simply exchange the original packing with extra packing already cleaned. That would shorten heater down-time and allow you to clean the coated packing as long as necessary. To do that you would need extra packing. It is absolutely essential for the extra packing to be identical to the original packing. Otherwise the heater will not perform properly! Please contact Heatec for information about your packing. If you plan to use extra packing be sure to scribe the wall of the heater to indicate the level of the original packing. When re-filling the heater with packing, increase its level about one inch higher than your scribe mark to allow for settling. 24
C18-054, CEI HHW-80 ECOHEAT Cleaning Strainers All Ecoheat heaters have an inlet water Y-Strainer and some also have an outlet water Y-Strainer. Clogged strainers can cause the heater to malfunction. Symptoms of a clogged strainer include tripping the inlet water pressure switch and/or abnormally high flue gas temperature. You should routinely check the strainers to make sure they are not clogged. Cleaning inlet water Y-Strainer Manually shut off the inlet water valve, remove the plug from the inlet water Y- Strainer and allow the water to drain. Only a small amount of water will drain from the strainer, so a bucket is all you need to catch the water. Remove the strainer basket and clean it if it is clogged. Replace the strainer basket and the plug. Cleaning outlet water Y-Strainer Allow the heater and water it contains to cool down enough to avoid being burned from contact with the shell and the water inside. On heaters that have an outlet water strainer open the drain valve that you installed in the drain connection at the bottom of the heater or remove the plug from the drain connection. Drain several gallons of water until the level shown on the water level indicator is slightly lower than the outlet Y-Strainer. You may want to connect a hose to the drain valve so the water can be directed to a suitable area away from the heater. Remove the plug from the outlet water Y-Strainer. Allow the water to drain. Only a small amount of water will drain from the strainer, so a bucket is all you need to catch the water. Remove the strainer basket and clean it if it is clogged. Replace the strainer basket and plug. Close the drain valve at the bottom of the heater or replace the plug in the drain connection. Freeze Protection Be sure to protect your heater from freezing if it is located where temperatures remain below freezing for several hours while not running. Otherwise water in the heater could freeze and cause extensive damage to heater components. One way to protect it from freezing is to drain all water from the heater shell, float chamber, piping, pump and strainer. All of these have drain plugs except for piping, which may require loosening connections to allow drainage where water is trapped. As an alternative to draining water from the piping you may want to install heat tracing around the piping. 25
Checking Water Level Switches Check water level switches if you encounter any of the following symptoms: Pump won t run Tank overflows Outlet water valve is inoperative Pump cycles on/off To check the switches proceed as follows: 1. Obtain a scrap piece of stiff wire (or a coat hanger) about 3 feet long. Bend one end of the wire to form a small hook. 2. Open the control panel so you can observe the lights on the PLC. 3. Turn on the electrical power using the main disconnect breaker inside the panel. 4. Open the top of the chamber where the switches are installed. 5. Insert the hooked end of the wire into the channel and grab onto the float of a switch. 6. Move the float up and down while observing the light on the PLC. The light should go on and off in response to float movement. 7. Repeat steps 5 and 6 for each of the remaining switches. Checking the Flame Scanner 1. Make sure that the BURNER switch is set to OFF. 2. Turn on power to the control panel while the front panel is open. 3. With no flame present, check for approximately 560 Vac between terminals S1 and S2 using an AC voltmeter. 4. Remove the flame scanner. 5. Create a flame using a cigarette lighter, a torch or a match. Hold the flame in front of the scanner eye. The voltage should drop to about 340 VAC and the Fireye burner display should show FALSE FLAME and should indicate a signal number. Otherwise, either the flame scanner or its amplifier is defective. 26
C18-054, CEI HHW-80 ECOHEAT Checking the Pilot Gas Pressure Regulator 1. Connect a manometer to the tee of the pilot gas line where it enters the burner. 2. Open the control panel and gain access to the Fireye burner control. 3. Turn on power to the control panel while the front panel is open. 4. Set BURNER switch to ON and let the heater start through its purge cycle. 5. Wait for the burner display to show IGNITION TIMING. Quickly place the switch marked CHECK/RUN on bottom of Fireye burner control to the CHECK position. This will hold the timing sequence while you check/adjust the regulator. 6. Check that the manometer indicates approximately 3 inches of W.C. or as specified for your burner in the burner manual. If not, adjust screw on the regulator to attain the recommended setting. 7. Place switch marked CHECK/RUN on bottom of Fireye burner control back to RUN. The timing sequence should continue and operation should be normal. Checking the High Fuel Gas Pressure Switch With the burner operating, remover the cover from the high fuel gas pressure switch being careful not to touch the live terminals. Adjust the switch to a lower setting that causes the switch to open. The following indicate that the pressure switch is operating properly: The burner should shut down. The HIGH FUEL GAS PRESSURE light on the control panel should go out. (All other indicator lights on the panel will also go out.) Fireye burner display shows LOCKOUT 3-P INTLK OPEN. Re-adjust the high pressure switch to its previous position and reset its manual reset button. Reinstall its cover. 27
Checking the Low Fuel Gas Pressure Switch Shut off the main gas manual shutoff valve and set BURNER switch to ON. Remove the plug from the tee fitting below the pressure switch allowing gas to escape. The following reactions should occur, indicating that the switch is operating properly: LOW FUEL GAS PRESSURE light on control panel should be the first light to go out. (Subsequent indicator lights on the panel will also go out.) Fireye burner display shows LOCKOUT 3-P INTLK OPEN. Reinstall plug in tee fitting. Slowly re-open the main gas manual shutoff valve. Reset the low fuel gas pressure switch using its manual reset button. Reset the Fireye control. Checking the High Flue Gas Stack Temperature Switch WARNING Do not touch the exposed terminals inside the stack temperature switch. Touching the terminals could cause electrical shock causing serious injury or death. With the burner operating, remove the cover from the high flue gas temperature switch. 1. Remove the plug from the analyzer port at the base of the exhaust stack. Insert a thermometer in the port and note the temperature of the exhaust gas. 28
C18-054, CEI HHW-80 ECOHEAT 2. Rotate the dial on the switch until its setting is a lower value than the temperature of the exhaust gas. Be careful not to slide the dial towards the switch while rotating it. Otherwise the dial may press on the small plunger in the switch and prematurely trip the switch. The following reactions indicate that the switch is operating properly: The burner shuts down. The HIGH FLUE GAS STACK TEMPERATURE light on control panel is the first light to go out. Burner display shows LOCKOUT 3-P INTERLOCK OPEN. Rotate the dial to its previous setting, then reset the manual reset button on the switch. Replace the cover. 29
Motor Controllers (inside electrical cabinet) 1 Breaker auxiliary contacts for combustion air blower motor 2 Breaker disconnect for combustion air blower motor 3 Contactor for combustion air blower motor 4 Contactor for water pump motor 5 Breaker disconnect for water pump motor 6 Breaker auxiliary contacts for water pump motor Checking the Auxiliary Contacts For Water Pump Motor Note: See Motor Controllers (inside electrical cabinet) on page 30 for numbered references below. With the burner operating, trip the breaker disconnect for the water pump motor (#7) causing its auxiliary contacts to open (#5). The following indicate that the contacts are operating properly: The burner shuts down. Fireye burner display shows STANDBY L1-3 OPEN. Reset the breaker disconnect for the water pump motor. 30
C18-054, CEI HHW-80 ECOHEAT Checking Auxiliary Contacts For the Combustion Air Blower Motor Note: See Motor Controllers (inside electrical cabinet) on page 30 for numbered references below. With the burner operating, trip the breaker disconnect for the combustion air blower motor (#2) causing its auxiliary contacts to open (#4). The following indicates that the contacts are operating properly: The burner shuts down. The COMB. AIR MOTOR AUX. CONTACTS light on control panel should is the first light out. Fireye burner display shows LOCKOUT 3-P INTERLOCK OPEN. Reset the breaker disconnect for the combustion air blower motor. Checking the Low Combustion Air Switch Note: See Motor Controllers (inside electrical cabinet) on page 30 for numbered references below. Make sure that the BURNER switch is set to OFF. 1. In the control panel unlatch the auxiliary contacts (#4) or the combustion air blower and physically remove it with wires attached. 2. Pull out the blue plunger on the module and hold it out to close its contacts. 3. Restart the burner. The COMB. AIR/ ALL LIMITS MADE light should come on almost immediately. 4. Trip the breaker disconnect for the combustion air blower. The COMB. AIR/ ALL LIMITS MADE light should go out within 4 to 5 seconds. If not, remove cover from combustion air switch and re-adjust it as follows: Turn the adjustment screw clockwise to shorten the cut-off response time. Turn it counterclockwise to lengthen the cut-off response time. Re-insert the auxiliary contacts module into the breaker disconnect. 31
Maintenance Schedule Maintenance Schedule Requirement Weekly Monthly Quarterly Yearly Clean flame scanner X Check intake area of blower to make sure it is not blocked by foreign material and is free from buildup of dirt X During normal operation check all pressure gauges and thermometers on heater and record any changes from previous indications X Check all operating and limit controls and settings to make sure they are set properly and are working properly X Check heater and piping to ensure there are no leaks X Check heater to ensure there is no structural damage to heater or signs of over-heating X Check burner control linkage to make sure it is not binding or loose X Remove packing from inside heater and check to ensure that calcium buildup is not excessive X Check strainers to ensure they are not clogged X Have exhaust stack gases analyzed and have burner tuned by a specialist X 32
C18-054, CEI HHW-80 ECOHEAT Troubleshooting Troubleshooting Problem Probable Cause Corrective Action Heater will not start Heater will not start. Flame monitor shows message LOCKOUT PTFI FLAME FAIL (PTFI means pilot trial for ignition) Low combustion air. The COMB. AIR/ALL LIMITS MADE indicator light is off, but all other lights in limit circuit are on High flue gas stack temperature indicator light is off Water level sight gauge does not accurately indicate water level in reservoir Burner does not modulate 1. Limit device in 3-P limit circuit is open. 2. Pump is not running. 3. Heater reservoir is full. 4. No signal from remote tank when burner switch is set to AUTO. 1. Defective flame scanner. 2. Igniter improperly set. 3. Defective ignition transformer. 4. Defective ignition wire. 5. Defective pilot solenoid. 6. Pilot gas regulator improperly set. 1. Breaker for blower is tripped. 2. Line to low combustion air switch is clogged. 3. Fan blades of combustion air blower clogged with dust. 4. Low combustion air switch out of adjustment. 5. Blower motor runs backwards 1. Inlet strainer clogged. 2. Inlet nozzle(s) are clogged. Two valves on sight gauge not open. 1. Burner modulation controller in manual mode. 2. Defective power transformer in modulating actuator. 3. Defective motor in modulating actuator. 1. See discussion of limit circuit in separate Tec-Note on controls. 2. (See this problem below) 3. Check for defective high water level switch. 4. Check for signal from remote tank (See wiring diagram) 1. Check the flame scanner per instructions in Tec-Note on maintenance. Replace if defective. 2. Reset per manual on Power Flame burner. 3. Check for 120 vac at primary. If OK check ignition wire for break. If OK check for spark. If no spark replace transformer. 4. Check wire for break. Replace if broken. 5. Check for click when energized. If no click check for 120 vac at solenoid terminals. Replace solenoid if there is no click when voltage is applied. 6. Check regulator and reset if necessary per separate Tec-Note on maintenance. 1. Reset breaker. 2. Disconnect air line and blow compressed air through the line. 3. Clean blades to remove dust. 4. Readjust low combustion air switch per separate Tec-Note on maintenance. 5. Check water pump rotation. If both are wrong, switch main power leads. If only the blower rotation is wrong, switch blower motor leads. 1. Flush strainer. Disassemble and clean if necessary. Reset stack switch. 2. Check nozzles for debris and/or wear. Clean/replace as needed. Reset stack switch Open both valves on sight gauge. 1. Reset controller to auto mode. 2. Check the transformer in the actuator and replace it if defective per separate Tec- Note. 3. Check the motor in the actuator and replace if defective per separate Tec-Note. 33
Modulation Motor Troubleshooting Problem Probable Cause Corrective Action Water does not reach set point temperature No water flows out of heater Water pump is not running 1. Burner not modulating. 2. Inlet water is too cold. 3. Water flow rate is too high. 4. Burner out of tune. 1. Manual water outlet valve is closed. 2. Auto water outlet valve is inoperative. 3. Incorrect rotation of water pump. 4. Water pump is not running. 1. Water level is too low. 2. Float switch(s) not operating properly. 3. Breaker for pump motor is tripped. 4. No signal from remote tank when water pump switch is set to AUTO. 1. (See problem above). 2. Use warmer supply water or reduce flow rate. 3. Reduce flow rate. 4. Have qualified technician to retune burner. 1. Open valve. 2. Check for compressed air supply if valve is pneumatically operated. Check solenoid if valve is solenoid operated. 3. Reverse rotation of pump motor per Tec- Note on operation. 4. (See problem below) 1. Check manual and automatic inlet water valves. 2. Check low and low-low water level switches and replace if necessary. 3. Reset breaker. 4. Check for signal from remote tank (See wiring diagram) Modulation Motor Troubleshooting Modulaion Motor 34
C18-054, CEI HHW-80 ECOHEAT Modulation Motor Troubleshooting What the Modulation Motor Does The mod motor is connected to mechanical linkage that opens and closes burner fuel valves and air dampers. It provides proportional control of its firing rate. The shaft of the mod motor operates the linkage as it rotates within an arc of 90 degrees. Key Components of Concern Low-fire cam and low-fire proof switch. High-fire cam and high-fire proof switch. Transformer. Note: For clarity some photos of mod motor are shown not installed on the heater. It is not necessary to remove it to perform the checks and adjustments described. Interaction with Fireye Burner Controls The Fireye burner controls monitor the open/closed status of the low-fire and high-fire proof switches in the mod motor while the burner is being purged. The low-fire proof switch is wired between terminals M and D. The high-fire proof switch is wired between terminals M and 8. Thus, the burner display shows either M-D LIMIT or M-8 LIMIT when indicating the status of these switches. Each switch is activated and de-deactivated by its own rotating cam in the mod motor. The low-fire proof switch remains in its normally closed position while the damper is fully closed. After the damper begins to open, the cam opens the switch. The high-fire cam closes the high-fire proof switch when the damper reaches a preset open position. After the damper begins to close, the cam opens the switch. 35
Modulation Motor Troubleshooting Interaction with Modulation Controller The modulation controller controls the mod motor using a circuit that provides an output of 4 to 20 ma after the burner is lit and operating. With a 4 ma signal the mod motor should be in the low-fire position with the damper fully closed. With a 20 ma signal the mod motor should open the damper to the high-fire position. Common Problem Faulty electrical connections are common causes of mod motor malfunctions. Faulty connections can be caused from loose connections, dust, or corrosion from moisture. Connection problems may occur at the following locations: Terminals in mod motor Terminals on temperature controller Terminal strip on back plate of heater panel Terminal strip in burner junction box 36
C18-054, CEI HHW-80 ECOHEAT Modulation Motor Troubleshooting Other Problems Cam Slippage Transformer Failure Symptoms of Problems Mod motor fails to move when burner is first turned on. Burner display indicates abnormal status of either M-D LIMIT or M-8 LIMIT. Mod motor fails to operate the linkage. Modulation controller fails to modulate the mod motor. Remedy for Faulty Electrical Connections All wire connections that pertain to the mod motor have either screw terminals or cage-clamp spring terminals. On screw terminal connections use a screwdriver to slightly loosen the screws and retighten them. On cage clamps connections push on the wire, wiggle it and then pull on it to make sure it is held tightly. Checking and Resetting Cams 1. Remove the top cover so that you can gain access to the tops of the cams. 2. Make sure the shaft of the mod motor is rotated to its position for a fully closed damper. 3. Check positions of the target lobes of the cams. The cams have click stops that hold them in position. Repositioning a cam does not turn the drive shaft of the mod motor. 4. You may be able to rotate the cams with your fingers. Otherwise insert the blade of a screwdriver in the slots of the cam and rotate them. 37
Modulation Motor Troubleshooting 5. In order to make sure the cams are positioned properly you may need to rotate them until you can see their target lobes (indicated by yellow dots) and then reset them to their proper positions. Note: The yellow dots are only shown in the illustration. There are no dots on the actual lobes. 6. You can also use the blade of a small screwdriver to press on the actuating arms of the switches to determine whether they are actuated. The switches should not be actuated while the damper is closed. Thus you should hear a distinct click if you press on their actuating arms. 7. Make sure the target lobes of the two cams are rotated to the positions shown above. The U-shaped ends of the switch arms should rest on the cams. Checking Transformer in the Modulation Motor 1. Make sure BURNER switch is set to OFF. 2. Make sure there is 120 Vac on the primary winding of the transformer using an ac voltmeter. Check for 24 Vac on its secondary winding. The transformer is defective if there is no voltage on its secondary winding. Checking Terminal Board and Motor 1. Make sure BURNER switch is set to OFF. 2. Make sure its transformer is not defective. Refer to instructions above. 3. Disconnect wires F, + and from the terminal board. 38
C18-054, CEI HHW-80 ECOHEAT Modulation Motor Troubleshooting 4. Connect a short jumper wire from terminals to F. The motor of the actuator should go to high-fire, indicating that the terminal board and motor are okay. If the motor moves, remove jumper and reconnect the F, + and wires. Otherwise, remove jumper only and continue with the following steps. 5. Set main disconnect switch on door of control panel to OFF. 6. Remove the two brown wires from terminals T1 and T2. Remove terminal board. 7. Reconnect one brown wire to the connector prong marked T1 on the circuit board. Connect the other brown wire to the connector prong marked T2 on the circuit board. 8. Temporarily connect a short jumper wire from the connector prong marked to prong marked F. 9. Set main disconnect switch on door of control panel to ON. 10. If motor moves it is good, but terminal board is defective and must be replaced. If motor does not move replace motor. 39
Modulation Motor Troubleshooting 40
HHW Burner Left Side 41 Note: Part numbers vary for different size burners. Using the descriptions below refer to your AS BUILT documentation and CEI with the burner model and serial numbers. Item Description Item Description Gas Train Components are covered in the part list 1 Blower Motor 4 Ignition Transformer Enclosure 2 Electrical Junction Box 5 Access to Gas Pilot Assembly 3 Gas Pilot Cutoff Solenoid Valve 6 Fireye UV1A6 Scanner Gas Only HHW Burners HHW Burner Left Side
42 HHW Burner Right Side Part numbers vary for different size burners. Using the descriptions below refer to your AS BUILT documentation and CEI with the burner model and serial numbers. Item Description CEI Part Number 1 Modulating Motor 0304006 Resistor Board a 0304007 a. The resistor board is mounted inside the modulating motor housing and must be ordered separately Gas Train Components are covered in the part list
Burner Internal 43 Gas Pilot Assembly Gas Pilot Assembly - Part Number 0614013-PF Component Description CEI Part Number 1 Electrode 0208011-PF 2 Cable 0205002-PF 1 2 Gas Only HHW Burners Burner Internal
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C18-054, CEI HHW-80 ECOHEAT HHW Water Heater Parts & Assemblies 5601021: Stack Switch See Water Train on page 46 See Gas Train on page 46 See Electrical on page 48 2601201: CR5-G-30 Burner Assembly Refer to the Burner As Built document for part numbers See Water Pump & Piping on page 47 See Water Level Indicator on page 47 45
C18-054, CEI HHW-80 ECOHEAT Water Train & Gas Train Components Water Train Gas Train Item Part # Description Item Part # Description A 1303302 3" Butterfly Valve w/handle A 980450 3" Main Gas Shutoff Ball Valve B 1204042 3" Y Strainer B 301100 3" Main Gas Pressure Regulator C 1301124 3" Bray Butterfly Valve C 161000 Low Gas Pressure Switch D 1301154 3" Swing Check Valve D 190700 6-14 Second Asco AH2E212A1 Actuator E 1301125 3" 150# Pressure Reducing Valve E 190900 Asco AH2E212S4 Actuator w/p.o.c. F 0402030 0-250 F 3" x 2½" Thermometer F 194400 6-14 Second Motorized Gas Valve G 1303081 ¼" Bronze Valve G 192800 6-14 Second Motorized Gas Valve H 0202152 0-30 PSI Pressure Switch H 0401008 0-15 H 2 0 Gas Gauge J 0403024 0-30 PSI Pressure Gauge J 1302081 ¼" Bronze Valve K 1304011 3" Main Gas Shutoff Ball Valve L 1601100 High Gas Pressure Switch 46
C18-054, CEI HHW-80 ECOHEAT Water Pump & Water Level Indicator Components Water Pump & Piping Water Level Indicator Item Part # Description Item Part # Description A 1303305 2½" Butterfly Valve A 0107202 Liquid Level Switch - upper 2 switches for high level lower 2 switches for low level B 0403022 0-60 PSI Pressure Gauge B 0403054 Valve Set for Water Level Gauge C 1302081 ¼" Bronze Valve C 2001003 ⅜" x ⅝" Clear Vinyl Tubing D 1303303 2½" Butterfly Valve w/actuator D 0103010 JJ20RL Thermocouple E 0402030 0-250 F 3" x 2½" Thermometer 47
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