Service manual

16
FCX INSTALLATION AND SERVICE MANUAL
MAINTENANCE - OPERATING FAULTS
V. OPERATING FAULTS
Fig. 42
6 - COMBUSTION PRODUCT FLUE
Examine the flue/combustion air system for leaks and
obstructions. Leaks can generally be detected by the
appearance of condensate stains on the outside of the pipes.
Replace any damaged seals if necessary. The flue/combustion
air pipe can be cleaned with running water, if necessary,
providing that the water flow is not too great to be drained
through the condensate drain system. Leave the excess water
in the condensate trap when cleaning is completed.
7 - CHANGING A THERMOSTAT OR THE THERMOMETER
Replacement of the thermostats or the thermometer requires
removal of the bulb from its location and the control from the
control box.
• The bulb for the Heating System Temperature Thermometer
is located on the first circuit heating output tube. Remove
the bulb from the tube, remove the thermometer mounting
screws in the control box and remove the thermometer.
Replace the thermometer with another, routing the bulb
capillary the same way as the original, replacing the bulb
on the tube properly and as securely as possible.
• The bulbs for the Heating System Temperature Control
Thermostat and the Water Overheating Safety Thermostat
are both located in pockets on the side of the heating system
shell. To change either, remove the bulb from the pocket,
remove the thermostat mounting screws in the control box
and remove the thermostat. Replace the thermostat with
another, routing the bulb capillary the same way as the
original, replacing the bulb properly into the pocket as far
as possible.
• The bulb for the Combustion Product Overheating
Thermostat is located in a well provided in the condenser
access plug/inspection port. Remove the combustion test
point plug and washer from the inspection port to free the
thermostat bulb, and remove the bulb from the well. Remove
the thermostat mounting screws in the control box and
remove the thermostat. Replace the thermostat with another,
routing the bulb capillary the same way as the original and
replacing the bulb properly into the well as far as possible.
Replace the combustion test point plug and washer in the
inspection port, securing the bulb in place.
Fig. 43
During the course of seemingly normal operation, there may
be operating faults experienced in the system. Some of the
more common faults that may be encountered are:
BURNER FAULT SHUT-DOWN
The burner may shut down for any of several reasons, at which
point the burner safety device light (red) on the control panel
will be ON and the there will be a green fault indicator light lit
on the oil burner. This may be caused by a loss of fuel oil (tank
empty?), a fouled oil spray nozzle in the burner, or perhaps a
fouled or faulty flame sensor. To attempt a restart after correcting
any burner problem and the fuel supply is assured, push the
reset button on the burner. The burner should restart after the
preset time delay period expires.
OVERHEATING SAFETY THERMOSTAT SHUT-DOWN
Opening of either the Water Overheating Safety Thermostat or
the Combustion Product Overheating Thermostat will result in
an oil burner shutdown. In either case, the burner safety device
light (red) on the control panel WILL REMAIN OFF, and the
green fault indicator light on the oil burner will REMAIN OFF.
The only way to tell if either device has opened is to check
electrically or check the position of the reset button, located
under the screw cap over each device.
• The Water Overheating Safety Thermostat may open if the
water temperature exceeds 230°F (110°C) in the heating
system. This can occur if the water temperature control is
near its maximum setting, and or the three way valve is
drawing its majority of water out of the secondary condenser.
This can be prevented if the water temperature control is
turned to a lower temperature, the three way valve is
readjusted clockwise or the burner is rewired for a post purge.
A faulty water temperature control can also cause a shutdown.
After correcting any fault, either thermostat must be manually
reset by removing the screw cap on top and depressing the
reset button.
Note: Actuation of the reset button may not be physically visible.
If tripped a button will have an audible click when trying to reset.
INLINE OIL HEATER OR THERMOSTAT SHUTDOWN
The heatwise Pioneer Burner is equipped with an inline oil
heater, this heats up and closes a thermostat for the burner to
get power. If the heater or the thermostat malfunction (one
complete unit) it will not allow the burner to start. If the fuel is
extremely cold the inline heater may not be able to keep up
and may momentarily shut off the burner until the oil gets
back to a temperature of 125-130° F.
PHONE [phone] • FAX [phone]
MPI offers technical support to qualified licensed heating
contractors during normal business hours. (Monday-Friday
8:30 A.M. to 4:30 P.M. Eastern Time)
To help us serve you properly our technicians will require
the following information:
Nozzle manufacturer, G.P.H., angle and pattern.
Pump pressure in PSI Pump vacuum in inchs of Hg
Head Setting and Air Setting
Oil delivery system: 1 pipe or 2 pipe.
Oil Tank: Indoor, outdoor. Above or below pump level.
Smoke reading CO reading in PPM CO 2 reading in %
Flue Outlet Temperature °F
Water Outlet temperature °F Water Return temperature °F
System load: Radiant, high temperature, DHW. Total BTU
requirement