Service Manual Manual

ManualsBrandsLAARS ManualsWater boiler9600 CB & HWG

Service Manual for

9600 CB & HWG

HWG-M2 Series CB-M2 Series

HWG-M2-250 CB-M2-250

HWG-M2-200 CB-M2-200

HWG-M2-175 CB-M2-175

HWG-M2-150 CB-M2-150

Hot Water Generator Condensing Boiler

For Natural or For Natural or

Propane Gas Propane Gas

FOR YOUR SAFETY: This product must be installed and serviced by a professional service technician,

qualified in hot water boiler installation and maintenance. Improper installation and/or operation could

create carbon monoxide gas in flue gases which could cause serious injury, property damage, or death.

Improper installation and/or operation will void the warranty.

WARNING

If the information in this manual is not followed exactly, a fire or explosion may result

causing property damage, personal injury or loss of life.

Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or

any other appliance.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone in your building.

• Immediately call your gas supplier from a nearby phone. Follow the gas supplier's

instructions.

• If you cannot reach your gas supplier, call the fire department.

Installation and service must be performed by a qualified installer, service agency, or gas

supplier.

Service Manual Document 2109

Summary of content (24 pages)

PAGE 1
Service Manual Document 2109 Service Manual for 9600 CB & HWG HWG-M2 Series HWG-M2-250 HWG-M2-200 HWG-M2-175 HWG-M2-150 Hot Water Generator For Natural or Propane Gas CB-M2 Series CB-M2-250 CB-M2-200 CB-M2-175 CB-M2-150 Condensing Boiler For Natural or Propane Gas FOR YOUR SAFETY: This product must be installed and serviced by a professional service technician, qualified in hot water boiler installation and maintenance.
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LAARS Heating Systems Page 2 TABLE OF CONTENTS SECTION 1. General Information 1A. 1B. 1C. 1D. 1E. 1F. 1G. 1H. 1I. 1J. 1K. 1L. 1M. 1N. Introduction ................................................... 3 Start Up Procedures ..................................... 9 Checkout Procedures ................................... 9 Cleaning the Combustion Chamber Coil .... 10 Diverting Valve ........................................... 10 Safety Limit Switch ..................................... 10 Boiler Control ......
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9600 CB & HWG Service Manual SECTION 1. General Information 1A. Introduction The Heatmaker 9600 CB condensing boilers and the Heatmaker 9600 HWG non-automatic circulating tank water heaters have a dual heat exchanger (H-X) design. The primary H-X is a copper coil type which operates in a non-condensing mode. A secondary stainless steel H-X (economizer) surrounds the primary H-X to condense water vapor from the flue gases and extract the maximum amount of heat from the combustion process.
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LAARS Heating Systems Page 4 A PORTION OF HOT WATER IS RECYCLED TO MAINTAIN COMBUSTION COIL INLET TEMPERATURE AT 140°F THERMOSTATIC DIVERTING VALVE (160° F THERMOSTAT) (E) (D) (B) (A) COMBUSTION COIL ECONOMIZER (A) Cold Water Inlet From Tank or System (B) Economizer Outlet (10°F Rise above inlet) (C) Combustion Coil Inlet 130-140°F Typical (D) Combustion Coil Outlet (E) Hot Water Outlet To Tank or System 160 - 170°F Typical Figure 2a. Water Flow through a Heatmaker 9600.
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9600 CB & HWG Service Manual Page 5 1 2 3 4 5 6 7 8 9 10 11 12 A B C D Figure 2b. Water Flow through a Heatmaker 9600.
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LAARS Heating Systems Page 6 EXHAUST INTAKE TERMINAL 43 WALL PLATE 50 EXHAUST TERMINAL AIR INTAKE 44 WALL PLATE 45 AIR ORIFICE GAS ORIFICE 1 2 COMBUSTION COIL GAS ECONOMIZER 7 FLAMEHOLDER 46 REFERENCE PAGE 8 FOR PART NUMBERS Figure 3. Air/Fuel Flow Through Heatmaker 9600.
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9600 CB & HWG Service Manual Figure 4. Cut Away View of Heatmaker 9600. Figure 5. Control Box.
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LAARS Heating Systems Page 8 32 HIGH LIMIT SAFETY SWITCH BOX 31 38 OPERATING LIMIT CIRCULATOR PUMP CONTROL BOX SUB-ASSY HEATMAKER 9600 BLOWER ASSEMBLY 16 BLOCKED FLUE DETECTOR 30 IGNITER ASSY 6 GAS VALVE 36 VENT THERMAL CUT OUT INTAKE THERMAL CUT OUT THERMAL CUT OUT 34 33 35 Figure 6.
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600 CB & HWG Service Manual Page 9 1B. Start Up Procedures Make sure that the system is properly filled, completely purged of air and system valves are open. 2. Open system gas cock(s) and gas control knob on gas valve (if closed). 3. Set the room thermostat, aquastat or storage tank aquastat to call for heat. 4. Turn on electrical power to the unit. 5. The green light on the boiler control will light and the internal circulator and blower will start.
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LAARS Heating Systems Page 10 COMBUSTION COIL MANIFOLDS ECONOMIZER OUTLET ECONOMIZER INNER SHROUD MANIFOLD DRAIN ECONOMIZER RETAINERS (4) OUTER SHROUD CLAMPS (4) COLD WATER INLET PLASTIC FLANGE, (4) NUTS Figure 8. Disassembly. 1D. Cleaning the Combustion Chamber Coil Note: In normal operation this procedure is seldom required. Should it prove necessary, the following procedure is used to access the coil for cleaning. 1. Turn off gas and electrical power to unit. 2.
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9600 CB & HWG Service Manual 1H. Stack Switch The Stack Switch is a normally open single pole switch which is operated by the pressure difference across the air orifice. It is set to close when a static pressure difference of 1 in. W.C. is generated by the combustion air blower. Its function is to prove airflow and to inhibit burner operation in the event of flue stoppage. The switch is wired directly to the boiler control. It is located on the inside of the jacket back panel. 1I.
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Page 12 gallon of water from it. Turn off electrical power and disconnect wires from operating control. Remove operating control from diverting valve body and replace with new control. Connect wires to control and open isolation valves. Bleed air from the diverting valve petcock, turn on electrical power and restart boiler. The strap on type may be changed without draining. 1P.
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9600 CB & HWG Service Manual Boiling noises can occur because of air in the secondary loop of a heating system (9600 CB applications) or because of pump failures in either the 9600 CB or 9600 HWG. Another boiling noise which occurs primarily on 9600 HWG units can result from liming of the primary heat exchanger. This noise is more pronounced and may occur at any temperature.
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LAARS Heating Systems Page 14 will require resetting. If a lockout occurs for any of the reasons stated in this section the “VALVE/FLAME” light on the boiler control will flash. Tripouts of the manual reset safety limit can be caused by a failure of the thermostat in the diverting valve, short cycling or a calibration change in the safety limit.
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9600 CB & HWG Service Manual Page 15 Note: If the stack switch contacts are closed for any reason when the blower isn’t operating, a sequence will not occur and after 45 seconds the control will “lock out” and the “PURGE” light will flash. If the stack switch contacts are open and do not close during purge period, after 5 minutes the control will lock out and the “PURGE” light will flash.
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LAARS Heating Systems Page 16 GENERAL TROUBLE SHOOTING RESET BOILER CONTROL BY SWITCHING OFF POWER AT SIDE OF UNIT FOR 15 SECONDS YES NO 1. IS SERVICE SWITCH ON? 2. IS CIRCUIT ON? 3.
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9600 CB & HWG Service Manual Page 17 TESTING LIMIT CIRCUIT (YOU MUST COMPLETE PAGE 16 FIRST) RED 1. SWITCH BOILER OFF 2. UNPLUG 9 PIN "CONTROL" PLUG 3. CHECK FOR CONTINUITY AT BACK OF "CONTROL" PLUG BETWEEN RED WIRES (BOILER TEMP BELOW 170F) 1 4 7 2 5 8 3 6 9 CN6 "CONTROL" RED CONTINUITY (0 OHMS ON LOW OHM SCALE) NO CONTINUITY ( OHMS) PUSH SAFETY LIMIT RESET BUTTON* BUTTON CLICKS ALL LIMITS OK.
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LAARS Heating Systems Page 18 RED "PURGE" LIGHT FLASHING (YOU MUST COMPLETE PAGE 16 FIRST) RESET BOILER CONTROL BY SWITCHING POWER OF FOR 15 SECONDS AND THEN ON AGAIN WITH A CALL FOR HEAT / HOT WATER AFTER APPROX. TWO SECONDS GREEN LIGHT COMES ON AND BLOWER STARTS NO YES NO AFTER FIVE MINUTES RED "PURGE" LIGHT FLASHES YES STACK SWITCH CONTACTS NOT CLOSING CHECK FOR FLUE BLOCKAGE (SNOW, LEAVES ETC.
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9600 CB & HWG Service Manual Page 19 CHECKING STACK SWITCH (YOU MUST COMPLETE PAGE 16 FIRST) 1. SWITCH OFF BOILER SWITCH 2. REMOVE BOTH TUBES FROM STACK SWITCH AND DISCONNECT ELECTRICAL WIRES 3. CHECK FOR CONTINUITY ACROSS SWITCH TERMINALS NO CONTINUITY ( OHMS) CONTINUITY (0 OHMS) REPLACE STACK SWITCH P/N 2400-110 YES 1. ATTACH TUBES DISCONNECTED FROM STACK SWITCH TO U-TUBE MANOMETER 2. SWITCH ON BOILER TO OPERATE BLOWER 3. MANOMETER INDICATES 1.5" W.C.
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LAARS Heating Systems Page 20 CHECKING BLOWER (YOU MUST COMPLETE PAGE 16 FIRST) WITH A CALL FOR HEAT RESET BOILER CONTROL BY SWITCHING OFF BOILER SWITCH FOR 15 SECS. AFTER TWO SECONDS GREEN POWER LIGHT COMES ON. NO YES BLOWER STARTS REFER TO GENERAL TROUBLE SHOOTING SECTION PAGE 16 YES NO CONNECT MANOMETER TO "PRESSURE TAP" ON GAS VALVE - PRESSURE DURING BLOWER OPERATION WITHOUT GASFLOW (VALVE/FLAME LIGHT NOT LIT) IS - 4 IN. W.C. YES BLOWER O.K.
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9600 CB & HWG Service Manual Page 21 RED "VALVE/FLAME" LIGHT FLASHING (YOU MUST COMPLETE PAGE 16 FIRST) ARE GAS VALVES AND GAS METER TURNED ON. IS THERE GAS IN LP TANK (LP UNITS). YES NO RESET BOILER BY SWITCHING POWER OFF FOR 15 SECONDS - WHEN "VALVE/FLAME" LITE LIGHTS IS THERE 24 VAC BETWEEN ORANGE AND YELLOW WIRES ON GAS VALVE AND/OR DOES GAS VALVE CLICK? TURN ON VALVES, FILL LP TANK ON LP UNIT - IF REQ'D - RESET BOILER BY SWITCHING POWER OFF FOR 15 SECONDS.
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LAARS Heating Systems Page 22 CHECKING INTERNAL PUMP (YOU MUST COMPLETE PAGE 16 FIRST) SWITCH POWER ON, GREEN POWER LIGHT LIGHTS NO YES SEE TROUBLE SHOOTING CHART PAGE 16 CALL FOR HEAT EXISTS (THERE IS 24 VOLTS ON PINS #7 & #9 ON 'CONTROL' PLUG - CN6) NO YES TURN UP T'STAT OR AQUASTAT OR CORRECT STAT PROBLEM THERE IS 120 VAC AT 'CIRCULATOR' PLUG-CN5 NO YES THERE IS 120 VAC AT PUMP REPLACE BOILER CONTROL P/N 2400-224 NO YES CORRECT WIRING BETWEEN PUMP AND CONTROL BOX MOTOR PUMP RUNS NO YES
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9600 CB & HWG Service Manual Figure 9. 9600 Ladder Diagram. Figure 10. 9600 Wiring Diagram. Caution Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.
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Quick Reference Trouble Shooter A. SHORT CYCLING: 1. 9600 HWG - tank aquastat set too high 2. 9600 CB and 9600 HWG - Units shuts down before reaching limit. Continuously restarts without resetting a. Limit out of calibration b. Wrong air/gas orifices for input or fuel (refer to HeatMaker 9600 gas orifice chart ONLY) c. Thermostat heat anticipator set below 0.9 amps. (9600 CB only). 3. 9600 CB - boiler oversized for total load or small zone. B.