PVI Industries Water Heater MAXIM INTEGRATED WATER HEATING SYSTEM User Manual

INSTALLATION & MAINTENANCE MANUAL FOR  
MAXIM  
INTEGRATED WATER HEATING SYSTEM  
TABLE OF CONTENTS  
Start-up Procedures  
2
Maintenance & Safety Inspections  
Wiring Diagrams  
3-5  
6,7  
Burner  
8
Burner Start-up  
9-12  
Burner Troubleshooting  
MXG Burner Manual  
MXO Burner Manual  
13.14  
Refer to PV500-21A  
Refer to PV500-22A  
FOR YOUR SAFETY  
WHAT TO DO WHEN 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  
phone outside the  
building. Follow the gas  
supplier’s instructions.  
If you cannot reach  
your gas supplier, CALL  
THE FIRE DEPARTMENT.  
FOR YOUR SAFETY  
DO NOT store or use gasoline or  
other flammable vapors and  
liquids in the vicinity of this or  
any other appliance.  
FOR YOUR SAFETY  
WARNING: Improper  
installation, adjustment,  
alteration, service, or  
maintenance can cause injury or  
property damage. Refer to this  
manual for assistance, or  
consult a qualified installer,  
service agency, or the gas  
supplier.  
TYPICAL CONSTRUCTION  
FIGURE 17-1  
1. VENT STACK *  
8. HANDHOLE CLEANOUT  
2. TEMPERATURE LIMITING DEVICE (set at 200°F)  
3. OPERATING THERMOSTAT (set at 120°F)  
4. CONTROL SWITCH(es) AND FUSE(s)  
5. GAS VALVE  
9. UPPER OPERATING THERMOSTAT (set at 130°F)  
10. COLD WATER INLET & RETURN CONNECTION  
11. DRAIN  
12. RELIEF VALVE  
6. GAS INLET  
13. PRIMARY SAFETY CONTROL  
14. DIFFERENTIAL AIR PROVING SWITCH  
7. BURNER  
(* NOT FURNISHED BY PVI)  
CAUTION: Temperatures higher than 130°F increase the risk of scald injury!  
IMPORTANT! Clearance to unprotected combustible material must be 8” min. at top, sides and rear, and 24” min. in front.  
MAXIM  
1
PV500-17 05-2000  
Section 17  
 
MAXIM  
MAINTENANCE AND SAFETY INSPECTIONS  
1. Establish a preventive maintenance program to  
more fresh water containing scale-forming  
chemicals is brought into the tank. As the  
temperature of water increases, the rate of  
scale deposition will be increased.  
assure a longer water heater life.  
2. The tank should be flushed at two- or three-  
month intervals depending on water conditions  
in your location. To flush, turn off electrical 4. The tank will have a handhole for inspection  
disconnect switch to prevent the burner from  
operating. Open the drain valve and allow  
water to flow through the tank until it runs clear.  
Close the drain valve and turn the electrical  
switch back on. Draining two or three gallons  
from the bottom of the tank on a weekly basis  
will also help prevent the accumulation of  
sediment. Water impurities consist of fine  
particles of soil or sand which will settle out  
and form a layer of sediment on the bottom of  
the tank.  
and cleaning. (See Figure 17-1, page 1.) To  
inspect tank for scale buildup, remove the  
handhole cover. If scale is present, it can be  
loosened with a high pressure stream of  
water. The smaller pieces can be flushed  
through the drain and the larger pieces  
removed by hand through the handhole. The  
frequency of inspections will be determined  
by the rate of scale buildup. Intervals of 30-  
60 days is recommended.  
5. If a firetube leaks for any reason, consult  
factory for instructions.  
3. A scale of lime will normally form during  
operation and will accumulate on the bottom of  
the tank. Lime is formed from the natural  
chemicals in the water which precipitate out  
during heating cycles. Some water supplies  
contain more of these chemicals than others  
and scale buildup will occur more rapidly.  
Other factors affecting scale buildup are the  
amount of hot water used and temperature of  
the water. The more hot water used, the  
NOTE: Condensate coming from the tubes on  
a cold start is normal and does not  
indicate a leaking tube.  
6. Regularly inspect the bottom tubesheet.  
Inspect the SCALEGUARDÒ tubesheet  
insulator for holes or areas that may have  
pulled away from tubesheet. Repair or  
replace as required.  
CARBON MONOXIDE WARNING:  
CAUTION: IMPROPER COMBUSTION MAY CAUSE SERIOUS INJURY.  
PVI recommends a seasonal or annual combustion check-out be performed by a  
qualified service agency to ensure safe and efficient operation.  
Periodic Inspection of Operational Components  
Periodic inspection and check-out of the burner ignition, control system, and fuel valve operation  
(for tight close-off) should be made. Refer to the burner installation instruction for  
recommendations.  
1. Examine the venting system at least once each  
year for proper connections, alignment and  
corrosion. The blower inlet will collect dust  
from the air during operation. Disconnect the  
power to the heater and clean the blower  
wheel when necessary.  
Inspect all parts and make replacements when  
necessary. Check wiring for loose connections  
and burned wires.  
3
PV500-17 05-2000  
Section 17  
 
MAXIM  
MAINTENANCE AND SAFETY INSPECTIONS (continued)  
Periodic Inspection of Operation Components (continued)  
CAUTION: THE RELIEF VALVE IS A PRIMARY SAFETY DEVICE.  
heater designs vary, only some of these  
listed inspections may be appropriate for  
your particular model.  
2.  
The temperature and pressure relief  
valve may be checked by slowly lifting the  
seat lever on top of the valve to determine  
its condition for safe operation. The  
openings inside the valve may become  
restricted by a buildup of scale and  
become inoperative. If the valve does not  
open and close properly when tested, it  
must be replaced. Replace the relief valve  
with like kind or one meeting the  
requirements stated on the rating decal  
located adjacent to the relief valve.  
4.  
PVI strongly recommends the  
recording of significant events, such as  
maintenance or repair actions and safety  
inspections,  
and  
encourage  
the  
preparation of an event log for this  
purpose. All recorded events should be  
dated, fully described, and signed by the  
individual performing the service, repair, or  
inspection. (See Table 17-1, page 5 for  
sample of Inspection Record.)  
3.  
A table of periodic safety inspections  
is an attachment of this manual for ease of  
reference by the building service technician  
or licensed equipment operator. Since  
water  
CALL YOUR PVI CUSTOMER SERVICE  
REPRESENTATIVE IF YOU HAVE ANY  
QUESTIONS. (1-800-433-5654)  
Instructions for Taking Water Heater Out of Service  
Extended shutdown of the appliance and  
restarting are as follows:  
C. Tag power switch(es) that fuel is off and  
tank is empty.  
A. Turn off all power and fuel supplies.  
D. Refill tank with water and turn fuel and  
power switch(es) on to restart. Reset all  
controls and conduct start-up of the  
appliance as discussed in the previous  
pages.  
B. Drain and flush tank as previously  
discussed.  
ELECTRICAL  
1. Wiring to the unit should conform to the  
National Electrical Code or the code  
legally authorized in your locality. A fused  
disconnect switch should be used for  
water heater control. Service wiring  
connections of 120V, 1 phase, 60 Hz. are  
located in the enclosure on the water  
heater.  
NOTE: Use only copper wire of proper  
sizing for incoming service. Damage  
resulting from use of aluminum wiring  
will be excluded from coverage under  
the warranty of this unit.  
4
PV500-17 05-2000  
Section17  
 
MAINTENANCE & SAFETY INSPECTION REPORT  
BURNER  
INSPECTION  
COMBUSTION  
ANALYSIS  
TANK  
TANK FLUSH TANK FITTING  
VENT  
THERMOSTAT GAS TRAIN  
LEAK TEST  
DATE  
INSPECTION & CLEANOUT INSPECTION INSPECTION INSPECTION  
Recommended  
Inspection  
YEARLY  
6 MONTHS  
6 MONTHS  
3 MONTHS  
6 MONTHS  
YEARLY  
YEARLY  
YEARLY  
Intervals  
TABLE 17-1  
NOTE: Burner Inspection and Combustion Analysis should be done by a factory authorized service person.  
5
PV500-17 05-2000  
Section 17  
 
MAXIM  
AXIAL FLOW GAS BURNER  
CARBON MONOXIDE WARNING:  
CAUTION: IMPROPER COMBUSTION MAY CAUSE SERIOUS INJURY.  
PVI recommends a seasonal or annual combustion check-out be performed  
by a qualified service agency to ensure safe and efficient operation.  
TYPICAL CONSTRUCTION  
FIGURE 17-2  
1. FAN HOUSING  
9. AIR PROVING SWITCH  
2. AIR DAMPER  
10. DAMPER ADJUSTMENT KNOB  
11. MANUAL SHUTOFF VALVES  
12. GAS PRESSURE REGULATOR  
13. GAS VALVE  
3. GAS NOZZLE ASSEMBLY  
4. PRESSURE PLATE  
5. BLAST TUBE & BURNER HOUSING JUNCTION  
6. IGNITION TRANSFORMER  
7. IGNITION ELECTRODE  
8. FLAME SENSING ROD  
14. AUXILIARY GAS VALVE  
15. MAIN GAS TRAIN  
16. ELECTRODE CLAMP  
6
PV500-17 05-2000  
Section 17  
 
MAXIM  
AXIAL FLOW GAS BURNER START-UP  
(Refer to Figure 17-2, page 6 to identify burner parts)  
1.  
Remove the enclosure panel cover on  
7. With the electrodes exposed, check them  
for the proper settings as called for in  
Figure 17-3, page 8. Check for any hairline  
cracks in the insulators. Should  
replacement of burner electrodes be  
required, certain procedures must be  
followed. In all cases, removal of the  
electrodes is accomplished by loosening  
the electrode mounting clamps. Draw the  
electrodes out of the nozzle assembly  
through the holes in the pressure plate.  
the water heater or boiler to expose the  
control circuit. A wiring diagram, included in  
this packet, will show the controls used in  
our circuitry.  
2.  
3.  
4.  
Visually check that all components are  
intact and no damage has occurred during  
transit.  
Check all connections within the control  
cabinet. A loose connection could cause  
intermittent shutdowns.  
8. Inspect the electrodes for cracked ceramic  
or loose retaining studs that hold the wire  
within the ceramic. Select the proper  
pressure plate hole to place each electrode  
and insert the electrode through the hole,  
retaining stud end first.  
Some burners will use direct spark  
ignition. They may use a single gas  
pressure regulator and gas valve or multiple  
valves and regulators. On a call for heat, the  
motor starts, the gas primary control is  
energized, and after a short delay (pre-  
purge) the gas valve(s) opens and ignition  
should occur.  
9. Tighten electrode mounting clamp slightly  
until electrode ceramics are seated firmly  
and completely in the mounting bracket  
without gaps between ceramics and  
mounting bracket at the bearing faces.  
NOTE: Do not tamper with or readjust  
program dipswitch settings. This will  
cause the control to become inoperable.  
Damage resulting from tampering will be  
excluded from coverage under the  
warranty of this unit.  
10. Measure and set electrodes according to  
Figure 17-3, page 8. After the gaps and  
setting are complete, fully tighten the  
electrode mounting clamp. Do not  
overtighten or the insulation may crack.  
5.  
Remove the flame safeguard control  
from its base. Check the connections in  
control mounting base; loose connections  
can cause nuisance shutdowns. Check the  
time card or programmer, when applicable,  
for good connection.  
11. Replace nozzle assembly; be sure to  
connect the flame and spark rod wires  
before installing nozzle assembly fully into  
blast tube. Check connectors on the ends  
of the flame and spark rod wires for good  
contact. Look for properly stripped wire  
ends. Be sure connectors are firmly  
attached to the flame and ignition rod ends.  
Insulating boots can give a false feeling of  
proper seating. DO NOT MOVE  
ELECTRODES. Be careful not to bump  
electrodes. Check fan wheel for free  
rotation.  
NOTE: Always secure gas lines and tag "Out  
of Service" before servicing burner  
nozzle or electrodes.  
6.  
Pull the nozzle assembly to check the  
flame and ignition electrodes. This is done  
by first disconnecting the gas train by  
breaking at the unions. Then removing the  
nozzle assembly which will have the  
electrodes and pressure plate attached.  
Disconnect the electrode wires and take  
care not to damage the insulation on the  
electrodes.  
12. Reinstall orifices in unions (if required).  
Reinstall gas nozzle assembly.  
7
PV500-17 05-2000  
Section 17  
 
MAXIM  
AXIAL FLOW GAS BURNER START-UP (continued)  
PRESSURE PLATE  
Set up and Tolerances  
Figure 17-3  
13. Connect a test meter to the control for  
must be monitored during the firing of the  
burner. Record static pressure; it must not  
exceed 14" W.C. Pressures above this could  
cause damage to the diaphragm in the gas  
valve or pressure regulator.  
reading the flame response signal.  
NOTE: Some controls read the flame signal  
in micro amps and some in volts DC.  
The TFM or MC120 series control has  
two terminals marked for reading volts  
DC. The S89 control uses a micro amp  
signal for measuring flame strength. For  
this control, a meter must be hooked in  
series with the flame rod wire.  
Disconnect the leadwire at the S89  
sensor terminal. Connect the positive  
lead of the meter to the quick-connect  
sensor terminal on the S89 and the  
negative lead to the free end of the  
sensor leadwire.  
15. Burners with pilot; inputs over 400,000  
Btu/h (See wiring diagram.)  
16. Connect a manometer to the manifold test  
port at the shutoff valve closest to the  
burner. Turn off the main gas shutoff valve.  
Set the air shutter as shown on the tag  
attached to gas train. This may not be the  
exact setting you end up with, but it is a  
good starting point. Turn the unit on using  
the rocker switch on the side of the control  
enclosure assembly. If the operating control  
switches are closed, the burner blower  
should come on and pre-purge begin.  
14. Be sure the tank is filled with water. Once  
the burner is reassembled, two devices to  
read  
pressure,  
preferably  
U-tube  
If nothing happens, check the control to be  
sure it is not in the tripped position and reset  
it by pushing the flame safeguard reset  
button. The burner should pre-purge for no  
longer than thirty seconds.  
manometers, will be needed to read gas  
pressures. Connect one to read the inlet  
pressure of the burner. This is the pressure  
measured before all components in the gas  
train. The manometer must stay connected  
throughout the testing as the inlet pressure  
8
PV500-17 05-2000  
Section 17  
 
MAXIM  
AXIAL FLOW GAS BURNER START-UP (continued)  
This section pertains to MC120 control only.  
NOTE: Where low gas pressure is a  
problem, special arrangements may have  
been made to fire the burner with reduced  
pressure. The appliance data decal will  
reflect this information.  
When the blower motor starts, the air proving  
light on the MC-120 should be on. This  
indicates a positive air flow condition. If the air  
proving light is not on, turn air proving switch  
adjustment screw counter-clockwise until the air  
proving light comes on, then turn screw one  
turn counter-clockwise. If the gas valves open  
and close intermittently during normal  
operation, turn screw one half turn counter-  
clockwise until this condition ceases. This  
procedure should be followed with every  
burner.  
16.  
Direct Spark Ignition - (DSI) Burners  
- No pilot. (See wiring diagram.)  
Connect manometer to the manifold test port.  
Set the air shutter as shown on the tag  
attached to gas train. This may not be the  
exact setting you end up with, but it is a good  
starting point.  
After purging is complete, terminal 3 energizes  
the pilot valve and terminal 4 energizes the  
ignition transformer on the control. The pilot is  
then established. The VDC reading on the  
meter should read a steady 14-17 VDC. Each  
different control will have the required flame  
response signal stamped on it. This is the  
minimum for it to properly operate. If the pilot  
fails to light during the initial period, it is  
probably due to air in the line. The control will  
lock out. Wait one minute and push the flame  
safeguard reset button to restart burner and  
begin the purge cycle again.  
Turn the unit on, using the rocker switch on  
the side of the control enclosure assembly.  
The burner should come on and ignition  
occur. If the burner fails to ignite, there may  
have been air in the line. To reset the control,  
turn the switch off for 60 seconds (S89  
controls only) and it should automatically  
reset, or push the reset button on the control.  
If after the appropriate prepurge, ignition  
does not occur, turn air proving switch  
adjustment screw counter-clockwise until TFI  
(try for ignition) occurs. Now in order to more  
precisely adjust the air failure set point,  
slowly turn screw clockwise until the burner  
shuts off. Then turn screw counter-clockwise  
one turn. If the gas valves open and close  
intermittently during normal operation, turn  
screw one half turn counter-clockwise until  
this condition ceases.  
Once the flame is established, set the pilot  
pressure (measured downstream of gas valve)  
at pressure shown on the tag attached to gas  
train. Next, open the main gas valve slowly. Set  
manifold pressure at pressure shown on the tag  
attached to gas train. Do not screw the  
adjusting nut of the regulator in past the point  
where no further increase in manifold pressure  
is noted. Check the incoming pressure with the  
burner running. This is recorded as inlet flow  
pressure.  
Once the burner fires, set manifold pressure  
at pressure shown on the tag attached to gas  
train. There will be a tap on the downstream  
side of the valve to measure pressure. The  
manifold pressure must be taken  
downstream of the gas valve. Check the  
incoming pressure with the burner running.  
This recorded flow pressure must be the  
minimum specified on the heater decal.  
Our standard flow pressure requirement on  
these burners is 8" W.C. flow. If the required  
manifold cannot be reached, check the inlet  
pressure. It should be a minimum of that shown  
on the heater decal with the burner running on  
full input. It is important that the incoming  
pressure does not fall below these minimums  
or nuisance control lockouts could occur.  
9
PV500-17 05-2000  
Section 17  
 
MAXIM  
AXIAL FLOW GAS BURNER START-UP (continued)  
17. Check flue gases with a flue analyzer to make  
i. Make sure the air shutter is locked  
securely in place.  
final settings of the air shutter.  
a. The readings need to be taken from a  
hole in the vent several inches above the  
heater vent connection, but before draft  
regulator.  
18. On burners with pilots, recheck pilot to  
make sure its operation has not  
deteriorated if adjustments are made to the  
air shutter. To do this, shut off the main  
valve, check the flame response signal by  
cycling the burner through several lightoffs.  
b. Insert draft gauge into the 1/4" test  
opening in the stack. Draft in stack should  
read -.02" to -.06" W.C. Adjust draft  
regulator, if installed.  
19. Check each operating and limit control to  
be sure they function properly by lowering  
and raising the temperature setting on  
each control, causing the burner to cycle  
on and off.  
c. When water in the tank is above 120? F,  
insert analyzer or O2 tester in 1/4" test  
opening and take O2 reading in  
percentage.  
NOTE: During the initial firing of the burner,  
smoke that is not related to the burner  
will be emitted from the heater. This is  
normal during "burn in" and could  
possibly continue for several hours.  
d. Gradually close air shutter, taking O2  
reading at each adjustment of air shutter  
until optimum O2 % (4-6%) is reached. If  
O2 % decreases, open air shutter to last  
reading where the greatest reading is  
achieved.  
20. Record the following information for future  
use:  
e. Insert CO tester in 1/4" test opening and  
take CO reading. CO should not exceed  
.03%. A reading greater than .03%  
indicates lack of air. Open air shutter  
slightly and take readings until CO is  
within proper range. Optimum reading is  
no CO.  
A. Air shutter position________________  
B. Manifold gas pressure________"W.C.  
C. Stack draft_________________"W.C.  
D. O2 reading_______________%(4-6%)  
E. CO2 reading______________%(8-9%)  
F. CO reading________%(less than .03%)  
G. Stack temperature:  
f. If air shutter was changed during CO test,  
take a final O2 reading.  
g. Insert CO2 tester in 1/4" test opening;  
record in percentage.  
h. Insert stack temperature gauge in 1/4"  
test opening and read gross stack  
temperature; maximum gross stack is to  
be 450°F, minimum net stack is to be  
300°F. (NOTE: net temperature is the  
total stack temperature, less room  
temperature.) If an excessively high  
gross stack temperature is recorded,  
check the flue tubes for turbulators.  
Gross _______________________°F.  
Less ambient__________________°F.  
Net__________________________°F.  
H. Combustion efficiency___________%  
10  
PV500-17 05-2000  
Section 17  
 
MAXIM  
TROUBLESHOOTING SUGGESTIONS  
AXIAL FLOW GAS BURNER  
1. BURNER FAILS TO START  
D. Occasional low voltage supply. Have local  
utility correct. Make certain the burner control  
circuit transformer (if supplied) is correct for  
the voltage and power (VAC) being supplied.  
Defective On/Off switch. Replace switch.  
A. Control circuit has an open control  
contact. Check limits, low water cutoff, proof  
of closure switch and others as applicable.  
E. Occasional low gas supply pressure.  
Have local utility correct.  
B. Bad fuse or switch open on incoming  
3. BURNER MOTOR RUNS, BUT PILOT DOES  
power source. Correct as required.  
NOT LIGHT  
C. Flame safeguard control safety switch  
tripped out. Reset and determine cause for  
apparent flame failure.  
A. Gas supply to burner shut off. Make sure  
all manual gas supply valves are open.  
Automatic high pressure valve at meter such  
as "Sentry" type tripped shut due to high gas  
pressure. Reset valve and correct cause for  
trip out.  
D. Loose connections or faulty wiring.  
Tighten all terminals screws and consult  
wiring diagram furnished with the burner.  
B. Pilot solenoid valve not opening. Listen  
and feel for valve actuation. Solenoid valve  
not being powered. Check electrical circuitry.  
Replace coil or entire valve if coil is burned  
out.  
E. Flame safeguard control starting circuit  
blocked due to flame relay being  
energized. Possible defective scanner or  
flame rod - replace. Possible defective  
amplifier - replace. Scanner actually sighting  
flame due to leaking fuel valve - correct  
unwanted flame cause. Defective flame  
safeguard control - replace.  
C. Defective gas pilot regulator. Replace.  
D. Gas pressure too high or too low at pilot  
orifice (if supplied). Check orifice size in gas  
pilot assembly. Replace if incorrect. Readjust  
pressure as required.  
F. Defective blower motor. Check for free  
rotation of fan wheel. Repair or replace.  
G. Air proving switch is not properly  
E. Defective ignition transformer. Replace.  
Incorrect ignition electrode settings.  
Readjust as required.  
adjusted. See Section 15, page 11.  
2. OCCASIONAL  
LOCKOUTS  
FOR  
NO  
APPARENT REASON  
F. Defective flame safeguard control or plug  
in purge timing card. Replace as required.  
A. Gas pilot ignition failure. Check to see that  
ignition is instant and that flame signal  
readings are stable and above minimum  
values. Use a manometer or 0 to 10" W.C.  
gas pressure gauge to make certain that  
pressure is as recommended.  
G. Air flow switch not making circuit. Check  
out electrically. Defective air flow switch-  
replace. Air switch negative pressure  
sensing tube out of position-reposition as  
necessary.  
B. Loose or broken wires. Check all wire nut  
connections and tighten all terminal screw  
connections in panel and elsewhere as  
appropriate.  
4. BURNER MOTOR RUNS & PILOT LIGHTS, BUT  
MAIN GAS FLAME IS NOT ESTABLISHED.  
A. Main shut off or test cock closed. Check to  
make certain fully open.  
C. With flame safeguard controls that  
incorporate the air flow switch in the non-  
recycling circuit, ensure that when main  
flame lights, the air flow switch is not so  
critically set as to allow occasional  
momentary opening of the air switch  
contacts.  
B. Pilot flame signal reading too low to pull in  
flame safeguard relay. Readjust as required.  
11  
PV500-17 05-2000  
Section 17  
 
MAXIM  
TROUBLESHOOTING SUGGESTIONS  
AXIAL FLOW GAS BURNER (continued)  
C. Gas line obstructed. Check and correct.  
C. Defective automatic main or auxiliary gas  
shut off valves. Check electrical circuitry to  
valves. Replace valves or correct circuitry as  
required.  
D. Gas train main and/or lead test cocks not  
fully open. Check and correct.  
E. Gas supply line between gas company  
regulator and burner inlet too small. Check  
supply pressure at meter, determine pressure  
drop and increase line size as required, or raise  
supply pressure to compensate for small line. Do  
not raise pressure so high that under static (no  
flow) conditions the pressure exceeds the  
maximum allowable pressure to the gas train  
components on the burner.  
D. Main diaphragm shut off valve opening too  
slowly. Adjust bleed on valve.  
E. Defective flame safeguard control or plug on  
amplifier. Check and replace as required.  
F. Main gas pressure regulator atmospheric  
vent line obstructed. Correct.  
F. Burner gas train components sized too small  
for supply pressure. Increase component size  
as appropriate or consult factory.  
G. Defective main gas pressure regulator.  
Replace. Misadjusted main gas pressure  
regulator. Readjust to meet required  
operational values.  
G. Automatic gas valve not opening fully due to  
defective operation. Replace gas valve.  
H. Polarity reversed on incoming power. (S89  
control only)  
H. Orifice (if supplied) too small. Replace with  
correct size.  
5. CARBON MONOXIDE READINGS ON GAS FIRING  
I. Defective main gas pressure regulator.  
A. Flame impingement on "cold" heat transfer  
surfaces caused by excessive firing rate.  
Reduce firing rate to correct input volume.  
Replace.  
J. Incorrect spring in main gas pressure  
regulator. Replace as required.  
B. Incorrect gas/air ratios. Readjust burner to  
correct CO2/O2 levels, eliminated all CO  
formation.  
K. Main gas pressure regulator vent line  
obstructed. Check and correct.  
L. Normally open vent valve (if supplied) not  
closing when automatic gas valves open.  
Check to see if valve is fully closed when  
automatic valves are open. Replace vent valve,  
if not closing fully.  
6. GAS HIGH FIRE INPUT CANNOT BE ACHIEVED  
A. Gas company pressure regulator or meter  
operating incorrectly, not allowing required  
gas pressure at burner train inlet. Contact gas  
company to correct.  
B. Gas cock upstream of train inlet not fully  
open. Check and correct.  
Additional troubleshooting information can be found in the Flame Safeguard bulletin supplied with the burner.  
12  
PV500-17 05-2000  
Section 17  
 

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