IMMEDIATE RESPONSE TECHNOLOGIES, INC. Burner Trubleshting Guide Flash Water Heater (all standard types) Created By: Stefan Swan Infrmatin in this guide was deemed technically accurate at the time f printing. Hwever, updates are made peridically t the infrmatin herein and this guide culd cntain technical inaccuracies r typgraphical errrs. If yu have cmments r suggested changes please frward them t Immediate Respnse Technlgies, Inc. Infrmatin included herein belngs t Immediate Respnse Technlgies, Inc. N reprductin r publicatin f this dcument in whle r in part shall be made withut written authrizatin frm Immediate Respnse Technlgies, Inc.
This is a general guide sheet fr trubleshting a flash water heater that is nt lighting. This guide als includes a prcess fr remving air (bleeding) frm the fuel lines and the fuel pump. This is nly a guide and illustratins may r may nt differ frm actual mdels. Nte: Befre yu begin trubleshting, verify that all setup instructins have been crrectly fllwed, including using the crrect fuel and/r pwer surce. Cautin: Please nte that wrking with fuel and mechanical equipment can be hazardus. Mishandling r misuse can cause damage and/r harm t the peratr. Please take adequate precautins t ensure safety, while wrking n/r with the equipment. Seek a certified technician fr repair r service if yu are nt qualified r d nt have the crrect tls t perfrm these tasks. Lcate the cntrl panel (1) and Fuel pump and Fuel Filter n the bttm side f the water heater (2). These are the main areas where yu will be wrking. Bth lcatins are circled in Figure 1. 1 2 Figure 1. Water Heater Wrk Lcatins Trubleshting Discnnect water supply line frm the water heater t ensure that there will nt be water flw thrugh the system while bleeding prcess is being perfrmed. If the flw switch senses flw Page 2 f 8
while the burner switch is turned n, the slid state relay will allw the burner t ignite while wrk is being perfrmed n the fuel system. If prper precautin is nt taken, this culd cause damage t the equipment r injury t the peratr. Plug the yellw electrical wire int an electrical utlet. Make sure the GFCI is in the n psitin (signified by a green light in the GFCI husing). Turn the switch, lcated n the cntrl panel shwn in figure 2, t the ON psitin. Figure 2. Burner Switch Is the blwer fan perating (Air flwing frm the tp f the water heater stack)? YES : Mve t the next questin. NO: 1) There may be a brken cnnectin in the drive mtr wiring. Check all cnnectins fr mtr inside r utside f the cntrl panel. (See belw fr pening the cntrl panel.) 2) Faulty Mtr Need Replacement Is there a buzzing nise (The sund f the igniter attempting t light)? YES: Mve t the next questin. NO: Page 3 f 8
1) There may be a brken cnnectin in the igniter wiring. Check all wiring cnnectins fr mtr inside r utside f the cntrl panel. (See belw fr pening the cntrl panel.) 2) Faulty igniter Need Replacement Is the fuel mving in the bttm f the fuel filter? The fuel filter is shwn in figure 3. YES: Check t make sure that fuel is getting t the nzzle line n the high pressure side f the pump. See bleeding prcedure belw. Figure 3. Fuel Filter NO: 1) If fuel is seen cming frm the fitting, shwn in figure 6, n the high pressure side f the pump, then the nzzle r nzzle line may be clgged. Turn ff the burner and unplug the water heater. Clear all tubing frm the nzzle tip t the cnnectr tube assembly. See manual and/r cnsult certified technician. If the water heater still is nt lighting, mve t the next questin. 2) If fuel is nt seen cming frm the fitting, shwn in figure 6, then the cnnectr tube assembly n the high pressure side f the pump may be clgged. Turn ff the burner and unplug the water heater. Clear all tubing frm the pump utlet t the nzzle line (up t the fitting). See manual and/r cnsult certified technician. If the water heater still is nt lighting, mve t the next questin. Page 4 f 8
1) Check fr leaks and make sure fuel lines are cnnected t the fuel supply. Secure, perfrm bleeding prcedure, and then try t light burner again. 2) There may be air in the fuel line and/r fuel pump. Need t perfrm bleeding prcedure. See belw. 3) May be faulty pump r cupling Need Replacement. Open the cntrl panel, remving screws hlding the cver in place, being careful nt t damage gasket while remving. Secure screws fr replacement after trubleshting steps. Yu will nw need a Vltmeter fr testing the flw switch and fuel slenid. In rder t perfrm these tests yu will need t cnnect and pen the water supply. Yu will need t establish a minimum flw f 2 GPM. With the burner switch in the ON psitin, what is the temperature reading n the temperature cntrller display, shwn in figure 4? (This is the temperature f the ht side f the flw) Figure 4. Temperature Cntrller Display Is OP1 bx n the left side f the temperature cntrller display lit? YES: Mve t the next questin. NO: If the temperature reading n the temperature cntrller is less than 110 degrees Fahrenheit and OP1 is nt lit, the temperature cntrller may be Page 5 f 8
cnfigured incrrectly r be faulty. Cnsult certified technician fr recnfiguring r replacement. Lcate the slid state relay, marked relay n the water heater wiring diagram. Verify that the minimum flw f water has been established. Use Vltmeter t measure vltage acrss slid state relay terminals A1 and A2. Is the vltage reading acrss these terminals apprximately 120 VAC? YES: The flw switch is peratinal. Mve t the next questin. NO: If reading shws little r n vltage, flw switch may be stuck r faulty. Turn supply water ff and then n in rapid successin r lightly tap the flw switch several times with a rubber mallet. If this cnditin persists, replace flw switch. Nw t test the fuel slenid, measure the vltage acrss the terminal marked T1 n the slid state relay and the terminal t the right f the grund terminal n the bttm rw f the terminal strip. This lcatin is shwn by the red arrw in figure 5. Figure 5. Terminal fr Fuel slenid measurement n Terminal Strip Is the vltage reading acrss these terminals apprximately 120 VAC? YES: Mve t the next questin. NO: The fuel slenid may be faulty. Need Replacement. Page 6 f 8
If yu have reached this step, the slid state relay, may be faulty. The vltmeter cannt be used t accurately test the slid state relay, therefre, have a certified technician test and/r replace the slid state relay as needed. If burner still des nt light at this pint, it is recmmended that the water heater unit be returned t the factry fr further evaluatin and qute f repair. Bleeding the Fuel Pump Befre bleeding the fuel pump, check the fllwing items t determine whether bleeding the fuel lines and pump is needed by answering the questins related t the fuel abve. Make sure the water heater is plugged in and the GFCI is active. The water supply shuld be shut ff r discnnected. Fllw the belw steps t make sure that fuel is getting t the nzzle line n the high pressure side f the pump. Be careful when ding s, as fuel is under pressure. 1) Place a suitable cntainer under the fitting shwn in figure 6. Figure 6. Fitting n High pressure side f pump 2) Turn the burner switch t the n psitin. 3) Lsen the fitting slwly as shwn in figure 6 using the apprpriate wrench size. Yu shuld nt have t lsen the fitting cmpletely t identify if fuel is getting t this side. If yu d nt see fuel frm this, cntinue t the next step. If fuel is cming frm this fitting, see abve. Page 7 f 8
4) Lcate the bleeder valve n the bttm f the water heater, shwn in figure 7. Place cup r ther cntainer under the bleeder valve pening t catch any fuel that will leak frm the bleeder valve cnnectin. 5) Open the valve, using an apprpriate sized wrench, by turning the stem a quarter turn. Figure 7. Bleeder Valve Prt 6) Once a steady stream f fuel is seen cming frm the bleeder prt, clse the prt, and mve all cntainers. The bleeding prcedure is cmplete. 01/12 by Immediate Respnse Technlgies, Inc., Glenn Dale, Maryland. All rights Page 8 f 8