en Hydronic Surface Heater S 3000 REPAIR MANUAL

Transcription

1 en Hydronic Surface Heater S 3000 REPAIR MANUAL E N

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3 S 3000 Repair Foreword Foreword Machines covered by this manual Machine Item Number S S Machine documentation Keep a copy of the Operator s Manual with the machine at all times. Use the separate Parts Book supplied with the machine to order replacement parts. If you are missing any of these documents, please contact Wacker Neuson Corporation to order a replacement or visit When ordering parts or requesting service information, be prepared to provide the machine model number, item number, revision number, and serial number. Expectations for information in this manual This manual provides information and procedures to safely repair the above Wacker Neuson model(s). For your own safety and to reduce the risk of injury, carefully read, understand, and observe all instructions described in this manual. Wacker Neuson Corporation expressly reserves the right to make technical modifications, even without notice, which improve the performance or safety standards of its machines. The information contained in this manual is based on machines manufactured up until the time of publication. Wacker Neuson Corporation reserves the right to change any portion of this information without notice. Copyright notice All rights, especially copying and distribution rights, are reserved. Copyright 2008 by Wacker Neuson Corporation. This publication may be reproduced through photocopying by the original purchaser of the machine. Any other type of reproduction is prohibited without express written permission from Wacker Neuson Corporation. Any type of reproduction or distribution not authorized by Wacker Neuson Corporation represents an infringement of valid copyrights, and violators will be prosecuted. Trademarks All trademarks referenced in this manual are the property of their respective owners. ghi_tx001020gb.fm 3

4 Foreword S 3000 Repair ghi_tx001020gb.fm 4

5 S 3000 Table of Contents 1 Safety Information Signal Words Found in this Manual Safety Guidelines for Operating the Machine Safety Guidelines for Lifting the Machine Safety Guidelines While Using Combustion Burners Safety Guidelines while Using Internal Combustion Engines Safety Guidelines for Maintaining the Machine Controls and Components External Components Internal Components Control Panel Detail Troubleshooting Basics Where to Start Power Components Checking the Power Supplies Checking a Circuit Breaker Checking a GFCI Heating System Burner Controller Periods and Modes Troubleshooting the Heating System Checking the Burner Switch Checking the Low-Level Shut-Down Device Checking Relay K Diagnosing the Heating System Checking the Temperature Controller Checking the Burner Controller Checking the Snap Disc (Thermal Limit)

6 Table of Contents S Checking the Burner Fan Motor Checking the Cad Cell Checking the Oil Valve Checking the Fuel Filter Checking the Ignition Transformer Checking the Thermocouple Circulation System Diagnosing the Circulation System Troubleshooting the Circulation System Checking the Pump Switches Checking the Low-Level Shut-Down Device Checking Relay K Checking the Pump Motors Rewind System Troubleshooting the Rewind System Checking Fuse 1 and Fuse Checking the Rectifier Checking the Rewind Transformer Checking the Foot Switch Checking the Rewind Switch Checking the Rewind Clutch (Solenoid) Checking the Rewind Motor Checking the Rewind System Mechanical Components Miscellaneous Components Checking an Indicator Light Checking the Fuel Prewarmer...80 ghi_br en_002toc.fm 6

7 S 3000 Table of Contents 9 Burner Setup Setting/Checking the Electrodes Replacing the Burner Nozzle Setting the Z Distance ( F head) Adjusting the Air Settings Setting the Fuel Pressure Disassembly and Assembly Tools Required for Disassembly/Assembly Procedures Information Regarding Replacement Parts Information Regarding Reference Numbers Removing the Burner Installing the Burner Replacing the Fuel Pump Replacing the Burner Fan Motor Replacing an HTF Pump Changing a Turbulator/Cleaning a Turbulator Tube Repairing a Hose Changing/Cleaning the HTF Filter Changing Low Level Probe Replacing the Thermocouple Schematics S 3000 Composite Schematic S 3000 Composite Components Heating System Circuit Circulation System Circuit Rewind System Circuit Technical Data S Dimensions

8 Table of Contents S Appendix Omron Temperature Controller Programming Fuji Temperature Controller Hysteresis (differential) Adjusting Fuji Temperature Controller Low Temperature Limit Adjusting Fuji Temperature Controller High Temperature Limit Adjusting Threadlockers and Sealants Torque Values ghi_br en_002toc.fm 8

9 S Safety Information 1.1 Signal Words Found in this Manual Safety Information This is the safety alert symbol. It is used to alert you to potential personal hazards. Obey all safety messages that follow this symbol. DANGER DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. Obey all safety messages that follow this symbol to avoid injury or death. WARNING WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. Obey all safety messages that follow this symbol to avoid possible injury or death. CAUTION CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. Obey all safety messages that follow this symbol to avoid possible minor or moderate injury. NOTICE: Used without the safety alert symbol, NOTICE indicates a situation which, if not avoided, could result in property damage. Note: Contains additional information important to a procedure. ghi_si000293gb.fm 9

10 Safety Information S Safety Guidelines for Operating the Machine Operator training Before operating the machine: Read and understand the operating instructions contained in all manuals delivered with the machine. Familiarize yourself with the location and proper use of all controls and safety devices. Contact Wacker Neuson Corporation for additional training if necessary. When operating this machine: Do not allow improperly trained people to operate the machine. People operating the machine must be familiar with the potential risks and hazards associated with it. Machine condition Only operate the machine when: All safety devices and guards are in place and in working order. All controls operate correctly. The machine is set up correctly according to the instructions in the Operator s Manual. The machine is clean. The machine s labels are legible. When operating the machine: Do not modify or defeat the safety devices. Do not use worn electrical cords. Do not use faulty fuel supplies. Guidelines for operator When operating the machine: Remain aware of the machine s moving parts. Keep hands, feet, and loose clothing away from the machine s moving parts. Wear protective clothing appropriate to the job site when operating the machine. Wear safety glasses. Wear gloves when handling the heat transfer hoses. When operating the machine: Never operate a machine in need of repair. Do not smoke near the machine. Do not disconnect the heat transfer hoses when the pumps are operating or a burner is firing. Work space When operating the machine: Position the machine on a firm, noncombustible, level surface, and chock wheels. Position the machine on the job site so that neither it or the operator are standing in water. ghi_si000293gb.fm 10

11 S 3000 Safety Information Keep the area immediately surrounding and underneath the machine clean, neat, and free of debris and combustible materials. Keep the area above the machine clear of debris that could fall on the machine. Store the machine properly when it is not being used. Keep unauthorized personnel, children, and pets away from the machine. When operating the machine: Never operate the machine in areas that contain flammable objects, fuels, or products that produce flammable vapors. 1.3 Safety Guidelines for Lifting the Machine Lifting/ transporting the machine When lifting/transporting the machine: Make sure all lifting devices are attached securely and have enough weightbearing capacity to lift or hold the machine safely. Remain aware of the location of other people when lifting the machine. Only use the lifting points and tie-downs described in the Operator s Manual. Only use suitable transport vehicles with sufficient load-carrying capacity. When lifting the machine: Never walk or stand under a suspended machine. Never climb, sit, or stand on the machine while it is being lifted or transported. Do not operate the machine when it is being lifted or towed. ghi_si000293gb.fm 11

12 Safety Information S Safety Guidelines While Using Combustion Burners When using the machine: Clean up any spilled fuel immediately. Replace the fuel tank cap after refueling the machine. Refill the fuel tank in a well-ventilated area. Shut down the generator if equipped when refueling. When using the machine: DANGER Exhaust gas from the burner contains carbon monoxide, a deadly poison. Exposure to carbon monoxide can kill you in minutes. Never run the machine indoors or in an enclosed area unless the machine is vented properly. Do not fill or drain the fuel tank near an open flame or while the machine is running. Do not smoke when refueling the machine. 1.5 Safety Guidelines while Using Internal Combustion Engines Running the engine When running the engine: Keep the area around exhaust pipe free of flammable materials. Check the fuel lines and the fuel tank for leaks and cracks before starting the engine. Do not run the machine if fuel leaks are present or the fuel lines are loose. When running the engine: Engine exhaust CAN KILL YOU IN MINUTES. Engine exhaust contains carbon monoxide. This is a poison you cannot see or smell. Never run the machine indoors or in an enclosed area such as a deep trench unless adequate ventilation, through such items as exhaust fans or hoses, is provided. Do not smoke while operating the machine. Do not run the engine near open flames. Do not touch the engine or muffler while the engine is running or immediately after it has been turned off. Do not operate a machine when its fuel cap is loose or missing. ghi_si000293gb.fm 12

13 S Safety Guidelines for Maintaining the Machine Safety Information Training Only trained personnel should troubleshoot or repair electrical problems occurring with the machine. Cleaning When cleaning and servicing the machine: Keep the area around the burner free of debris such as leaves, paper, cartons, etc. Keep the machine clean and labels legible. When cleaning the machine: Do not clean the machine while it is running. Never use gasoline or other types of fuels or flammable solvents to clean parts. Fumes from fuels and solvents can become explosive! Maintenance guidelines Replacing parts and labels When maintaining the machine: Keep the fuel lines in good condition and properly connected. Allow the burner to cool before maintaining the machine. Allow the Heat Transfer Fluid (HTF) to cool before maintaining the machine. Re-install the safety devices and guards after repairs and maintenance. Keep all electrical cords away from heat, oil, vibrating surfaces, and sharp edges. When maintaining the machine: Replace worn or damaged components. Use only spare parts recommended by Wacker Neuson Corporation. Replace all missing and hard-to-read labels. Replace or repair electrical components with components that are identical in rating and performance as the original component. When maintaining the machine: Do not attempt tire repairs. Accessories, safety devices and modifications When using the machine: Use only accessories/attachments that are recommended by Wacker Neuson Corporation. When using the machine: Never operate the machine if any safety devices or guards are missing or inoperative. Do not defeat safety devices. Do not modify the machine without the express written approval of Wacker Neuson Corporation. ghi_si000293gb.fm 13

14 Controls and Components S Controls and Components 2.1 External Components ghi_gr Ref. Description Ref. Description 1 Hitch (ball or pintel) 5 Fender 2 Tie down 6 Onan genset (option) 3 Fuel tank 7 Jack stand 4 Fuel cap 8 Lifting bail ghi_tx001021gb.fm 14

15 S Internal Components Controls and Components Ref. Description Ref. Description a Genset 12V battery g Fuel sight gauge b Hydronic heater h Fuel sight gauge valve c Heat Transfer Fluid (HTF) pmp i Burner d Expansion tank sight gauge j Low-level shut-down device e Fuel filter k Thermocouple f Fuel return line n/a n/a ghi_tx001021gb.fm 15

16 Controls and Components S 3000 Ref. Description Ref. Description a Control panel e Foot pedal b Return plumbing f Hose reel c Supply plumbing g Main power connections d Hose reel brake h Expansion tank ghi_tx001021gb.fm 16

17 S Control Panel Detail Controls and Components ghi_tx001021gb.fm 17

18 Troubleshooting Basics S Troubleshooting Basics 3.1 Where to Start The chart below lists the four basic problems the machine may experience. Refer to the chart to determine which chapter to see for each basic problem. If The machine does nothing when turned on, The machine does not heat the HTF, The machine does not circulate the HTF, The machine does not rewind the hose, Then see Chapter 4 Power Components. see Chapter 5 Heating System. see Chapter 6 Circulation System. see Chapter 7 Rewind System. ghi_tx001022gb.fm 18

19 S 3000 Power Components 4 Power Components Components For any system of the machine to function, the following three power components must function properly: Power supply (supplies) Main circuit breaker(s) GFCI(s) Best practice The best practice when troubleshooting the power components is to: 1. Isolate and check each power component individually. 2. When a malfunctioning component is found, repair or replace it. This chapter of the manual provides procedures to check the power components. Testing sequence Check the function of the power components in the sequence below. 1. Power supply See Section 4.1 Checking the Power Supplies. 2. Main circuit breaker See Section 4.2 Checking a Circuit Breaker. 3. GFCI See Section 4.3 Checking a GFCI. ghi_tx001023gb.fm 19

20 Power Components S Checking the Power Supplies Prerequisites Two sources of 120 VAC Two 10-gauge, 3-wire extension cords max. 100 feet not applicable for machines with generators Procedure Follow the procedure below to check the power supplies. 1. Check the connection of each extension cord. One should be connected to Main Power 1 and the other to Main Power Place circuit breaker 1 in the ON position. 3. Place circuit breaker 2 in the ON position. WARNING Electric shock hazard. High voltage exists inside the control panel. High voltage can cause severe injury or death. Use extreme care when working inside the control panel. 4. Open the control panel. 5. Measure the voltage between L1 and N1. Is VAC measured? Continue. 6. Measure the voltage between L2 and N2. Is VAC measured? The power supplies are OK. The supply source is inadequate or non-existent. Check the power source. ghi_gr The power source is inadequate or non-existent. Check the power source (generator or wall outlet). The power supplies have now been checked. Continue with Section 4.2 Checking a Circuit Breaker. ghi_tx001023gb.fm 20

21 S 3000 Power Components 4.2 Checking a Circuit Breaker Prerequisites Power supplies check OK Multimeter Background The procedures to check either circuit breaker are similar. Use terminal N1 of the terminal strip for neutral when checking circuit breaker 1. Use terminal N2 of the terminal strip for neutral when checking circuit breaker 2. Procedure Follow the procedure below to check a circuit breaker. 1. Verify that each power source is plugged in. WARNING Electric shock hazard. High voltage exists inside the control panel. High voltage can cause severe injury or death. Use extreme care when working inside the control panel. 2. Open the control panel. 3. Measure the voltage between the incoming side of the circuit breaker and neutral. Is VAC measured? Continue. The wiring to the circuit breaker is faulty. Disconnect the main power supplies and repair the wiring. 4. With the circuit breaker in the OFF position, measure the voltage between the outgoing side of the circuit breaker and neutral. Is any voltage measured? The circuit breaker has failed. Disconnect the main power sources and replace the circuit breaker. Continue. This procedure continues on the next page. ghi_tx001023gb.fm 21

22 Power Components S 3000 Continued from the previous page. WARNING Electric shock hazard. High voltage exists inside the control panel. High voltage can cause severe injury or death. Use extreme care when working inside the control panel. 5. Place the circuit breaker in the ON position. 6. With the circuit breaker in the ON position, measure the voltage between the outgoing side of the circuit breaker and neutral. The circuit breaker is OK. The circuit breaker has failed. Disconnect the main power supplies and replace the circuit breaker. The circuit breaker has now been checked. Continue with Section 4.3 Checking a GFCI. ghi_tx001023gb.fm 22

23 S 3000 Power Components 4.3 Checking a GFCI Prerequisites Power supplies check OK Circuit breakers check OK Background The procedures to check either GFCI are similar. Use terminal N1 of the terminal strip for neutral when checking GFCI 1. Use terminal N2 of the terminal strip for neutral when checking GFCI 2. Procedure Follow the procedure below to check either GFCI. 1. Verify that each power supply is plugged in. WARNING Electric shock hazard. High voltage exists inside the control panel. High voltage can cause severe injury or death. Use extreme care when working inside the control panel. 2. Open the control panel. 3. Place the circuit breaker of the GFCI to be tested in the ON position. 4. Measure the voltage between the black wire on the incoming side (b) of the GFCI and neutral. Is VAC measured? Continue. The black wire to the GFCI is faulty. Disconnect the main power supplies and repair the wiring. 5. Measure the voltage between the white and the black wires on the incoming side of the GFCI. Is VAC measured? Continue. The white wire to the GFCI is faulty. Disconnect the main power supplies and repair the wiring. This procedure continues on the next page. ghi_tx001023gb.fm 23

24 Power Components S 3000 Continued from the previous page. 6. Push the OFF/TEST button on the face of the GFCI. Does the test light (a) of the GFCI illuminate? Continue. The GFCI has failed. Disconnect the main power supplies and replace the GFCI. 7. Measure the voltage between the white and the black wires on the outgoing side of the GFCI. Is VAC measured? Continue. The GFCI has failed. Disconnect the main power supplies and replace the GFCI. 8. Press the ON/RESET button. With the ON/RESET button pushed in, measure the voltage between the white and the black wires on the outgoing side of the GFCI. Is any voltage measured? The GFCI is OK. The GFCI has failed. Disconnect the main power supplies and replace the GFCI. The GFCI has now been checked. Power is available to the components of the machine. If the machine still does not function, refer to Section 3.1 to determine which system and corresponding components should be checked. ghi_tx001023gb.fm 24

25 S 3000 Heating System 5 Heating System 5.1 Burner Controller Periods and Modes Periods The burner controller has several periods it sequences through during normal operation. These periods are described below.. Period Power up Safety (5 seconds) Valve-ondelay Action or Function As soon as power is supplied to the burner controller, it conducts an internal safety check. If all internal conditions are OK, the burner controller enters the idle mode and will remain there until there is a call for heat or power is disconnected. When the setpoint of the temperature controller is set at a temperature higher than that of heat transfer fluid, the output contacts of the temperature controller close completing a circuit between terminal T and 3T of the burner controller. This is the call for heat. The burner controller initiates the safety period. If flame or light is detected, the burner controller remains in the idle mode and no other functions take place. If flame or light is not detected after 5 seconds: Power is sent to the burner motor/fuel pump. Fuel is pumped from the supply tank and returned to the supply tank through the return/ bypass port of the fuel pump. This process purges air from the fuel lines. Power is sent to the electrodes and any residual fuel is burned off. Fresh air fills the combustion chamber. The valve-on-delay period starts. The valve-on-delay period lasts 15 seconds. It is enabled (turned on or off) with DIP switch 3. When enabled: Power is sent to the burner motor/fuel pump. Power is sent to the electrodes. The fuel shut-off valve is energized (opens) and fuel flows to the nozzle after the valve-on-delay times out. ghi_tx001024gb.fm 25

26 Heating System S 3000 Period Carry-over Trial-forignition Burner-motoroff delay Action or Function The trial-for-ignition period immediately follows the valve-on-delay period. During this period: The fuel shut-off valve is opened (energized). Pressurized fuel atomizes at the burner nozzle. The atomized fuel is vaporized and ignited by the electrodes. The burner fires and the flame is monitored by the cad cell. If flame is not detected: The burner controller enters lockout mode. Power is disconnected from the fuel shut-off valve, electrodes, and the burner motor. The indicator light flashes. The ignition carry-over period starts as soon as the flame is established. During this cycle: The fuel shut-off valve is open (energized). Pressurized fuel atomizes at the burner nozzle. The atomized fuel is ignited by the electrodes The electrodes stay powered for up to 30 seconds after flame is sensed. Once the carry-over period has expired: The ignition transformer is shut off. The burner controller enters the run mode. If the flame is lost: If the lockout time has not expired, the burner controller returns to trial-for-ignition period. If the lockout time has expired, the burner controller enters the recycle mode. The burner-motor-off-delay period starts immediately after the setpoint is reached, i.e., the call for heat has been satisfied. The time of this period is set by the DIP switches (DIP switches 1 and 2 in the down position; 3 in the up position). During this period: The fuel shut-off valve is closed (de-energized). The burner motor runs until the burner-motor-off delay expires, then the burner motor turns off. The burner controller returns to the idle mode. Non-fault modes The burner non-fault modes are described below. Mode Idle Functional description The burner controller will enter the idle mode if: At power up, the internal conditions are correct and the cad cell senses no light. The cad cell senses light during the safety period. The call for heat has been satisfied. During this mode: The burner controller powers no outputs. ghi_tx001024gb.fm 26

27 S 3000 Heating System Mode Startup Run Recycle Functional description The burner controller will enter the startup mode as soon as there is a call for heat. This mode consists of the following periods: Safety Valve-on-delay Trial-for-ignition Carry-over The run mode starts and continues once the ignition carry-over period has elapsed. During this mode: The fuel shut-off valve is open (energized). Pressurized fuel atomizes at the burner nozzle. The flame is monitored by the cad cell. Once the setpoint is reached (call for heat satisfied): The output contacts of the temperature control open, interrupting the circuit between terminal T and 3T. The fuel shut-off valve is closed (de-energized). The burner motor runs for the selected burner-motor-off delay time (period), then turns off. The burner controller returns to the idle mode. If the flame is lost during the run mode: The burner controller enters the recycle mode. The burner will enter the recycle mode when the burner stops firing due to loss of flame. During the recycle mode: The diagnostic light on the burner controller will flash in twosecond intervals. The burner will attempt to automatically restart. Flame must be detected during each restart attempt. If no flame is detected, the burner controller goes into burner fault lockout mode. The burner controller will wait 60-seconds between restart attempts. If after three restart attempts in which the call for heat is not satisfied, the burner controller will go into burner fault lockout mode. If the call for heat is satisfied, the recycle counter resets. This procedure continues on the next page. ghi_tx001024gb.fm 27

28 Heating System S 3000 Continued from the previous page. Fault modes The burner controller fault modes are described below. Lockout Restricted lockout The burner will enter the lockout mode after three unsuccessful attempts to re-light the flame. During the lockout mode: The burner will not fire. The diagnostic light on the burner controller will flash in halfsecond intervals. The burner fault light on the control panel will illuminate. To clear the lockout fault so a restart can be attempted, press and release the reset button. Note: After the third attempt to manually clear the lockout fault, the burner controller will enter the restricted mode. The burner will enter the restricted mode after three unsuccessful attempts to manually reset the lockout fault. During the lockout mode: The burner will not fire. The diagnostic light on the burner controller will flash in halfsecond intervals. The burner fault light on the control panel will illuminate. To clear the restricted lockout fault so a restart can be attempted, press and hold (approximately seconds) the reset button until the diagnostic light flashes once. Note: The burner will return to the lockoutmode with each unsuccessful burner restart until a successful heating cycle has occurred. ghi_tx001024gb.fm 28

29 S Troubleshooting the Heating System Heating System Best practice The best practice when troubleshooting the heating system is to: 1. Isolate and check each component of the heating system individually. 2. When a malfunctioning component is found, repair or replace it. 3. After replacing a malfunctioning component, retry system operation. This chapter of the manual provides procedures to check the components of the heating system. Fundamental components Testing sequence For the heating system to function, the following three fundamental components must function properly. Burner switch Low-level shut-down device Relay K2 Before performing any troubleshooting procedures of the heating system, check the function of the fundamental components in the sequence below. Note: If power ( VAC) exists at the burner switch, it means the other fundamental components are functioning properly. In such a case, there is no need to test them. 1. Burner switch See Section 5.3 Checking the Burner Switch. 2. Low-level shut-down device See Section 5.4 Checking the Low-Level Shut-Down Device. 3. Relay K2 See Section 5.5 Checking Relay K2. If the heating system still does not function after verifying the fundamental components, see Section 5.6 Diagnosing the Heating System. ghi_tx001024gb.fm 29

30 Heating System S Checking the Burner Switch Prerequisites Power components check OK Power connected to the machine Procedure Follow the procedure below to check the burner switch. Note: If power ( VAC) exists at the burner switch, it means the other fundamental components are functioning properly. In such a case, there is no need to test them. WARNING Electric shock hazard. High voltage exists inside the control panel. High voltage can cause severe injury or death. Use extreme care when working inside the control panel. 1. Open the control panel. 2. Place circuit breaker 1 in the ON position. 3. Place the burner switch (a) in the OFF position. 4. Measure the voltage between terminal/wire 18 on the incoming side of the burner switch and N1 of the main terminal strip. Is VAC measured? If Then Yes, continue with step 5. No, one of the fundamental components has failed. Check: the low-level shut-down device. See Section 5.4 Checking the Low-Level Shut-Down Device. relay K2. See Section 5.5 Checking Relay K2. This procedure continues on the next page. ghi_tx001024gb.fm 30

31 S 3000 Heating System Continued from the previous page. 5. With the burner switch still in the OFF position, measure the voltage between terminal/wire 10 on the outgoing side of the burner switch and N1 of the main terminal strip. Is VAC measured? The burner switch has failed. Disconnect the power supplies and replace the burner switch. Continue. 6. Place the burner switch in the ON position. 7. Measure the voltage between terminal/wire 10 on the outgoing side of the burner switch and N1 of the main terminal strip. Is VAC measured? The burner switch and all fundamental components are OK. The burner switch has failed. Disconnect the power supplies and replace the burner switch. The burner switch has now been checked. If the heating system still does not function, continue with Section 5.4 Checking the Low-Level Shut-Down Device. ghi_tx001024gb.fm 31

32 Heating System S Checking the Low-Level Shut-Down Device Prerequisites All power components check OK Multimeter Procedure Follow the procedure below to check the low-level shut-down device. 1. Check the level of the HTF on the sight gauge. Add HTF as necessary. WARNING Electric shock hazard. High voltage exists inside the low-level shut-down device. High voltage can cause severe injury or death. Use extreme care when working inside the low-level shut-down device. 2. Turn off circuit breaker 1 and circuit breaker Open the side panel and locate the low-level shut-down device (a). 4. Remove the cover from the low-level shut-down device. 5. Remove the wing nut and the probe wire from the probe (b). 6. Measure the resistance between the end of the probe and ground (bare metal location on the heater unit). Is any resistance measured? Reconnect the probe and continue. The probe has failed; replace it. This procedure continues on the next page. ghi_tx001024gb.fm 32

33 S 3000 Heating System Continued from the previous page. 7. Turn on circuit breaker 1 and circuit breaker 2. WARNING Electric shock hazard. High voltage exists inside the control panel. High voltage can cause severe injury or death. Use extreme care when working inside the control panel. 8. Measure the voltage between wire/terminal black 17 and N2 of the main terminal strip. Also measure between wire/terminal orange 1 and N1 of the main terminal strip. Is VAC measured in each case? Continue. The wiring (orange 1 or black 17) is faulty. Disconnect the power supplies and repair the wiring. 9. Measure the voltage between the black wire 17 and the white wire/terminal of the low-level shut-down device. Is VAC measured? Continue. The white wire is faulty. Disconnect the power supplies and repair the wiring. 10.Measure the voltage between red wire 5 and N1 of the terminal strip. Is VAC measured? The low-level shutdown device is OK. The low-level shut-down device has failed. Disconnect the power supplies and replace it. The low-level shut-down device has now been checked. If the heating system still does not function, see Section 5.5 Checking Relay K2. ghi_tx001024gb.fm 33

34 Heating System S Checking Relay K2 Prerequisites All power components check OK Multimeter Procedure Follow the procedure below to check relay K2. 1. Place circuit breaker 1 and circuit breaker 2 in the OFF position. WARNING Electric shock hazard. High voltage exists inside the control panel. High voltage can cause severe injury or death. Use extreme care when working inside the control panel. 2. Open the control panel. 3. Locate relay K2. 4. Label, then disconnect the wires from relay K2. 5. Measure the resistance across the coil of the relay (terminals 0 and 1). Is ohms measured? Continue. Relay K2 has failed; replace it. 6. Measure the resistance (check continuity) across normally closed contacts (terminals 3 and 4). Is approximately 0.1 ohms measured? Continue. Relay K2 has failed; replace it. 7. Measure the resistance across normally open contacts (terminals 2 and 4). Is any resistance measured? Relay K2 has failed; replace it. Continue. This procedure continues on the next page. ghi_tx001024gb.fm 34

35 S 3000 Heating System Continued from the previous page. 8. Reconnect the wiring to relay K2. WARNING Electric shock hazard. High voltage exists inside the control panel. High voltage can cause severe injury or death. Use extreme care when working inside the control panel. 9. Place circuit breaker 1 and circuit breaker 2 in the ON position. 10.Measure the voltage between the incoming side (wire 18) of the burner switch (a) and N1 of the main terminal strip. Is VAC measured? Continue. Relay K2 has failed. Disconnect the power supplies and replace relay K2. 11.Measure the voltage between the incoming side (wire 26) of the low-level fault light and N1 of the main terminal strip. Is VAC measured? Relay K2 has failed. Disconnect the power supplies and replace relay K2. Relay K2 is OK. Relay K2 has now been checked. The fundamental components of the heating system are OK. If the heating system still does not function, see Section 5.6 Diagnosing the Heating System. ghi_tx001024gb.fm 35

36 Heating System S Diagnosing the Heating System Prerequisites All power components check OK All fundamental components check OK Procedure Follow the procedure below to determine which component(s) of the heating system to check. 1. Place circuit breaker 1 and circuit breaker 2 in the ON position. 2. Place the burner switch in the ON position. 3. Set the temperature controller to 180 F. Does the display of the temperature controller and LED C1 (a) illuminate? Continue. See Section 5.7 Checking the Temperature Controller. 4. Observe the burner fault light on the control panel. Does the BURNER FAULT light illuminate? Continue. There is a problem with one of the two components below. Verify the wiring to, and function of, each component. See the following sections in order: Section 5.8 Checking the Burner Controller Section 8.1 Checking an Indicator Light This procedure continues on the next page. ghi_tx001024gb.fm 36

37 S 3000 Heating System Continued from the previous page. 5. Locate the primary control (a). 6. Push the red reset button (b) on the primary control for 45 seconds and release. Does the burner attempt to start? Continue. 7. If the burner attempted to start, follow the guide below. If Ignition occurs and the burner stays lit, Ignition occurs then stops after approximately 20 seconds of blower run time, Ignition does not occur and the blower stops after approximately 20 seconds of blower run time, The procedure is now complete. The problem is one of the three components below. Verify the wiring to, and function of, each component. See the following sections in order: Section 5.8 Checking the Burner Controller Section 5.9 Checking the Snap Disc Section 5.10 Checking the Burner Fan Motor Then use machine as normal. the problem is the cad cell. See Section 5.11 Checking the Cad Cell. the problem is one of the four components below. Verify the wiring to, and function of, each component. See the following sections in order: Section 5.12 Checking the Oil Valve Section 5.13 Checking the Fuel Filter Section 9.2 Replacing the Burner Nozzle Section 5.14 Checking the Ignition Transformer Section 9.1 Setting/Checking the Electrodes ghi_tx001024gb.fm 37

38 Heating System S Checking the Temperature Controller Prerequisites Power components check OK Fundamental components check OK Procedure Follow the procedure below to check the temperature controller. 1. Place circuit breaker 1 and circuit breaker 2 in the ON position. 2. Observe the temperature controller. Does the temperature controller read UUUU or 5ERR? Check the connection of the thermocouple wires (terminals 17 & 18). Make sure the blue wire is connected to terminal 17; red to terminal 18. If the controller still reads UUUU or 5ERR see Section 5.15 Checking the Thermocouple. Continue. WARNING Electric shock hazard. High voltage exists inside the control panel. High voltage can cause severe injury or death. Use extreme care when working inside the control panel. 3. Open the control panel and locate the back of the temperature controller. 4. Place circuit breaker 1 and circuit breaker 2 in the OFF position. 5. Check continuity between the wire connected to terminal 6 and neutral (N1 on the main terminal strip). There must be continuity (0.1 Ohms). Repair or replace the wire as needed. 6. Place circuit breaker 1 and circuit breaker 2 in the ON position. 7. Place the burner switch in the ON position. 8. Measure the voltage between wire #1 connected to temperature controller (terminal 5) and neutral (N1 on the main terminal strip). Is VAC measured? Continue. Disconnect the power sources and repair wire #1. This procedure continues on the next page. ghi_tx001024gb.fm 38

39 S 3000 Heating System Continued from the previous page. 9. Adjust the temperature controller to 180 F by pressing the UP arrow. 10.Check the C1 LED (a) on the front face of the temperature controller. Does the LED and the readout display illuminate? Continue. The temperature controller has failed. Disconnect the power supplies and replace the temperature controller. 11.Disconnect the wires from terminals 14 and With the temperature controller still set at 180 F, measure the resistance (continuity) across the terminals. Is 0.1 Ohms measured? The temperature controller should be OK. If you suspect a problem with the programming of the temperature controller, see Appendix. The temperature controller has failed. Disconnect the power supplies and replace the temperature controller. The temperature controller has now been checked. If the heating system still does not function, see Section 5.8 Checking the Burner Controller. ghi_tx001024gb.fm 39

40 Heating System S Checking the Burner Controller Prerequisites Power components check OK Fundamental components check OK Procedure Follow the procedure below to check power to the primary control. 1. Place circuit breaker 1 in the ON position. 2. Set the temperature controller to 50 F. 3. Place the burner switch in the ON position. 4. Measure the voltage between terminal T and terminal 3T of the primary control. Is VAC measured? Continue. The wiring between the temperature controller and the primary control may have failed. Check the wiring. 5. Place circuit breaker 1 in the OFF position. 6. Remove the primary control by loosening screws (c). INTRPT/IGNITER BURNER/MOTOR L1 L2 L2 L2 L2 CAD CELL 2 LIMIT VALVE This procedure continues on the next page. ghi_tx001024gb.fm 40

41 S 3000 Heating System Continued from the previous page. 7. Check the connections and the continuity of white wire 2 that runs between an L2 terminal of the primary control and the terminal strip. Does the wire have continuity? Continue. Wire 2 between the L2 terminal and the terminal strip has failed; replace it. WARNING Electric shock hazard. High voltage exists inside the primary control. High voltage can cause severe injury or death. Use extreme care when working inside the primary control. 8. Place circuit breaker 1and circuit breaker 2 in the ON position. 9. Place the burner switch in the ON position. 10.Measure the voltage between wire 10 (at the LIMIT terminal) and any L2 terminal of the primary control. Is VAC measured? Continue. Wire 10 between the LIMIT terminal and the burner switch has failed. Disconnect the power supplies and repair wire Measure the voltage between wire 1 (at the L1 terminal) and any L2 terminal of the primary control. Is VAC measured? Continue. Wire 1 between the L1 terminal and the terminal strip has failed. Disconnect the power supplies and repair wire 1. This procedure continues on the next page. ghi_tx001024gb.fm 41

42 Heating System S 3000 Continued from the previous page. 12.Turn OFF and then back ON the burner switch. After the burner purge cycle, measure the voltage between the INTRPT/IGNITER terminal and any L2 terminal. Is VAC measured? Continue. 13.Continue with the burner switch in the ON position 14.Measure the voltage between the BURNER/MOTOR terminal and any L2 terminal. Is VAC measured? Continue. 15.Measure the voltage between the VALVE terminal and any L2 terminal. Is VAC measured? The primary control is OK. The primary control has failed. Disconnect the power supplies and replace the primary control. The primary control has failed. Disconnect the power supplies and replace the primary control. The primary control has failed. Disconnect the power supplies and replace the primary control. The primary control has now been checked. If the heating system still does not function, see Section 5.9 Checking the Snap Disc. ghi_tx001024gb.fm 42

43 S 3000 Heating System 5.9 Checking the Snap Disc (Thermal Limit) Prerequisites Machine cool Multimeter Procedure Follow the procedure below to check the snap disc. WARNING Burn hazard. The furnace chamber is hot when the machine is operating. If touched, it may cause severe burns. Allow the furnace chamber to cool before performing this test. 1. Place circuit breaker 1 and circuit breaker 2 in the OFF position. 2. Locate the snap disc above the furnace chamber. It is located in a brass housing (a). 3. Reset the snap disc by pushing in the reset button (b). 4. Remove the face plate of the brass housing. 5. Remove the two wires that lead to the snap disc. 6. Measure the resistance across the terminals of the snap disc. Is approximately 0.1 ohms measured? Continue. The snap disc has failed; replace it. This procedure continues on the next page. ghi_tx001024gb.fm 43

44 Heating System S 3000 Continued from the previous page. 7. Re-attach the wires to the snap disc. 8. Remove the primary control by loosening the screws (d). 9. Among the wires of the primary control junction box, locate the wire that runs from the primary control to the snap disc (e). Also locate the wire that runs from the snap disc to the burner motor. Disconnect each wire. 10.Measure the resistance between the two wires that run to the snap disc. Is approximately 0.1 ohms measured? The snap disc and its wiring are OK. The wiring to the snap disc has failed; replace it. The procedure to check the snap disc is now complete. If the heating system still does not function, see Section 5.10 Checking the Burner Fan Motor. ghi_tx001024gb.fm 44

45 S 3000 Heating System 5.10 Checking the Burner Fan Motor Prerequisites Power components check OK Multimeter Procedure Follow the procedure below to check the burner fan motor. WARNING Electric shock hazard. High voltage exists inside the primary control. High voltage can cause severe injury or death. Start this test with circuit breaker 1 and circuit breaker 2 in the OFF position. 1. Remove the primary control by loosening screws (c). INTRPT/IGNITER BURNER/MOTOR L1 L2 L2 L2 L2 CAD CELL 2 LIMIT VALVE 2. Locate and remove the orange wire and the white wire (that power the burner fan motor) from the primary control. 3. Measure the resistance between the orange wire and white wire. Is ohms measured? Continue. The burner fan motor has failed; replace it. 4. Measure the resistance between one of the wires and ground. Is infinity ohms (OL) measured? Continue. The burner fan motor has failed; replace it. 5. Reconnect the orange wire. This procedure continues on the next page. ghi_tx001024gb.fm 45

46 Heating System S 3000 Continued from the previous page. 6. Place circuit breaker 1 and circuit breaker 2 in the ON position. WARNING Electric shock hazard. High voltage exists on the burner fan motor when the burner switch is in the ON position. High voltage can cause severe injury or death. Use extreme care when working on the burner fan motor. 7. Place the burner switch in the ON position. 8. Measure the voltage between the white wire and N1 of the main terminal strip. Is VAC measured? The burner fan motor is OK. The burner fan motor has failed; disconnect the power supplies and replace the burner fan motor. The burner fan motor has now been checked. ghi_tx001024gb.fm 46

47 S Checking the Cad Cell Heating System Prerequisites Power disconnected from the machine Multimeter Procedure Follow the procedure below to check the cad cell. 1. Remove the primary control by loosening screws (c). 2. Loosen tabs (b) and hinge back the igniter plate cover. 3. Disconnect the yellow wires (d) from the bottom of the primary control. 4. Measure the resistance of the cad cell (e) by measuring across the yellow wires. Be sure the cad cell is exposed to light. Is ohms measured? Continue. The cad cell is dirty or defective. First, clean the glass eye, then re-measure. If the reading remains out of the range listed above, replace the cad cell. This procedure continues on the next page. ghi_tx001024gb.fm 47

48 Heating System S 3000 Continued from the previous page. 5. Deprive the cad cell of light (cover the cad cell) and measure the resistance again. Is 20,000 50,000 ohms measured? The cad cell is OK. The cad cell is dirty or defective. First, clean the glass eye, then re-measure. If the reading remains out of the range listed above, replace the cad cell. The procedure to check the cad cell is now complete. ghi_tx001024gb.fm 48

49 S 3000 Heating System 5.12 Checking the Oil Valve Prerequisites Power components check OK Fundamental components check OK Procedure Follow the procedure below to check the oil valve. 1. Remove the primary control by loosening screws (c). INTRPT/IGNITER BURNER/MOTOR L1 L2 L2 L2 L2 CAD CELL 2 LIMIT VALVE 2. Place circuit breaker 1 and circuit breaker 2 in the ON position. 3. Position all dip switches (a) in the down or disabled position. 4. Remove the oil valve electrical plug (b). WARNING Electric shock hazard. High voltage exists at the oil valve plug when the burner switch is in the ON position. High voltage can cause severe injury or death. Do not touch the receptacles of the electrical plug. 5. Place the burner switch in the ON position. This procedure continues on the next page. ghi_tx001024gb.fm 49

50 Heating System S 3000 Continued from the previous page. 6. Measure the voltage at the electrical plug. Is V measured? Continue. The wiring to the oil valve has failed. Disconnect the power supplies and replace the wiring. 7. Place circuit breaker 1 and circuit breaker 2 in the OFF position. 8. Measure the resistance between the male terminals on the solenoid body. Is ohms measured? The oil valve is OK. The solenoid has failed; replace it. 9. Position the dip switches back to the original position. The oil valve has now been checked. If the heating system still does not function, see Section 5.13 Checking the Fuel Filter. ghi_tx001024gb.fm 50

51 S Checking the Fuel Filter Heating System Prerequisites Power components check OK Fundamental components check OK Removal procedure Follow the procedure below to check/change the fuel filter. 1. Place circuit breaker 1 and circuit breaker 2 in the OFF position. 2. Locate the fuel filter assembly (a). 3. Disconnect both quick-connect couplings (b and c). Note: There will be fuel in the fuel filter canister. Take measures to capture any fuel that spills. Dispose of this fuel in accordance with local environmental regulations. 4. Remove the bolt (d) from the top of the canister cap and remove the canister cap. 5. Remove the fuel filter (e) and the gasket (f). 6. Clean the inside of the canister. Installation procedure Follow the procedure below to install the fuel filter. 1. Install a new gasket to the canister. 2. Install a new fuel filter into the canister. Be sure to align the fuel filter properly with the bottom of the canister. 3. Re-install the canister cap and secure it with the bolt. 4. Reconnect the quick-connect couplings. The fuel filter has now been checked. If the heating system still does not function, see Section 5.14 Checking the Ignition Transformer. ghi_tx001024gb.fm 51

52 Heating System S Checking the Ignition Transformer Prerequisites Power components check OK Fundamental components check OK Procedure Follow the procedure below to check the ignition transformer. WARNING Electric shock hazard. High voltage exists at the igniter when the machine is powered. High voltage can cause severe injury or death. Use caution when working on the ignition transformer. 1. Open the primary control by loosening screws (a). 2. Position the dip switches (d) in the down or disabled position. 3. Place circuit breaker 1 and circuit breaker 2 in the ON position. 4. Place the burner switch in the ON position. 5. Measure the voltage between terminal INTRPT/IGNITER and the wire at L2. Is VAC measured? Continue. Check that the wire from L2 has continuity to neutral of terminal strip. If it does, the primary control has failed. Shut down the machine and replace the primary control. This procedure continues on the next page. ghi_tx001024gb.fm 52

53 S 3000 Heating System Continued from the previous page. 6. Place circuit breaker 1 and circuit breaker 2 in the OFF position. 7. Loosen tabs (b) and hinge back the igniter plate cover (c). 8. Measure the resistance between the blue/white striped wire and the white wire which are connected to the ignition transformer. Is approximately 7 megohms measured? Continue. The ignition transformer has failed; replace it. 9. Measure the resistance from spring to spring. The springs are located in on the bottom of the igniter plate. Is ohms measured? The ignition transformer is OK. The ignition transformer has failed. Disconnect the power supplies and replace the ignition transformer. The ignition transformer has now been checked. If the heating system still does not function, see Section 9.1 Setting/Checking the Electrodes. ghi_tx001024gb.fm 53

54 Heating System S Checking the Thermocouple Prerequisites Power components check OK Fundamental components check OK Procedure Follow the procedure below to check the thermocouple. 1. Place circuit breaker 1 and circuit breaker 2 in the ON position. 2. Observe the temperature controller. Is the temperature controller displaying the setpoint temperature and the actual temperature as a positive number between 50 and 180 F? The thermocouple/connections are OK. Continue. 3. Place circuit breaker 1 and circuit breaker 2 in the OFF position. WARNING Electric shock hazard. High voltage exists inside the control panel. High voltage can cause severe injury or death. Use extreme care when working inside the control panel. 4. Open the control panel and locate the temperature controller. 5. Check the red and blue wires connected to the temperature controller. Clean the wires and terminals if any corrosion is found. This procedure continues on the next page. ghi_tx001024gb.fm 54

55 S 3000 Heating System Continued from the previous page. 6. Locate the thermocouple housing (a). 7. Remove the cover of the thermocouple housing. 8. Check the connections of the wiring. Disconnect the wires and clean the wires and terminals if any corrosion exists. Reconnect the wires. 9. Place circuit breaker 1 and circuit breaker 2 in the ON position. Is the temperature controller displaying the setpoint temperature and the actual temperature as a positive number between 50 and 180 F? The thermocouple/connections are OK. The thermocouple has failed. Disconnect the power sources and replace the thermocouple. The thermocouple has now been checked. Re-assemble the machine. ghi_tx001024gb.fm 55

56 Circulation System S Circulation System 6.1 Diagnosing the Circulation System Background Procedure There are two types of problems that the circulation system may experience: A mechanical problem with the HTF filter or with the HTF pump An electrical problem with a component within the system Follow the procedure below to determine the type of circulation problem. 1. Place circuit breaker 2 in the ON position. 2. Place the pump switch in the ON position. Does the pump run? Continue. See Section 6.2 Troubleshooting the Circulation System 3. Observe the flow meter and pressure gauge. If There is high pressure and low flow, There is low pressure and low flow, Then the hose is pinched or kinked. Check the hose. the HTF filter is clogged, or the pump has failed. Check the HTF filter (see Section Changing/ Cleaning the HTF Filter). If the HTF filter is OK, replace the HTF pump (see Section 10.8 Replacing an HTF Pump). The procedure is now complete. ghi_tx001025gb.fm 56

57 S Troubleshooting the Circulation System Circulation System Best practice The best practice when checking the circulation system is to: 1. Isolate and check each component of the heating system individually. 2. When a malfunctioning component is found, repair or replace it. 3. After replacing a malfunctioning component, retry system operation. This chapter of the manual provides procedures to check the components of the circulation system. Fundamental components Testing sequence For the circulation pumps to function, the following four fundamental components must function properly. Pump 1 switch Pump 2 switch Low-level shut-down device Relay K1 Check the function of the fundamental components in the sequence below. Note: If power ( VAC) exists at the pump switches, it means the low-level shut-down device and relay K1 are functioning properly. In such a case, there is no need to test them. 1. Pump 1 switch/pump 2 switch See Section 6.3 Checking the Pump Switches. 2. Low-level shut-down device See Section 6.4 Checking the Low-Level Shut-Down Device. 3. Relay K1 See Section 6.5 Checking Relay K1. After the fundamental components have been verified, check the pump motor. See Section 6.6 Checking the Pump Motors. ghi_tx001025gb.fm 57

58 Circulation System S Checking the Pump Switches Prerequisites Power components check OK Power connected to the machine Procedure Follow the procedure below to check the pump switch(es). WARNING Electric shock hazard. High voltage exists inside the control panel. High voltage can cause severe injury or death. Use extreme care when working inside the control panel. 1. Open the control panel. 2. Place circuit breaker 1 and circuit breaker 2 in the ON position. 3. Place the pump switches (a) in the OFF position. 4. Measure the voltage between the incoming side of each pump switch (wire 19 or wire 20) and N2 of the main terminal strip Is VAC measured? Continue. Relay K1 may have failed. Check relay K1. 5. With the each pump switch still in the OFF position, measure the voltage between the outgoing side of each pump switch and N2 of the main terminal strip. Is any voltage measured? The pump switch(es) has failed. Disconnect the power supplies and replace the pump switch(es). Continue. This procedure continues on the next page. ghi_tx001025gb.fm 58

59 S 3000 Circulation System Continued from the previous page. 6. Place the pump switches in the ON position. 7. Measure the voltage between the outgoing side of each pump switch and N2 of the main terminal strip. Is VAC measured? The pump switches are OK. The pump switch(es) has failed. Disconnect the power supplies and replace the pump switch(es). The procedure to check the pump switches is now complete. If the circulation system still does not function, see Section 6.4 Checking the Low-Level Shut-Down Device. ghi_tx001025gb.fm 59

60 Circulation System S Checking the Low-Level Shut-Down Device Prerequisites All power components check OK Multimeter Procedure Follow the procedure below to check the low-level shut-down device. 1. Check the level of the HTF on the sight gauge. Add HTF as necessary. WARNING Electric shock hazard. High voltage exists inside the low-level shut-down device. High voltage can cause severe injury or death. Use extreme care when working inside the low-level shut-down device. 2. Turn off circuit breaker 1 and circuit breaker Open the side panel and locate the low-level shut-down device (a). 4. Remove the cover from the low-level shut-down device. 5. Remove the wing nut and the probe wire from the probe (b). 6. Measure the resistance between the end of the probe and ground (bare metal location on the heater unit). Is any resistance measured? Reconnect the probe and continue. The probe has failed; replace it. This procedure continues on the next page. ghi_tx001025gb.fm 60

61 S 3000 Circulation System Continued from the previous page. 7. Turn on circuit breaker 1 and circuit breaker 2. WARNING Electric shock hazard. High voltage exists inside the control panel. High voltage can cause severe injury or death. Use extreme care when working inside the control panel. 8. Measure the voltage between wire/terminal black 20 and N2 of the main terminal strip. Also measure between wire/terminal orange 4 and N1 of the main terminal strip. Is VAC measured in each case? Continue. The wiring (orange 4 or black 20) is faulty. Disconnect the power supplies and repair the wiring back to the main terminal strip. 9. Measure the voltage between the black wire 20 and the white wire/terminal of the low-level shut-down device. Is VAC measured? Continue. The white wire is faulty. Disconnect the power supplies and repair the wiring back to the main terminal strip. 10.Measure the voltage between red wire 5 and N1 of the main terminal strip. Is VAC measured? The low-level shutdown device is OK. The low-level shut-down device has failed. Disconnect the power supplies and replace it. The low-level shut-down device has now been checked. If the circulation system still does not function, see Section 6.5 Checking Relay K1. ghi_tx001025gb.fm 61

62 Circulation System S Checking Relay K1 Prerequisites All power components check OK Multimeter Procedure Follow the procedure below to check relay K1. 1. Place circuit breaker 1 and circuit breaker 2 in the OFF position. WARNING Electric shock hazard. High voltage exists inside the control panel. High voltage can cause severe injury or death. Use extreme care when working inside the control panel. 2. Open the control panel. 3. Locate relay K1. 4. Label, then disconnect the wires from relay K1. 5. Measure the resistance across the coil of the relay, terminals 0 and 1. Is ohms measured? Continue. Relay K1 has failed; replace it. 6. Measure the resistance across normally open contacts terminals 2 and 4. Is approximately 0.1 ohms measured? Relay K1 has failed; replace it. Continue. 7. Measure the resistance across normally open contacts terminals 6 and 8. Is approximately 0.1 ohms measured? Relay K1 has failed; replace it. Continue. This procedure continues on the next page. ghi_tx001025gb.fm 62

63 S 3000 Circulation System Continued from the previous page. 8. Reconnect the wiring to relay K1. WARNING Electric shock hazard. High voltage exists inside the control panel. High voltage can cause severe injury or death. Use extreme care when working inside the control panel. 9. Place circuit breaker 1 and circuit breaker 2 in the ON position. 10.Measure the voltage between the incoming side of both pump switches (a) and N2 of the terminal strip. Is VAC measured in both cases? Rely K1 is OK. Relay K1 has failed. Disconnect the power sources and replace relay K1. Relay K1 has now been checked. If the circulation system still does not function, see Section 6.6 Checking the Pump Motors. ghi_tx001025gb.fm 63

64 Circulation System S Checking the Pump Motors Prerequisites Power components check OK Fundamental components check OK Procedure Follow the procedure below to check either pump motor. 1. Start this test with circuit breaker 1 and circuit breaker 2 in the OFF position. 2. Locate the pumps. Note: Several different styles of motors have been used. Your motors may differ slightly from those shown. 3. Remove the cover plate from the junction box. WARNING Electric shock hazard. High voltage exists inside the pump motor junction boxes. High voltage can cause severe injury or death. Use extreme care when working inside the pump motor junction boxes. This procedure continues on the next page. ghi_tx001025gb.fm 64

65 S 3000 Circulation System Continued from the previous page. 4. Disconnect white wire 9. WARNING Electric shock hazard. High voltage exists inside the pump motor junction boxes. High voltage can cause severe injury or death. Use extreme care when working inside the pump motor junction boxes. 5. Place circuit breakers 1 & 2 in the ON position. 6. Measure the voltage between black wire (7 or 8 depending on the pump) of the pump and N2 of the main terminal strip. Is VAC measured? Continue. The wiring to the pump motor has failed. Disconnect the power supplies and repair the wiring. 7. Measure the voltage between white wire 9 and black wire 7 or 8. Is VAC measured? The pump motor has failed. Disconnect the power supplies and replace the pump motor. White wire 9 has failed. Disconnect the power supplies and repair the wiring. The pump motor(s) have now been checked. Re-assemble the machine. ghi_tx001025gb.fm 65

66 Rewind System S Rewind System 7.1 Troubleshooting the Rewind System Best practice The best practice when troubleshooting the rewind system is to: 1. Isolate and check each component of the rewind system individually. 2. When a malfunctioning component is found, repair or replace it. 3. After replacing a malfunctioning component, retry system operation. This chapter of the manual provides procedures to check the components of the rewind system. Mechanical components When diagnosing rewind system problems, first rule out problems with the mechanical components. If Then The rewind motor runs and the rewind clutch solenoid activates (a distinct click can be heard), but the system still won t function, there is a mechanical problem. See Section 7.9 Checking the Rewind System Mechanical Components. For all other scenarios, see the chart below. Electrical components Check the electrical components in the sequence listed below. 1. Fuse 1 and Fuse 2 See Section 7.2 Checking Fuse 1 and Fuse Rectifier See Section 7.3 Checking the Rectifier. 3. Rewind transformer See Section 7.4 Checking the Rewind Transformer. 4. Foot switch See Section 7.5 Checking the Foot Switch. 5. Hose rewind switch See Section 7.6 Checking the Rewind Switch. 6. Rewind clutch solenoid See Section 7.7 Checking the Rewind Clutch (Solenoid). 7. Rewind motor See Section 7.8 Checking the Rewind Motor. ghi_tx001026gb.fm 66

67 S 3000 Rewind System 7.2 Checking Fuse 1 and Fuse 2 Prerequisites Power supplies disconnected Replacement fuses if necessary Procedure Follow the procedure below to check fuse 1 and fuse Disconnect the power supplies. WARNING Electric shock hazard. High voltage exists inside the control panel. High voltage can cause severe injury or death. Disconnect the power supplies before conducting this test. 2. Open the control panel. 3. Open the cover (a) for fuse 1 and inspect fuse Replace fuse 1 if it is blown, or re-install fuse Repeat the procedure for fuse 2 (b). Fuse 1 and fuse 2 have now been checked. If the rewind system still does not function, see 7.3 Checking the Rectifier. ghi_tx001026gb.fm 67

68 Rewind System S Checking the Rectifier Prerequisites Power components check OK Rewind transformer checks OK Procedure Follow the procedure below to check the rectifier. 1. Start this test with circuit breaker 1 in the OFF position. WARNING Electric shock hazard. High voltage exists inside the control panel. High voltage can cause severe injury or death. Use extreme care when working inside the control panel. 2. Open the control panel and locate the rectifier (a). 3. Place circuit breaker 1 in the ON position. 4. Measure the voltage between terminal 22 and terminal 24 of the main terminal strip. Is VAC measured? Continue. The wiring between the rewind transformer and the terminal strip has failed. Disconnect the power supplies and repair the wiring. 5. Measure the DC voltage between terminal 14 and terminal 16. Is VDC measured? The rectifier is OK. The rectifier has failed. Disconnect the power supplies and replace the rectifier. The rectifier has now been checked. If the rewind system still does not function, see Section 7.4 Checking the Rewind Transformer. ghi_tx001026gb.fm 68

69 S 3000 Rewind System 7.4 Checking the Rewind Transformer Prerequisites Power components check OK Fuse 2 checks OK Procedure Follow the procedure below to check the rewind transformer. 1. Start this test with circuit breaker 1 and circuit breaker 2 in the OFF position. 2. Open the control panel and locate the rewind transformer (a). WARNING Electric shock hazard. High voltage exists inside the control panel. High voltage can cause severe injury or death. Use extreme care when working inside the control panel. This procedure continues on the next page. ghi_tx001026gb.fm 69

70 Rewind System S 3000 Continued from the previous page. 3. Place circuit breaker 1 in the ON position. 4. There are two black wires 21 connected to the rewind transformer. Measure the AC voltage between one of the black wires 21 and N1 of the terminal strip. Measure the AC voltage between the other black wire 21 and N1 of the terminal strip. Is VAC measured in each case? Continue. The wiring between fuse 1and the rewind transformer has failed. Disconnect the power supplies and repair the wiring. 5. Measure the AC voltage between terminal/wire 23 and terminal/wire 24 of the rewind transformer. Is VAC measured? The rewind transformer is OK. The rewind transformer has failed. Disconnect the power supplies and replace the rewind transformer. The rewind transformer has now been checked. If the rewind system still does not function, see Section 7.5 Checking the Foot Switch. ghi_tx001026gb.fm 70

71 S 3000 Rewind System 7.5 Checking the Foot Switch Prerequisites Power components check OK Rewind transformer checks OK Rectifier checks OK Procedure Follow the procedure below to check the foot switch. 1. Start this test with circuit breaker 1 in the OFF position. WARNING Electric shock hazard. High voltage exists inside the control panel. High voltage can cause severe injury or death. Use extreme care when working inside the control panel. 2. Open the control panel. 3. Place circuit breaker 1 in the ON position. 4. Step on (or close) the foot switch. 5. Measure the resistance between terminal 14 and terminal 15 of the main terminal strip while stepping on the foot switch. Is approximately 0.1 ohms measured? Continue. The wiring or the foot switch has failed. Disconnect the power supplies and repair the wiring or replace the foot switch. 6. Measure the resistance between terminal 14 and terminal 15 of the main terminal strip while not stepping on the foot switch. Does your meter read OPEN or OL? Continue. The wiring or the foot switch has failed. Disconnect the power supplies and repair the wiring or replace the foot switch. This procedure continues on the next page. ghi_tx001026gb.fm 71

72 Rewind System S 3000 Continued from the previous page. 7. Measure the DC voltage between terminals 15 and 16 of the terminal strip while stepping on the foot switch. Is VDC measured? The foot switch is OK. The foot switch has failed. Disconnect the power supplies and replace the foot switch. The foot switch has now been checked. If the rewind system still does not function, see section 7.6 Checking the Rewind Switch. ghi_tx001026gb.fm 72

73 S 3000 Rewind System 7.6 Checking the Rewind Switch Prerequisites Power components check OK Fuse 1 checks OK Procedure Follow the procedure below to check the rewind switch. 1. Place circuit breaker 1 in the ON position. 2. Place the rewind switch in the ON position. Does the rewind motor run? The rewind switch is OK. Continue. WARNING Electric shock hazard. High voltage exists inside the control panel. High voltage can cause severe injury or death. Use extreme care when working inside the control panel. 3. Open the control panel. 4. Measure the voltage between the incoming side (wire 21) of the rewind switch (a) and N1 of the main terminal strip. Is VAC measured? Continue. The wiring between fuse 1 and the rewind switch has failed. Disconnect the power supplies and repair the wiring. 5. With the rewind switch still in the OFF position, measure the voltage between terminal/wire 6 on the outgoing side of the rewind switch and N1 of the main terminal strip. Is VAC measured? The rewind switch has failed. Disconnect the power supplies and replace the rewind switch. Continue. This procedure continues on the next page. ghi_tx001026gb.fm 73

74 Rewind System S 3000 Continued from the previous page. 6. Place the rewind switch in the ON position. 7. Measure the voltage between terminal/wire 6 on the outgoing side of the rewind switch and N1 of the main terminal strip. Is VAC measured? The rewind switch is OK. The rewind switch has failed. Disconnect the power supplies and replace the rewind switch. The rewind switch has now been checked. If the rewind system still does not function, see Section 7.7 Checking the Rewind Clutch (Solenoid). ghi_tx001026gb.fm 74

75 S 3000 Rewind System 7.7 Checking the Rewind Clutch (Solenoid) Prerequisites Power components check OK Fuse 1 checks OK Fuse 2 checks OK Procedure Follow the procedure below to check the rewind clutch solenoid. 1. Open the control panel. WARNING Electric shock hazard. High voltage exists inside the control panel. High voltage can cause severe injury or death. Use extreme care when working inside the control panel. 2. Place circuit breaker 1 in the ON position. 3. Step on (or close) the foot switch and measure the DC voltage between terminals 15 and 16. Is VDC measured? Continue. One of the following components has failed: rewind transformer, rectifier, or foot switch. 4. Place circuit breaker 1 in the OFF position. 5. Measure the resistance across terminal 15 and terminal 16. Is ohms measured? The rewind clutch solenoid is OK. The rewind clutch solenoid has failed; replace it. The rewind clutch solenoid has now been checked. If the rewind system still does not function, see section 7.8 Checking the Rewind Motor. ghi_tx001026gb.fm 75

76 Rewind System S Checking the Rewind Motor Prerequisites Power components check OK Rewind switch checks OK Procedure Follow the procedure below to check the rewind motor. 1. Start this test with circuit breaker 1 in the OFF position. 2. Locate the rewind motor (a). Note: Graphic for reference only; your machine may differ from that shown. This procedure continues on the next page. ghi_tx001026gb.fm 76

77 S 3000 Rewind System Continued from the previous page. WARNING Electric shock hazard. High voltage exists inside the rewind motor. High voltage can cause severe injury or death. Use extreme care when working inside the rewind motor. 3. Remove the cover (b) of the rewind motor in question. 4. Disconnect white wire Place circuit breaker 1 in the ON position. 6. Place the rewind switch in the ON position. 7. Measure the voltage between black wire 6 and N1 of the terminal strip. Is VAC measured? Continue. The wiring between the rewind switch and the rewind motor has failed. Disconnect the power supplies and repair the wiring. 8. Measure the voltage between black wire 6 and white wire 2. Is VAC measured? The rewind motor has failed. Disconnect the power supplies and replace the rewind motor. White wire 2 has failed. Disconnect the power supplies and repair white wire 2. The rewind motor has now been checked. Re-assemble the machine. ghi_tx001026gb.fm 77

78 Rewind System S Checking the Rewind System Mechanical Components Prerequisites Power supplies disconnected Machine cool Procedure Follow the procedure below to check the rewind system mechanical components. WARNING Pinching/crushing hazard. Moving parts of the rewind system can pinch or crush. Disconnect the power supplies before checking the mechanical components. 1. Remove the chain guard (a) or side panels to access the system. 2. Inspect all the mechanical components: chain, gears, keys, bearings, etc. 3. Replace all damaged or missing components. ghi_tx001026gb.fm 78

79 S 3000 Miscellaneous Components 8 Miscellaneous Components 8.1 Checking an Indicator Light Prerequisites Power components check OK K3 relay checks OK Procedure Follow the procedure below to check an indicator light. 1. Start this test with circuit breaker 1 and circuit breaker 2 in the OFF position. 2. Simulate a burner fault by removing the cad cell from burner. 3. Place the burner switch in the ON position. WARNING Electric shock hazard. High voltage exists inside the control panel. High voltage can cause severe injury or death. Use extreme care when working inside the control panel. 4. Open the control panel. 5. Locate the indicator light to be tested. 6. Simulate a low level fault by placing only circuit breaker 1 in the ON position. Do the indicator lights illuminate? The indicator lights are OK. Continue. 7. Measure the voltage between the incoming side (black wire 27 or 29) of the indicator light and N1. Is VAC measured? Continue. The wiring to the indicator light has failed. Disconnect the power supplies and repair the wiring. 8. Check the resistance (continuity) of the white wire back to the terminal strip. Does the white wire have continuity? The indicator light has failed. Disconnect the power supplies and replace the indicator light. Disconnect the power supplies and repair the wiring. The indicator light has now been checked. Re-assemble the machine. ghi_tx001027gb.fm 79

80 Miscellaneous Components S Checking the Fuel Prewarmer Prerequisites Power components check OK Heating system fundamental components check OK Procedure Follow the procedure below to check the fuel prewarmer. 1. Remove the primary control by loosening screws (c). 2. Loosen tabs (b) and hinge back the igniter plate cover. 3. Disconnect the fuel prewarmer. 4. Measure the resistance of the fuel prewarmer at the connector (d). Is ohms measured? Continue. The fuel prewarmer has failed. Disconnect the power supplies and replace the prewarmer. This procedure continues on the next page. ghi_tx001027gb.fm 80

81 S 3000 Miscellaneous Components Continued from the previous page. 5. Place circuit breakers 1 and circuit breaker 2 in the ON position. WARNING Electric shock hazard. High voltage exists on the fuel prewarmer when the burner switch is in the ON position. High voltage can cause severe injury or death. Use extreme care when working on the fuel prewarmer. 6. Place the burner switch in the ON position. 7. Measure the voltage between the two wires of the connector (e). Is VAC measured? The fuel prewarmer is OK. The wiring to the fuel prewarmer has failed. Disconnect the power supplies and replace the wiring. The procedure to check the fuel prewarmer is now complete. ghi_tx001027gb.fm 81

82 Miscellaneous Components S 3000 ghi_tx001027gb.fm 82

83 S 3000 Burner Setup 9 Burner Setup Factory settings Head Firing rate L/hr (gph) Nozzle size Fuel pressure bar (psi) Air band setting Air shutter F (2.0) B 10.0 (145) 4 0 Background The burner consists of several different components and subsystems. Each of these components or subsystems must be operating correctly for the burner to function properly. Fuel Low ambient temperatures cause diesel fuels to gel. Gelled fuels will cause burner ignition failure and/or burner fuel pump damage. Always use the proper fuel for the conditions. Lowest expected ambient temperature F ( C) Below 5 (-15) 5 to 25 (-15 to -4) Above 25 (-4) Fuel Blend Guide Generator powered blend of #2 diesel and #1 diesel, plus additives OR blend #2 diesel and K1 kerosene, plus additives Shore powered 100% #1 diesel plus additives OR 100% K1 kerosene, plus additives blend of #2 diesel and #1 diesel, plus additives OR blend of #2 diesel and K1 kerosene, plus additives Winter-blend diesel Tools required The following tools are required to adjust the burner: High-quality combustion analyzer Smoke spot tester Fuel pressure test gauge General hand tools Mandates Adjustments made shall be done so that the machine conforms to the requirements of local, state, and federal codes and authorities. Adjustments shall be made at the job site. This procedure continues on the next page. ghi_tx001176gb.fm 83

84 Burner Setup S 3000 Continued from the previous page. When Procedure Adjust the burner: Before operating the machine at elevations 305 m (1,000 ft) above or below the location of where the last adjustments were made. Before starting at a new job site. After any burner maintenance or repair has been performed. If burner performance is in question. Follow the procedures below to set up the burner. 1. Shut down the machine. 2. Set the burner electrodes. (See Section 9.1 Setting/Checking the Electrodes on page 89.) 3. Check the burner nozzle. (See Section 9.2 Replacing the Burner Nozzle on page 91.) 4. Check/set the Z distance. (See Section 9.3 Setting the Z Distance ( F head) on page 94.) 5. Set the air settings. (See Section 9.4 Adjusting the Air Settings on page 96.) 6. Start the machine and the burner. 7. Check/set the fuel pressure. (See Section 9.5 Setting the Fuel Pressure on page 97.) 8. Conduct a smoke spot test. Follow the smoke spot tester manufacturer s instructions and the general guidelines below. Use the access hole in the exhaust stack. Several samples should be taken as the heater warms. The final sample should be taken just before the heater reaches 71 C (160 F). This procedure continues on the next page. ghi_tx001176gb.fm 84

85 S 3000 Continued from the previous page. Burner Setup 9. Analyze the combustion. Follow the combustion analyzer manufacturer s instructions and the general guidelines below. Use the access hole in the exhaust stack. Take several samples as the heater warms. Take the final sample just before the heater reaches 71 C (160 F). 10.Re-adjust the air setting(s) if necessary until the smoke spot test and combustion analysis are within the following parameters: O 2 content: 4 6% Smoke spot: 1 or less Result You have now setup the burner. Background Fuel The burner consists of several different components and subsystems. Each of these components or subsystems must be operating correctly for the burner to function properly. Low ambient temperatures cause diesel fuels to gel. Gelled fuels will cause burner ignition failure and/or burner fuel pump damage. Always use the proper fuel for the conditions. Lowest expected ambient temperature F ( C) Below 5 (-15) 5 to 25 (-15 to -4) Fuel Blend Guide Generator powered blend of #2 diesel and #1 diesel, plus additives OR blend #2 diesel and K1 kerosene, plus additives Shore powered 100% #1 diesel plus additives OR 100% K1 kerosene, plus additives blend of #2 diesel and #1 diesel, plus additives OR blend of #2 diesel and K1 kerosene, plus additives ghi_tx001176gb.fm 85

86 Burner Setup S 3000 Fuel Blend Guide Above 25 (-4) Winter-blend diesel Tools required The following tools are required to adjust the burner: High-quality combustion analyzer Smoke spot tester Fuel pressure test gauge General hand tools Mandates Adjustments made shall be done so that the machine conforms to the requirements of local, state, and federal codes and authorities. Adjustments shall be made at the job site. This procedure continues on the next page. ghi_tx001176gb.fm 86

87 S 3000 Continued from the previous page. Burner Setup When Procedure Adjust the burner: Before operating the machine at elevations 305 m (1,000 ft) above or below the location of where the last adjustments were made. Before starting at a new job site. After any burner maintenance or repair has been performed. If burner performance is in question. Follow the procedures below to set up the burner. 1. Shut down the machine. 2. Set the burner electrodes. (See Section 9.2 Setting/Checking the Electrodes on page 99.) 3. Check the burner nozzle. (See Section 9.3 Checking/Replacing the Nozzle on page 101.) 4. Check/set the Z distance. (See Section 9.4 Setting the Z Distance ( L head) on page 104.) or (See Section 9.5 Setting the Z Distance ( F head) on page 105.) 5. Set the air settings. (See Section 9.6 Adjusting the Air Settings on page 107.) 6. Start the machine and the burner. 7. Check/set the fuel pressure. (See Section 9.7 Setting the Fuel Pressure on page 108.) 8. Conduct a smoke spot test. Follow the smoke spot tester manufacturer s instructions and the general guidelines below. Use the access hole in the exhaust stack. Several samples should be taken as the heater warms. The final sample should be taken just before the heater reaches 71 C (160 F). This procedure continues on the next page. ghi_tx001176gb.fm 87

88 Burner Setup S 3000 Continued from the previous page. 9. Analyze the combustion. Follow the combustion analyzer manufacturer s instructions and the general guidelines below. Use the access hole in the exhaust stack. Take several samples as the heater warms. Take the final sample just before the heater reaches 71 C (160 F). 10.Re-adjust the air setting(s) if necessary until the smoke spot test and combustion analysis are within the following parameters: O 2 content: 4 6% Smoke spot: 1 or less Result You have now setup the burner. ghi_tx001176gb.fm 88

89 S Setting/Checking the Electrodes Burner Setup Prerequisites Power supplies disconnected Measuring device Procedure Follow the procedure below to check the electrodes. Note: Procedure shows the F head. 1. Disconnect the power supplies. 2. Remove the copper fuel line (a) between the fuel pump and the burner housing. Note: Only remove the fuel fitting closest to the burner housing. 3. Remove the knurl nut (b) that is seated against the escutcheon plate. NOTICE: Handle the knurled knob with care. It is easily damaged. 4. Loosen tabs (c) and hinge back the igniter cover.. 5. Disconnect the wiring to the electrode assembly. 6. Maneuver the electrode assembly (d) up and out of the burner. This procedure continues on the next page. ghi_tx001176gb.fm 89

90 Burner Setup S 3000 Continued from the previous page. 7. Use the measurements below to properly set the electrode tips on both the F and the L head. Note: Beckett also has special tools for measuring the Z distance: The Beckett Z gauge may be used on F heads. The Beckett T501 gauge may be used on both F and L heads. Ref. Description Gap distance h Electrode tip to electrode tip 5/32 in. (4 mm) i Nozzle center to electrode tip 5/16 in. (7.5 mm) j Nozzle end to electrode tip end 1/16 in. (1.5 mm) Result You have now checked/adjusted the electrodes. ghi_tx001176gb.fm 90

91 S Replacing the Burner Nozzle Burner Setup Prerequisites Power supplies disconnected Machine cool Removal Follow the procedure below to remove the burner nozzle. 1. Disconnect the power supplies. 2. Remove the copper fuel line (a) between the fuel pump and the burner housing. 3. Remove the knurl nut (b) that is seated against the escutcheon plate. Note: Handle the knurled knob with care. It is easily damaged. 4. Loosen tabs (c) and hinge back the igniter cover.. 5. Disconnect the preheater wiring. 6. Maneuver the electrode assembly (d) up and out of the burner. This procedure continues on the next page. ghi_tx001176gb.fm 91

92 Burner Setup S 3000 Continued from the previous page. 7. Unscrew the burner nozzle from the burner tube. The procedure to remove the burner nozzle is now complete. Installation Follow the procedure below to install the burner nozzle. 1. Thread the new burner nozzle into the burner tube. Note: Do not use thread sealant on the threads. 2. Position the igniter assembly (d) into the burner. 3. Connect the preheater wiring. 4. Close the igniter cover and secure it with tabs (c). This procedure continues on the next page. ghi_tx001176gb.fm 92

93 S 3000 Continued from the previous page. 5. Install the knurl nut (b) that is seated against the escutcheon plate. Note: Handle the knurled knob with care. It is easily damaged. Burner Setup 6. Install the copper fuel line (a) between the fuel pump and the burner housing. Result You have now replaced the nozzle. ghi_tx001176gb.fm 93

94 Burner Setup S Setting the Z Distance ( F head) Prerequisites Burner removed from the machine T501 gauge or Z gauge Procedure Follow the procedure below to set the Z distance on F-style heads. 1. Remove the burner from the machine. 2. Loosen the knurled nut (b). 3. Loosen the position locking screw (e). 4. Set the Z distance by using one of the three following methods: using Beckett T501 gauge, by measuring, or using Beckett Z gauge. Beckett T501 gauge Using the Beckett T501 gauge. a. Position the gauge into the flame retention head as shown. b. Slide the nozzle assembly so that the front face of the burner nozzle touches the T501 gauge. c. Tighten the position locking screw. d. Tighten the knurled nut. e. Mark the escutcheon plate for later reference. See step 5. This procedure continues on the next page. ghi_tx001176gb.fm 94

95 S 3000 Measuring Continued from the previous page. Measuring the Z distance. a. Place a straight edge over the end of the flame retention head. Burner Setup b. Adjust the nozzle assembly until the distance between the front face of the burner nozzle and the end of the head measures 1-1/8 inches (28 mm). c. Tighten the position locking screw (e). d. Tighten the knurled nut. f. Mark the escutcheon plate for later reference. See step 5. Beckett Z gauge The Beckett Z gauge may also be used. Refer to the Beckett instructions for detailed information. x 5. Mark (x) the escutcheon plate for later reference. Result You have now set the Z distance. ghi_tx001176gb.fm 95

96 Burner Setup S Adjusting the Air Settings Background There are two parts to the adjusting the air setting: 1) air band; and 2) air shutter. Adjust the air band to make large adjustments. Adjust the air shutter to make small adjustments. Affects The air setting has the following effect on combustion. Higher O 2 percentage (excess air settings) lowers soot production but raises stack temperature and reduces efficiency: lean mixture. Lower O 2 percentage (inadequate air settings) increases efficiency and lowers stack temperature but may cause soot build-up: rich mixture. Procedure Follow the procedure below to adjust the air settings. 1. Initial setting of the air damper should be performed with the machine shut down. 2. Loosen the air band locking screw (a) and the air shutter locking screw (b). 3. Using the band position pointer (c) to determine position, move the air band to a higher number to increase air volume. Turn it to a lower number to decrease air volume. 4. Using the shutter position pointer (d) to determine position, move the air shutter to a higher number on the shutter position pointer to increase air volume. Turn it to a lower number to decrease air volume. 5. After the air settings have been made, tighten the band-locking screw (a) and the shutter-locking screw (b). Result You have now adjusted the air settings. ghi_tx001176gb.fm 96

97 S 3000 Burner Setup 9.5 Setting the Fuel Pressure Factory setting Factory settings: F head: 145 psig (10.0 bar) L head: 180 psig (12.4 bar) Procedure Follow the procedure below to check and adjust the fuel pressure. 1. Shut down the machine. 2. Remove the bleeder valve (a) from the fuel pump. 3. Insert the gauge in place of the bleeder valve. 4. If your machine has a generator, start it. 5. Turn the control switch to HEAT. The burner will go through a pre-purge cycle. Monitor and make adjustments during the pre-purge cycle. 6. Turn the adjusting screw (b) clockwise to increase fuel pressure, counterclockwise to decrease fuel pressure. Result You have now adjusted the fuel pressure. ghi_tx001176gb.fm 97

98 Disassembly and Assembly 10 Disassembly and Assembly 10.1 Tools Required for Disassembly/Assembly Procedures S 3000 Repair It is up to the mechanic to use common sense and good judgment in tool selection to reduce the risk of injury while repairing the machine. In cases where a special tool is required, the special tool is listed in the prerequisite section of the procedure. Before substituting another tool or procedure from those recommended in this manual, the mechanic must be satisfied that neither personal injury nor damage to the machine will result due to the substitution Information Regarding Replacement Parts The repair procedures contained in this manual do not include part numbers. For replacement parts information, refer to the Parts Book originally supplied with the machine. If the original Parts Book has been lost, a replacement may be ordered from Wacker Neuson Corporation. When ordering a replacement Parts Book, please list the model number, item number, revision level, and serial number of the machine. Parts Books are also available on the Wacker Neuson Corporation Web site. See Enter the site as a visitor Information Regarding Reference Numbers Repair procedures contain reference numbers enclosed in parentheses ( ). These numbers refer to the item numbers shown on the assembly drawings and other detailed drawings. They are included to aid the mechanic in identifying parts and assembling components. ghi_tx001028gb.fm 98

99 S 3000 Repair 10.4 Removing the Burner Disassembly and Assembly Prerequisites Power supplies disconnected Machine cool Procedure Follow the procedure below to remove the burner. 1. Disconnect the power supplies. 2. Disconnect fuel lines (a) at the quick-connects. 3. Remove the primary control (b) to expose the wiring. Label all the wires to assist in reconnecting. 4. Disconnect all wires coming from the snap switch cable (c). Note: The snap switch cable is a large black insulated wire that enters the electrical enclosure from the rear. 5. Disconnect all wires coming from the burner cable (d). Note: The burner cable is a large black insulated wire that enters the electrical enclosure from the left side. 6. Remove the screws that secure the burner to the machine and maneuver the burner from the machine. The procedure to remove the burner is now complete. ghi_tx001028gb.fm 99

100 Disassembly and Assembly S 3000 Repair 10.5 Installing the Burner Prerequisites Power supplies disconnected Machine cool Procedure Follow the procedure below to install the burner. 1. Position the burner inside the machine and secure it to the hydronic heater. 2. Connect fuel lines (a) at the quick-connects. 3. Install the primary control (b). 4. Connect all wires coming from the burner cable (d). 5. Connect all wires coming from the snap switch cable (c). The procedure to install the burner is now complete. ghi_tx001028gb.fm 100

101 S 3000 Repair 10.6 Replacing the Fuel Pump Disassembly and Assembly Prerequisites Machine shut down Burner removed from machine Removal Follow the procedure below to remove the fuel pump. 1. Remove the solenoid power cord (a). 2. Remove the copper fuel line (b). 3. Remove the pump mounting screws (c). Save them for later use. 4. Pull the pump away from the burner housing. This exposes the drive coupling (d). Save the drive coupling for later use. This procedure continues on the next page. ghi_tx001028gb.fm 101

102 Disassembly and Assembly Continued from the previous page. S 3000 Repair 5. Remove both fuel line assemblies and hose barbs (e) from the fuel pump. Save them for later use. 6. Remove the bypass plug (set screw) from the return port (f). Save it for later use. The procedure to remove the fuel pump is now complete. Installation Follow the procedure below to install the fuel pump. 1. Install the bypass plug (set screw) into the return port (f). NOTICE: To avoid damage to the fuel pump, the bypass plug must be installed. Re-use the bypass plug from the old fuel pump or use the bypass plug shipped with the new fuel pump. 2. Apply thread sealant to the hose barbs (e) and install the fuel line assemblies into the proper ports. Note: Install the fuel line with the attached fuel filter into the SUPPLY port. 3. Mount the new pump onto the burner housing. Take care to align the new pump shaft into the drive coupling. This procedure continues on the next page. ghi_tx001028gb.fm 102

103 S 3000 Repair Disassembly and Assembly Continued from the previous page. 4. Use the old screws (c) to secure the pump to the burner housing. 5. Reconnect the copper fuel line (b) onto the new pump. 6. Reconnect the existing solenoid power cord (a) onto the new pump. The procedure to replace the fuel pump is now complete. ghi_tx001028gb.fm 103

104 Disassembly and Assembly 10.7 Replacing the Burner Fan Motor S 3000 Repair Prerequisites Machine shut down Burner removed from machine Removal Follow the procedure below to remove the burner fan motor. 1. Remove the primary control by loosening screws (c). INTRPT/IGNITER BURNER/MOTOR L1 L2 L2 L2 L2 CAD CELL 2 LIMIT VALVE 2. Locate and remove the orange wire and white wire that power the burner fan motor from the primary control. 3. Pull the orange wire and white wire from the junction box. 4. Remove the burner fan motor assembly from the burner housing. Note: Be careful not to pull out the fuel pump coupling when removing the burner fan motor. This procedure continues on the next page. ghi_tx001028gb.fm 104

105 S 3000 Repair Disassembly and Assembly Continued from the previous page. 5. Loosen the set screw and remove the fan (a). Save the fan for reuse. The procedure to remove the burner fan motor is now complete. Installation Follow the procedure below to install the burner fan motor. 1. Install the fan (a) onto the burner fan motor shaft (tighten the set screw onto the flat of the shaft). 2. Install the burner fan motor assembly (b) to the burner housing. 3. Route the orange wire and the white wire into the junction box. 4. Connect the orange wire to the BURNER MOTOR terminal of the primary control. 5. Connect the white wire to the L2 terminal of the primary control. 6. Reconnect the primary control. The procedure to install the burner fan motor is now complete. ghi_tx001028gb.fm 105

106 Disassembly and Assembly 10.8 Replacing an HTF Pump S 3000 Repair Prerequisites Power supplies disconnected Machine cool Removal Follow the procedure below to remove the pump. 1. Disconnect the power supplies. 2. Disconnect the pump 1 quick-connect (a). 3. Close valve 2 (b) located between the hydronic heater and the fluid filter. 4. Loosen the female swivel fittings (c) that connect the discharge and supply lines. 5. Remove the pump mounting bolts and remove the pump (d) from the motor adapter (f). This procedure continues on the next page. ghi_tx001028gb.fm 106

107 S 3000 Repair Continued from the previous page. Disassembly and Assembly 6. Remove the Lovejoy coupling (e) from the pump shaft. Save the Lovejoy coupling for reuse. The procedure to remove the pump is now complete. Installation Folow the procedure below to install the pump. 1. Install the old Lovejoy coupling (e) onto the shaft of the new pump. Make sure to tighten the set screw against the flat of the pump shaft. 2. Align the two halves of the Lovejoy coupling and install the new pump onto the motor adapter (f). This procedure continues on the next page. ghi_tx001028gb.fm 107

108 Disassembly and Assembly S 3000 Repair Continued from the previous page. 3. Use a 1-1/4" wrench to tighten the fittings (c) onto the new pump. 4. Open valve 2 (b). 5. Reconnect the pump 1 quick-connect (a). The procedure to replace the pump is now complete. ghi_tx001028gb.fm 108

109 S 3000 Repair Disassembly and Assembly 10.9 Changing a Turbulator/Cleaning a Turbulator Tube Prerequisites Machine shut down Machine cool Procedure Follow the procedure below to clean/change the turbulator tubes. 1. Allow the machine to cool. WARNING Burn hazard. The hydronic heater is very hot when the machine is operating. When hot it can cause severe burns. Allow the machine to cool before performing this procedure. 2. Remove the nuts (a) that secure the flue box door. 3. Open the flue box door (b). NOTICE: If the door panel insulation does not open with the door, carefully remove it from where it is caught on the bolts (c). 4. Locate the turbulators housed in the burner tubes. 5. Remove the turbulators (d) by pulling the turbulator tab. Replace any turbulator that is badly corroded. 6. Clean each burner tube with a bottle brush. 7. Vacuum out each burner tube. The procedure is now complete. Re-assemble the machine. ghi_tx001028gb.fm 109

110 Disassembly and Assembly Repairing a Hose S 3000 Repair Prerequisites Hose nipple Two hose ferrules Hose crimping tool part number Procedure Follow the procedure below to repair a damaged hose. 1. Shut down the machine and allow the Heat Transfer Fluid (HTF) to cool. 2. Locate the damaged portion of the hose and clamp locking pliers on either side of the damaged portion. 3. Cut away the damaged portion of the hose (a) using a utility knife or similar tool. 4. Install a ferrule (b) on either end of the freshly cut hose. 5. Install the nipple (c) into one of the hoses. NOTICE: Do not use petroleum to lubricate the nipple. If lubrication is needed, use HTF. 6. Install the nipple into the second hose with ferrule. Be sure to push each end of each hose to the lip of the nipple. This procedure continues on the next page. ghi_tx001028gb.fm 110

111 S 3000 Repair Disassembly and Assembly Continued from the previous page. 7. Use a Wacker Neuson brand hose crimper (e) to crimp both ferrules. The procedure is now complete. ghi_tx001028gb.fm 111

112 Disassembly and Assembly Changing/Cleaning the HTF Filter S 3000 Repair Prerequisites Machine shut down Machine cool Removal Follow the procedure below to remove the Heat Transfer Fluid (HTF) filter. 1. Shut down the machine and allow the HTF to cool. 2. Close valve 2 (a) and valve 3 (b). Note: HTF may spill when changing the filter. Do not allow the HTF to spill on the ground. Clean up spilled HTF immediately. Dispose of the HTF and soiled rags in accordance with local environmental regulations. 3. Remove the bolt (c) from the top of the filter head (d) and separate the filter head from the bowl (e). 4. Remove and inspect the filter (f) and the gaskets (g). Discard a damaged filter or gaskets. 5. If reusing the filter or gaskets, wash them thoroughly with tap water. The procedure to remove the filter is now complete. This procedure continues on the next page. ghi_tx001028gb.fm 112

113 S 3000 Repair Continued from the previous page. Disassembly and Assembly Installation Follow the procedure below to install the HTF filter. 1. Install gaskets (g) to the filter (f). 2. Place the filter and gaskets into the bowl (e). 3. Install the assembly using bolt (c). The procedure to change the HTF filter is now complete. ghi_tx001028gb.fm 113

114 Disassembly and Assembly Changing Low Level Probe S 3000 Repair Prerequisites Machine shut down Heat Transfer Fluid (HTF) drained Removal Follow the procedure below to remove the low-level probe. 1. Drain the HTF from the machine. See the Operator s Manual. 2. Open the side panel and locate the low-level shut-down device (a). Remove the cover from the low-level shut-down device. 3. Disconnect the wire (b) to the low-level probe. 4. Loosen the screws (c) that secure the low-level shut-down device. 5. Rotate the low-level shut-down device and pull it from the machine. This procedure continues on the next page. ghi_tx001028gb.fm 114

115 S 3000 Repair Disassembly and Assembly Continued from the previous page. 6. Unscrew the low-level probe and remove it from the hydronic heater. The procedure to remove the low-level probe is now complete. Installation Follow the procedure below to install the low-level probe. 1. Apply thread sealant to all but the first three threads of the low-level probe. 2. Screw the low-level probe into the hydronic heater. NOTICE: Use care when installing the low-level probe to avoid damaging it. 3. Align the two screws of the low-level probe so that they are level (horizontal to the ground). 4. Attach the low-level shut-down device to the low-level probe and tighten screws (c). 5. Re-install the wire to the low-level probe. 6. Re-install the cover to the low-level shut-down device. 7. Refill the machine with HTF. See the Operator s Manual. The procedure to replace the low-level probe is now complete. ghi_tx001028gb.fm 115

116 Disassembly and Assembly Replacing the Thermocouple S 3000 Repair Prerequisites Machine shut down Machine cool Removal Follow the procedure below to remove the thermocouple. 1. Remove the canister lid (a) from the thermocouple body. 2. Loosen the strain relief (b). 3. Disconnect the wiring (c). 4. Unscrew the thermocouple (d) from the well in the hydronic heater. The procedure to remove the thermocouple is now complete. Installation Follow the procedure below to install the thermocouple. 1. Screw the thermocouple (d) into the well of the hydronic heater. 2. Thread the wiring (c) through the strain relief and connect it to the thermocouple. 3. Tighten the strain relief (b). 4. Install the canister lid (a). The procedure to replace the thermocouple is now complete. ghi_tx001028gb.fm 116