AI Trouble Shooting Guide - Superior Sauna & Steam

TROUBLE SHOOTING GUIDESAUNATEC AI-SERIES COMMERCIAL BOILERSSYMPTOM1.Boiler will notfill with water2.Boiler tankoverfills withwater. Note: Itmay benormal for thetank to overfillduring a autodrain cycleCONTROLPANEL LIGHTFeedwater Light"On" Low waterin site glassFeedwater Light"OFF" Low waterin site glassFeedwater Light"ON"Feedwater Light"Off"TEST #1(ROOM "Off")PROBABLE CAUSE ACTION TO BE TAKEN WHAT SHOULD HAPPENWater Supply "off"Clogged StrainerOrClogged Water inlet LineOrClogged Water Solenoid ValveWater Inlet Valve FaultyWater level probe calcified causinglow resistance condition. The ProbeAccess Cover is located on top of theboiler near the pressure relief valve.Water level probe/s calcified causinghigh resistance condition. - TheProbe Access Cover is located on topof the boiler near the pressure reliefvalve."H" Water level probe wire (red) isopenTank / Baffle ClogWater Inlet Valve faultyWater Pressure too high -i.e... over100psiTurn "On" water supplyClean StrainerOrClean Water inlet LineOrClean Water Solenoid ValveInspect valve assembly and replace valve ifnecessaryReplace Water Inlet ValveRemove wires from level probes & retestboiler, if tank fills clean or replace all levelprobesIf Tank does not fill, call Tech Support 800-331-0349Remove and clean level probesOrReplace level probesOhm out wire with both ends disconnected &replace wire if necessaryClean Tank and Baffle area (located on insideleft wall of tank)Call Amerec Tech Support at 800-331-0349 toorder Element Gasket kitInspect and clean valve assembly or replacevalveInstall Pressure Reducer in Water Supply LineIf problem not corrected, call Tech Support at800-331-0349Check Level Probe voltage (should be 0vac to1vac from top of probe to ground)Tank should fill to(3/4 full in site glass)Tank should fill to (3/4 full in siteglass)No Water should enter Tank3.Boiler will notproducesteampressureBoiler Heating Lightnot "On"Water level probe/s calcified causinghigh resistance condition. - TheProbe Access Cover is located on topof the boiler near the pressure reliefvalve.Honeywell Pressure switch trippedIf voltage is correctCall Tech Support at 800-331-0349If voltage is incorrectClean or replace level probesCheck "L" (Red) & "M" (White) Probe wires forcontinuity, ohm out each wire with both endsdisconnected and replace wires if necessaryCall Tech Support at 800-331-0349Push red reset button on Honeywell pressureswitch. If pressure switch continues to tripcall Tech Support at 800-331-0349All Contactors should close andprovide full line to line voltage toeach element and steam pressureshould be producedAsco Pressure Switch openCheck for 120vac to ground on each side ofPressure Switch(s) contactsIf voltage is correctCall Tech Support at 800-331-0349If voltage is incorrectClean or replace pressure switch & pressureswitch plumbing line4216-10 06-08-09 Page 2

TROUBLE SHOOTING GUIDESAUNATEC AI-SERIES COMMERCIAL BOILERSTurn All Power On !Check line to line voltage to each element onright side of contactor(s) contactsContactor(s) coil(s)OrContacts burned outIf proper Line to Line Voltage not presentthen replace contactor(s)If proper Line to Line voltage is present thensee Probable Cause Element FailureCall Tech Support at 800-331-0349Turn All power OffRemove contactor/element access coverlocated on Control Panel light/switch side ofBoiler and follow wiring diagramOhm out contactor coil(s). They should read90 ohms with black and white wiresconnected to both contactor coils or 180ohmsif only one coil connected. If boiler has 4contactors and all 4 coils are connected, ohmreading should read 45ohms.If coils do not ohm out properly then replaceappropriate contactor(s)Boiler Heating Light"On"Turn All Power OffElement(s) FailureRemove contactor/element access coverlocated on Control Panel light/switch side ofBoiler and follow wiring diagramOhm out elements. Ohm reading should rangefrom 5ohms to 60ohms depending on kw andvoltage rating of elementIf elements do not ohm out properly - Replaceelements4.BoilerOverheatsRoom withRoom Control"off"Steam ValveOpen Light "Off"Steam Valve stuck openInspect and clean valve assembly or replacevalveNo steam should enter room whenroom is off4216-10 06-08-09 Page 3

TROUBLE SHOOTING GUIDESAUNATEC AI-SERIES COMMERCIAL BOILERSControl Panel Set-up for Test #2 & Symptoms 5 thru 7 (Room "On")1) Boiler "On" Switch to the right / "Manual Run" position & Boiler "on" light illuminated2) All other switches to the left3) Thermostat turned "On" / L.E.D. illuminated4) Optional I60 pushed “On” / L.E.D. illuminatedSYMPTOM5.RoomOverheats6.Room Not HotEnough7.ExcessiveWater out ofSteamheadCONTROLPANEL LIGHTBoiler HeatingLight "On"Boiler HeatingLight "Off" AndSteam Valve(s)Open Light "OffBoiler HeatingLight "On" &Steam Valve(s)Open Light "On"Boiler HeatingLight "On" &Steam Valve(s)Open Light "On"TEST #2 / ROOM "On"PROBABLE CAUSE ACTION TO BE TAKEN WHAT SHOULD HAPPENSensor FailureThermostat FaultySensor FailureThermostat FaultyElement(s) FailureImproper Configuration of Steam LineFoaming inside boiler tankTurn All Power "Off"Disconnect Sensor Cable from PCA, Ohm outSensor Cable with Sensor still plugged intoother end of cableApproximate ohm readings: 100K @ 77deg.F;57K @100deg. F; 32K @ 125deg. FIf ohm readings are incorrectReplace Sensor or CableTurn All Power "Off"See Installation Instructions: Step 2.Thermostat Installation for proper wiringsequenceDisconnect Thermostat Cable from PCA, Ohmacross red and white wires of thermostatcable with thermostat still connected to otherend of cableApproximate ohm readings with thermostatdial in"Off" position: 9.8K ohms; "5" position: 5.5Kohms; "10" position: 5-10 ohms; "Max'position: 2-4 ohmsTurn All Power "Off"Disconnect Sensor Cable from PCA, Ohm outSensor Cable with Sensor still plugged intoother end of cableApproximate ohm readings: 100K @ 77deg.F;57K @100deg. F; 32K @ 125deg. FIf ohm readings are incorrect, Replace Sensoror CableSee Installation Instructions: Step 2.Thermostat Installation for proper wiringtermination.Disconnect Thermostat Cable from PCA, Ohmacross red and white wires of thermostatcable with thermostat still connected to otherend of cableApproximate ohm readings with thermostatdial in"Off" position: 9.8K ohms; "5" position: 5.5Kohms; "10" position: 5-10 ohms; "Max'position: 2-4 ohmsSee Symptom 3. Contactor and ElementFailureSee Installation Instructions: Step 2. InstallSteam LineSee Installation Instructions: Pages 17-19Blowdown/Drain/Flush TankRoom should heat to Set PointTemperature then Steam Valveshould close and remain closeduntil room temperature dropsapprox. 2 Deg. below Set PointTemperatureSteam should be dispersed fromsteam head without excessive water4216-10 06-08-09 Page 4