LAARS 9600 CB-HWG Service Manual
Service Manual Document 2109
Service Manual for
9600 CB & HWG
HWG-M2 Series CB-M2 Series
HWG-M2-250 CB-M2-250
HWG-M2-200 CB-M2-200
HWG-M2-175 CB-M2-175
HWG-M2-150 CB-M2-150
Hot Water Generator Condensing Boiler
For Natural or For Natural or
Propane Gas Propane Gas
FOR YOUR SAFETY: This product must be installed and serviced by a professional service technician,
qualified in hot water boiler installation and maintenance. Improper installation and/or operation could
create carbon monoxide gas in flue gases which could cause serious injury, property damage, or death.
Improper installation and/or operation will void the warranty.
WARNING
If the information in this manual is not followed exactly, a fire or explosion may result
causing property damage, personal injury or loss of life.
Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or
any other appliance.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone in your building.
• Immediately call your gas supplier from a nearby phone. Follow the gas supplier's
instructions.
• If you cannot reach your gas supplier, call the fire department.
Installation and service must be performed by a qualified installer, service agency, or gas
supplier.
Page 2
LAARS Heating Systems
TABLE OF CONTENTS
SECTION 1.
General Information
1A. Introduction...................................................3
1B. Start Up Procedures ..................................... 9
1C. Checkout Procedures...................................9
1D. Cleaning the Combustion Chamber Coil.... 10
1E. Diverting Valve........................................... 10
1F. Safety Limit Switch ..................................... 10
1G. Boiler Control .............................................. 10
1H. Stack Switch............................................... 11
1I. Igniter .......................................................... 11
1J. Transformer ................................................. 11
1K. Unit Pump ................................................... 11
1L. Blower ......................................................... 11
1M. Gas Valve ................................................... 11
1N. Time Delay Relay (TDR) .............................. 11
1O. Operating Control ........................................ 11
1P. Vent TCO .................................................... 12
1Q. Intake TCO .................................................. 12
1R. Thermal Cut-Out (TCO)................................ 12
1S. Delayed Ignition........................................... 12
1T . High Gas Consumption ............................... 12
1U. Noisy Operation .......................................... 12
1V. Short Cycling .............................................. 13
1W. Lock Outs (& Trip Outs) .............................. 1 3
1X. Routine De-Liming Procedure ...................... 14
1Y. Sequence of Operation ................................ 14
SECTION 2.
Troubleshooting
2A. Code ........................................................... 15
9600 CB & HWG Service Manual
Page 3
SECTION 1.
General Information
1A. Introduction
The Heatmaker 9600 CB condensing boilers and
the Heatmaker 9600 HWG non-automatic circulating
tank water heaters have a dual heat exchanger (H-X)
design. The primary H-X is a copper coil type which
operates in a non-condensing mode. A secondary
stainless steel H-X (economizer) surrounds the primary
H-X to condense water vapor from the flue gases and
extract the maximum amount of heat from the
combustion process. Condensate from the economizer
drains into the bottom of the outer shroud of the boiler
section and into the exhaust duct which provides for
condensate drainage.
Flow rates through the primary H-X are
controlled by a thermostatic diverting valve which
diverts water, as required, from the outlet of the
primary H-X back to its inlet so that the primary H-X
temperature is always maintained above the
condensation temperature of the water vapor in the flue
gases. A circulator is built into the unit to provide
enough head to circulate water through the H-X’s and
to a secondary heating loop or separate hot water
storage tank.
The forced draft premixed combustion system
contains a blower to provide air flow through the unit,
the air inlet and exhaust piping. The cylindrical burner
is provided with an air/gas mixture which is metered
through fixed orifices. A hot surface igniter (glow coil)
is controlled by the Integrated Boiler Control which
also controls the blower, circulator, and gas valve and
provides for burner flame safety.
The Heatmaker 9600 is designed to use 3" PVC*
or ABS DWV pipe or PVC, ABS or CPVC schedule
40 pipe for both air intake and flue material. Vent
terminations are provided with the unit.
* CB / HWG - M2- 250 flue material can only be ABS or CPVC.
(1) Diverting valve
(2) Circulator
(3) Mixer tube
(4) Exhaust
(5) Blower
(6) Gas valve
(7) Burner
(8) Economizer
(9) Combustion coil
(10) Cold water inlet
(11) Hot water outlet
(12) Heat exchanger drain
(13) Air vent
Figure 1. Heatmaker 9600 Assembly View.
Page 4
LAARS Heating Systems
A PORTION OF
HOT WATER
IS RECYCLED
TO MAINTAIN
COMBUSTION
COIL INLET
TEMPERATURE
AT 140°F
THERMOSTATIC
DIVERTING
VALVE
(160° F THERMOSTAT)
(E)
(D)
(B)
(A)
ECONOMIZER
(A) Cold Water Inlet From Tank or System
(B) Economizer Outlet (10°F Rise above inlet)
(C) Combustion Coil Inlet 130-140°F Typical
(D) Combustion Coil Outlet
(E) Hot Water Outlet To Tank or System 160 - 170°F Typical
Figure 2a. Water Flow through a Heatmaker 9600.
HWG - Before S/N 394 - 068
CB - Before S/N 795 - 0014
COMBUSTION
COIL
9600 CB & HWG Service Manual
Page 5
Legend
1 Mixing V alve
2 Internal Pump
3 Mixer Tube
4 Flue Outlet
5 Combustion Fan
6 Air Pressure Switch
7 Burner
8 Secondary Heat Exchanger
9 Primary Heat Exchanger
10 Return (From Primary Loop)
11 Gas V alve
12 Flow (T o Primary Loop)
A Secondary Heat Exchanger Inlet
B Secondary Heat Exchanger Outlet
C Primary Heat Exchanger Inlet
D Primary Heat Exchanger Outlet
Figure 2b. Water Flow through a Heatmaker 9600.
HWG - After S/N 394 - 067
CB - After S/N 795 - 0013
Page 6
LAARS Heating Systems
AIR
INTAKE
INTAKE
TERMINAL
EXHAUST
43
WALL
PLATE
50
EXHAUST
TERMINAL
44
WALL
PLATE
45
AIR
ORIFICE
GAS
ORIFICE
1
COMBUSTION
COIL
2
ECONOMIZER
7
FLAMEHOLDER
REFERENCE PAGE 8 FOR PART NUMBERS
Figure 3. Air/Fuel Flow Through Heatmaker 9600.
EXHAUST
46
ASSEMBLY
GAS
CONDENSATE
9600 CB & HWG Service Manual
Page 7
Figure 4. Cut Away View of Heatmaker 9600.
Figure 5. Control Box.
Page 8
31
OPERATING LIMIT
38
CIRCULATOR PUMP
CONTROL BOX
SUB-ASSY
HEATMAKER
9600
HIGH LIMIT
32
SAFETY
SWITCH BOX
LAARS Heating Systems
BLOWER
ASSEMBLY
BLOCKED
FLUE
DETECTOR
IGNITER ASSY
GAS VALVE
VENT
THERMAL
CUT OUT
INTAKE
THERMAL
CUT OUT
16
30
6
36
34
33
Figure 6. Control Components
# Part Description Part #
1 Combustion Coil (Primary H-X) HWG 2400-086
Combustion Coil (Primary H-X) CB 2400-284
2 Economizer Coil (Secondary H-X) 10-078
3 Upper Head 10-034
4 Inner Shroud 10-112
5 Outer Shroud 10-124
Ignitor (w/Gasket) after s/n 391-126
6
791-044
6 Ignitor, before s/n 391-127 791-045 2400-248
7 Burner (Flameholder) (w/Gaskets) 2400-082
Burner (w/Gaskets) (250 Series) 2400-308
8 Upper Insulation (Blanket) 10-048
9 Upper Insulation (Board) 10-050
10 Lower Insulation (Board) 10-106
11 Lower Insualtion (Blanket) 10-108
12 Gasket, Igniter (1 req'd) 10-332
13 Gasket, Burner (2 req'd) 10-338
14 Gasket, Blower Inlet (1 req'd) 1-254
15 Gasket, Blower Discharge (1 req'd) 10-324
Gasket, Blower Discharge (250 series) 11-066
16 Blower Assembly (w/Gaskets) 2400-079
Blower Assembly (w/Gaskets) (250) 2400-310
17 Orifice, Air *
18 Orifice, Gas *
19 Orifice Union 1-252
20 Mixer Tube 10-252
Mixer Tube (250 Series) 11-016
21 Air Duct Hose 1-458
Air Duct Hose (250 Series) 11-038
22 Gas Valve Balance Line 2400-026
*Not available separately - purchase orifice kit for type of gas
and input desired.
2400-286
THERMAL
CUT OUT
35
# Part Description Part #
23 Jacket, Front Removeable 10-402
24 Jacket, Top 10-406*
25 Jacket, Bottom 10-010
26 Control, Boiler Integrated 2400-224
27 Transformer, 40 VA 2400-006
28 Time Delay Relay 2400-062
29 Wiring Harness 10-354
30 Stack Switch 2400-110
31 Operating Control 2400-056
32 Safety Limit 2400-055
33 Intake T.C.O. 2400-058
34 Exhaust T.C.O. 2400-058
35 T.C.O. 2400-020
36 Gas Valve 2400-014
Gas Valve (250 Series) 2400-015
37 Capacitor (Blower Start/Run) 2400-088
Pump, Grundfos UP 26-99-BF CB
CB-250
38
HWG
HWG-250
39 Valve, Pressure Relief (150 PSI) 2400-094
Valve, Pressure Relief (250 Series) 2400-095
40 Valve, Pressure Relief (125 PSI) 2400-096
Valve, Pressure Relief (250 Series) 2400-097
41 Diverting Valve (Complete) 2400-001
Thermostat (O-Rings
included)(160°F)
42
before S/N 394-068 or 795-0014
Thermostat (O-Rings
included)(140°F)
before S/N 394-067 or 795-0013
43 Terminal, Intake 2400-102
44 Terminal, Exhaust 2400-104
45 Flange, Wall, Vent Pipe 2400-100
46 Exhaust Assembly 2400-390
Exhaust Assembly (250 Series) 2400-402
* Specify Serial Number
2400-386
2400-387
2400-388
2400-389
2400-129
2400-130
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