Arcotherm EC 200 User manual

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DIESEL SPACE HEATER - SERVICE MANUAL
INDEX
1. CONTROLS AND COMPONENTS
2. FLAME CONTROL CYCLES
3. MAINTENANCE SCHEDULE
4. TROUBLESHOOTING GUIDE
5. REPAIR PROCEDURES
1. FAN MOTOR ASSEMBLY
2. FUEL FILTER ASSEMBLY
3. FUEL PUMP ASSEMBLY
4. ELECTRIC PANEL ASSEMBLY
5. AIR PRESSURE SWITCH
6. COMBUSTION HEAD ASSEMBLY
7. COMBUSTION CHAMBER
8. COMBUSTION TEST
6. WIRING DIAGRAMS
7. TECHNICAL SHEETS
EC 200 – EC 300
GE 360 – GE 400 – GE 600
L-S 102.01-BM
WARNING
The operations described in this booklet must be carried out by qualified and instructed personnel only.
Incorrect maintenance may result in improper operation and serious injury.

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1. CONTROLS AND COMPONENTS
INDIRECT HEATER WITH STACK:EC 200 –EC 300
DIRECT HEATER WITHOUT STACK:GE 360 –GE 400 –GE 600
CONTROL PANEL
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1 COMBUSTION CHAMBER
2 BURNER ASSEMBLY
3 NOZZLE
4 FUEL VALVE
5 DIESEL PUMP
6 MOTOR
7 FAN
8 FUEL FILTER
9 FUEL CIRCUIT
10 FUEL TANK
11 FUEL TANK PLUG
12 DRAIN PLUG
13 RESET BUTTON/LAMP OF
CONTROL FLAME
14 MAIN SWITCH
15 ROOM THERMOSTAT PLUG
16 CONTROL LAMP
17 POWER CORD
18 OVERHEAT THERMOSTAT
19 AIR PRESSURE SWITCH GAUGE
(LOW PRESSURE SIDE)
20 AIR PRESSURE SWITCH GAUGE
(HIGH PRESSURE SIDE)
21 FLAME DETECTOR (PHOTOCELL)
22 STACK
2 22 34 6 75
8
9
10 11
12
21
18 20 19
16
13 14 17
15
1 2 34 6 75
8
9
10 11
12
21
18 20 19

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CONTROL SYSTEM
The heater has all operational controls located in a watertight control panel mounted on the lateral side of the unit.
The control panel consists of:
a 3-position switch for heating function: normal operation, stop or thermostat operation
plug to connect a remote room thermostat
power cord
high voltage transformer that generates a spark to ignite the flame
control flame box to handle starting / running cycle (see paragraph 2.).
The control flame box is equipped with a reset
The control system utilizes:
a safety shut off switch that is a overheat thermostat shutting down the unit if the temperature of combustion
chamber and outlet air exceed the maximum allowed level
an air pressure switch, that stops the unit if the air flow is not sufficient for combustion.
a flame detector, that is a photocell monitoring constantly the flame presence and its integrity.
a pair of ignition rods to create the ignition spark
FUEL SYSTEM
The fuel system consists of:
fuel tank, that is steel, corrosion proof
The fuel tank hase a drain plug located underneath it to allow discharge of residual fuel before cleaning.
fuel filter
fuel pump. A screw fitted on the fuel pump allows the adjustment of fuel pressure setting
fuel ON/OFF solenoid valve
oduring normal operation the valve is open and the pressurized fuel flows to the nozzle, where it is
atomized, mixed with primary combustion air and ignited by the electrode spark
oduring abnormal operation (see paragraph 2.) the flame control unit closes the fuel solenoid valve and
the unit stops.
fuel circuit, including suction and return hoses from fuel tank to fuel pump and high pressure microhose from
fuel pump to nozzle
burner head
nozzle
COMBUSTION CHAMBER
For indirect heater it consists of:
the internal combustion chamber (stainless steel made) that containing the flames and
the external high efficient heat exchanger (aluminated steel made), that leads smokes to chimney / stack.
For direct heater it consists of the internal combustion chamber (stainless steel made) that containing the flames and
exhanges heat with the main airflow stream.
BURNER HEAD
The burner head is the assembly that determines the correct mixing of combustion air and fuel inside the combustion
chamber and it consists of:
Fuel nozzle
Nozzle support
Flame diffuser
Air opening baffle: a screw fitted on the burner head allows the adjustment of combustion air setting
Ignition electrodes
Flame detector
FAN – MOTOR ASSEMBLY
The electric motor drives the fuel pump assembly and a fan which blows air inside and around combustion chamber.

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2. FLAME CONTROL CYCLES
2.1 RESET LAMP LIGHT
During the operating condition, the reset button may have different type of light depending of its operating status
(FUNCTION LIGHT):
• flashing green: unit is in stand-by status, waiting for heating request.
• steady green light: unit is working normally (starting cycle or working cycle)
• flashing orange: presence of extraneous flame in stand-by status (waiting for heating request)
• flashing green / orange: presence of extraneous flame in prepurge time
• steady red light: the heater stops permanently in lock-out status and can restart only if reset button
is pressed.
To troubleshooting the unit when it is in lock-out condition, press the reset button for about 10
seconds and then release it. A diagnostic routine is enabled, causing the reset button on the main
board to flash (SELF-DIAGNOSIS LIGHT) with the following description
Number of
blinks Fault description
2 Flame failure in starting cycle
4 Extraneous light / flame in starting cycle
7 Flame failure in running cycle
8 - 14 Internal failure of electronic control
2.2 OPERATING CYCLES
Depending on the type of the operating cycles, the main components (room thermostat, fan, ignition transformer,
fuel valve) and controls element (photocell, reset button) are activated or de-activated according to specific rules
and times.
In the following diagrams are shown
Starting cycle
Shut off cycle
Flame failure in starting cycle
Extraneous light or flame during starting cycle
Flame failure in running cycle
The flame control unit starts the sequence of operation after a heating request (normal operation or thermostat
operation) and it consists of the following steps:

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Self-test (less than 3 s): self-check of electronics efficiency;
Purging time TP(20 seconds): fan motor and ignition transformer are simultaneously switched on while the fuel
valve remains closed to eliminate any fuel or unburnt residual.
During the purging stage, the flame signal is constantly monitored and any kind of failure leading to combustion
prevents the burner ignition causing the controls to lock out the unit.
In case of heating request opening (room thermostat opening), the control unit goes to stand-by position. The
device remains in this status till closing of the room thermostat;
Safety time (5 seconds): at the end of the purging time TP, the fuel valve is switched on and opens the fuel to
the nozzle.
In case of flame detection failure by the end of the TSsafety time, the control unit goes to lockout, and the fan
motor, the ignition transformer and the fuel valve are de-energized, while the lockout signal is enabled.
Otherwise, at the end of the TSsafety time the control unit disables the ignition transformer and goes to running
position.
At the end of the TS safety time the control unit keeps the ignition transformer operating for about 30 s.
When the heating request (normal operation or thermostat operation) opens:
fuel valve and ignition transformer are switched off and the flame lights off;
burner fan operates a 90 s post-purge ventilation
Restoring the heating request causes the post-purge to be interrupted and the starting cycle to be performed.
If during the safety time TS, the photocell monitors a flame failure (signal to photocell become lower than minimum),
at the end of safety time the unit tries to restart twice: should the flame failure being confirmed, then the unit goes in
lock out:

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burner fan, ignition transformer and fuel valve are de-energized;
alarm lamp on reset button becomes steady red
If troubleshooting on reset button is activated as described in 2.1, then the alarm lamp on reset button starts
flashing with 2 blinks.
FUNCTION LIGHT: steady red
SELF-DIAGNOSIS LIGHT: flashing red with 2 blinks
Unit can re-start only after pressing the reset button.
NOTE: While starting cycle is repeated, a cooling time TXP is required to get the ignition transformer be ready to
operate.
If during the pre-purge time the photocell monitors any residual flame then the unit goes in lock out:
burner fan stop to purging combustion chamber
fuel valve and ignition transformer are de-energized
reset lamp becomes steady red
If troubleshooting on reset button is activated as described in 2.1, then the alarm lamp on reset button starts
flashing with 4 blinks.
FUNCTION LIGHT: orange/green flashing then steady red
SELF-DIAGNOSIS LIGHT: flashing red with 4 blinks
Unit can re-start only after pressing the reset button.
In case of flame failure in running status, the flame control unit make one trial restarting the unit.
If the reason of flame failure is confirmed, then the unit stops in lock-out mode, and the reset lamp becomes steady
red.

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If troubleshooting on reset button is activated as described in 2.1, then the alarm lamp on reset button starts
flashing with 7 blinks.
FUNCTION LIGHT: steady red
SELF-DIAGNOSIS LIGHT: flashing red with 7 blinks
Unit can re-start only after pressing the reset button.

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3. MAINTENANCE SCHEDULE
Periodic maintenance of the heater is necessary to ensure proper performance and to prevent failures and it shall be
performed at the following periodic intervals:
Daily maintenance
i. Inspect air inlet / air outlet and exhaust stack, remove debris if any
ii. If any air duct is installed, secure it is fixed. Minimize bends and keeps ducts straight
iii. Verify fuel tank is full
iv. Verify that exhaust stack is properly installed
Weekly maintenance
i. Disassemble, inspect and clean fuel filter with clean fuel
ii. Remove top cover and clean the motor, fan blade and the interior shell
iii. Inspect the fuel hose assembly and check for any leaks
6 months maintenance
i. Disassemble burner head
1. Inspect and clean burner diffuser
2. Inspect and replace nozzle if necessary
3. Clean ignition electrodes and adjust settings
4. Check air combustion setting
ii. Check overheat thermostat
iii. Inspect and clean the combustion chamber
iv. Open electric board, inspect electrical components and check connections
v. Check fuel pressure setting of fuel pump
vi. Inspect and test the burner

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4. TROUBLESHOOTING GUIDE
PROBLEM RESET BUTTON (13) CAUSE REMEDY
• Check mains
• Check proper positioning and functioning of
switch
Off - • No electrical current
• Check fuse
• Wrong setting of room thermostat or
other control
• Check correct setting of heater control. If
thermostat, make sure selected temperature is
higher than room temperature
• Motor does not start, no
ignition
Flashing green -
• Defective thermostat or other control • Replace control device
• Voltage below 68 V • Check supply voltage: heater will restart
automatically when voltage exceeds 78 VFlashing
orange - • Voltage above 147V • Check supply voltage: heater will restart
automatically when voltage is below 138 V
• Fan does not start or stops
during start-up or heating Flashing
orange and
green - • Presence of extraneous flame in
prepurge time • Clean and eliminate diesel residue in combustion chamber
• Presence of flame before transformer
ignites • Clean and eliminate diesel residue in combustion chamber
4 blinks • Defective photocell • Replace photocell
• Defective electrical motor • Replace electrical motor
• Defective electrical motor bearings • Replace electrical motor bearings
• Burned out condenser • Replace condenser
• Check connection of H.T. wires to electrodes
and transformer
• Check electrodes setting (see scheme
“SETTING THE ELECTRODES”)
• Check electrodes for cleanliness
• Defective electric ignitor
• Replace H.T. transformer
• Defective flame control box • Replace control box
• Defective photocell • Clean or replace photocell
• Insufficient or no air to burner • Check fan motor
• Check air pressure switch and air pipes
connection
• Check state of motor-pump plastic coupling
• Check for any air infiltrations in the fuel line by
checking the air-tightness of the pipes and of the
filter.
• Insufficient or no fuel at burner
• Clean or replace oil nozzle
• Check electrical connection
• Check thermostat LI
2 blinks or 7
blinks
• Defective solenoid
• Defective electric ignitor • Clean solenoid valve and replace it if necessary
• Fan stops during start-up or
heating • Steady red
8 – 14 blinks • Internal error of electronic control board • Reset the device and attempt at least two starts. If the problem persists, replace the
electronic control board
• Check the position of the air regulation ring
• Insufficient combustion air • Clean burner disc
• Excess combustion air • Check the position of the air regulation ring
• Drain fuel in tank and load with clean fuel
• Fuel contaminated or contains water • Replace oil filter
• Air leaks in fuel circuit • Check the seals on the ducts
• Check pump pressure
• Insufficient fuel at burner • Clean or replace fuel nozzle
• Check pump pressure
• Fan starts and flame lights,
generating fumes • Off -
• Excess fuel at burner • Replace nozzle
• Heater does not stop
FUNCTION LIGHT
• Off
SELF-DIAGNOSIS LIGHT
- • Defective solenoid seal • Replace complete solenoid valve

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5. REPAIR PROCEDURES
WARNING
Before carrying out any maintenance operation the heater must be disconnected from power supply.
Refer to instruction manual to fully stop the heater. Therefore:
• Stop the machine as instructed
• Turn off the disconnecting switch on the main electric switchboard
• Wait until the heater has cooled.
Never service heater while it is plugged in, operating or hot.
Severe burns or electrical shock can occur.
1) FAN MOTOR ASSEMBLY
a) To clean the fan blades and motor, carry out the following procedure.
i) Remove the air inlet grille (a) by removing four screws that secure it to the machine.
ii) Remove the top cover access panel (b) by removing four screws
iii) Inspect and, if necessary, clean the motor using compressed air, being carefully not to direct the air jet to
the air pressure switch gauge (c) (the pressure switch could be damaged)
iv) Clean the fan blades using a stiff brush.
v) Reinstall the internal access panel.
vi) Reinstall the fan grille.
a
b
c