MPI KWH124 User manual

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MODEL
TM
InstantaneousKeroseneFiredWaterHeater
ServiceManual
MONITOR PRODUCTS
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CONTENTS
1. Specifications
1'3
2. SpecialPrecautions 4
3. OperationalProcedure. Fuel/lnstallation/Operation 5-9
4. Freeze-Proofing ofthe Piping 10
5. MaintenanceChecklist 11-12
6. VentingInstallation
6-1 Chimney Installation 13-14
6-2 Side Wall Installation 15-16
6-3 L Type/Vertical Venting 17-20
6-4 MPI Venting Kit& Accessories 21-25
7. Installation of FuelPipe 26-27
8.Hot& ColdWaterPlumbingWork 28-29
9. ElectricWiring 30
10. Test Run , 31
11. Operating Information
11-1 WorkingPrinciples32-33
11-2 PerformanceData 34
11-3 ErrorCode 34
11-4 RecommendedMaintenanceProcedure 35
12. Troubleshooting
A.) Guideline & CorrectiveMeasures 36
B.) ErrorCode - their possible causes and possible solutions 37-40
"4"/"5"/"67"7"/"8"/"9"/"H"/"P"
C.) Causes of troubles and irregularities which arenot reflected in MonitorIndicatorLamp
1.) Desirabletemperature ofhot water is unobtainable 41
2.)NOhot water.Burner does not ignite 42
3.) Powerlampdoes not light 42
4.) Strangesound in Combustion Burner/soot is produced/smell of kerosene ...... 43
5.) Smoke is coming offthe unit. Paint onthe exterior
has burned dueto excessheat. ... 44

13. FunctioningPartsData & Howto Check Them
1.) Burner & BurnerHead 45-46
2.) IgnitorTransformer ,
3.) Electrodes 4o
4.)Fan MotorUnit 49
5.) Water Governor 50
6.) MixingTank 50
7.) HeatExchanger 51
8.) Thermostat For Prevention of Overheating 52
9.) OverTemperatureFuse 55
11.) Air PressureSwitch 56
12.) FlowSensor57-58
13.)PrintedCircuitBoard 59
14.) ControlPanelBaseBoard 60
15.) ElectromagneticPumpUnit.BypassValve 61
16.) FlameSensor 62
17.) Nozzle
18.) PowerTransformer 6t
19.) FuelFilter 64
20.) Dismounting & Dismantling of Parts/Components 65
14. CapacityDataGraph66-69
15. ElectricSpecifications
A.) TimingSequenceGraph70-71
B.) Flowchart 72
C.) Wiring Diagram 73
D.) ResistanceValues 74
E.) VoltageValues onPCB Connector 75
F.) FailureMode and Effects 76
G.) CircuitBlockDiagram 77
16. SchematicDisassembly 78
17. ServicePartsList
18. Gauge 80-81

1 SPECIFICATION
1-1 SPECIFICATION
Model
Typ«
Combustion Type
Air Intake/Exhaust
Heating
Source of Water
Ignition
Fuel
Hot Water OUTPUT
Fuel Consumption(Max)
Efficiency
Capacity of HeatExchanger
MaximumPressure Applied
Minimum Water Flow to Activate Burner
Area of HeatTransmission
ExteriorDimensions
Weight
Voltage/Frequency
Rated:Ampere
(Rated PowerConsumption)
Flue Size(Diameter)
Exhaust Air Temperature
Nozzle
Quantity of Vapor
Spray Pattern
Spraying Angle
Temperature Fuse
ElectricCurrentFuse
Safety Devices
PipeConnection
Water Intake
Hot Water Outlet
Drain
Accessories(supplied)
Hot WaterOutlet(Maximum)
DegreeRise
KWH124
PressureVapor
Indoor/Forced Exhaust
Instantaneous
DirectConnection of MainSupply
High VoltageDischargeSpark
CrystalClean 1-K Kerosene
123.000 BTU/H
1.1GAL/H
86%*
1.057QT(1.0L)
150PSI
0.45 QAL/MIN
620 in2
35in(H) X 1 1 .8ln(W) X 20.9in(D)
88 Ibs.
AC 120V/60HZ
Ignition: 1.05A(127W)
Combustion: 1.00A(110W)
4 In.
482°F
0.85 GPH
Pattern A
60"
302°F
6A
* Safe Ignition * FlameSensor
* OverHeatProtector
' Air PressureSwitch
* SurgeAbsorber
3/4 NPT Male
3/4 NPT Male
1/2 NPT Mate
Fuel Filter
Water IntakeInsulator
Hot WaterOutlet Insulator
70°F Rise 210 GALTH
80° F 184
90° F 164
100° F 147
110°F 134
3.5 GA17MIN
3.07
2.73
2.45
2.23
(Maximum hot water supplied by this
unit Is about 221 GAL/H.)
if Thisrepresentsefficiencyunderlaboratory conditions. This efficiency rating can vary upto4%.
"SINCE WEARE CONSTANTLY IMPROVING OUR PRODUCTS, ALL SPECiRCATIONS ARE SUBJECT TO
CHANGE WITHOUT NOTICE"
1

1 SPECIFICATION
1-2 PARTS DESCRIPTION
• APPEARANCE
Hot WaterOutlet
Drain
CONTROL PANEL
Temperature
AdjustingKnob
CONSTRUCTION
Cold Water Intake
Fan Motor
Printedcircuit
Board
Hot Water Thermistor
Cold Water Intake
-Filter
ControlPanel
Front Door
Power Lamp
Power Switch
Maintenance
Cover
Fuel Filter
Connection
Junction
Box
Hot Water Outlet
Air Damper
Mixing Tank
Burner
Overheat ProtectorThermo
HeatExchanger
TemperatureFuse

1 SPECIFICATION
1-3 UNPACKING
Unpack unitcarefully.
The followingparts are contained inthe package.
Locate fuel filter andset aside touse whenconnecting the fuelline.
FuelFilter
Water IntakeInsulator
Hot Water OutletInsulator
NOTE: Theseparts are located inside the styrofoampacking atthetopofthe unit.
1-4 SECTIONDESIGNATIONS & MAINDIMENSIONS
DimensionalOutlineDrawing (Unit: Inches)
Hot WaterOutlet
VentConnector
6.13.1
Cold WaterIntake
Oil Filter Connection
=,
Drain
16.9
10.6 j_ 10.2
20.8
1.7 I 11,

2 SPECIALPRECAUTIONS
WARNING
Use onlycrystalclear 1 -K kerosene.Never use gasoline, whitegas,campfuel orother flammable liquids.
Use of suchfuels can result inan explosion and causesevereinjury.
A damaged or malfunctioningpartshould be discarded andbe replacedwith anew genuine service part.
All repairsshould be left to professionals.Contactyourlocalauthorizedservicedealer.
- CAUTION -
DO NOT STOREflammable liquids or materialssuch as gasoline near the unit.
Make surethat the flue is properlyinstalled and connected.
A separation inthe flueduring the operation ofthe unit can causethe release of exhaust gas into the room.
The consequencescould be dangerous.
Turn offthe unit in case ofan accident oran emergency.Staycalm anddonot panic.Justturn offthe
unit.
In case ofa fuelleak,exhaustfumes in home, nohot water.Turn off unit. Call an authorizedservice
person.
When using a shower,feel the temperature ofhot waterwithyourhand first, beforemovingyourselfunder
thehot water.
Avoid theuseof hardwater. In regionswherehardwater isthe onlysource,takeadvantage ofa water
softener.
This unit is only for indooruse.Avoid its exposure to rain or moisture.

3 OPERATIONALPROCEDURES
3-1 FUEL
FUELTYPE
Use only crystal clear Type 1-K Kerosene.
FUEL SUPPLY
Precaution -
No water or debrisshould be allowed to enter the fueltank.Whenthese twoare mixedwithfuel,imperfect
combustion can result thereby shortening the life ofthe burner.
1. Keep the tankfilter cap tight.
2. Donot allowtank torun empty.
If the KWH124 is allowed to operatewithout fuel, air must be purged inthe following manner:
a. Refillkerosenetank.
b. Allow 30 minutes after refilling to activate KWH124.
(Thisallowsfuel to settle.)
c. Makesuretankvent is open.
d. Openshut-offvalve on fueltank.
Loosen air purgescrew at fuel filter.
Discharge airoutofall channelsthroughwhichfuelruns.
e. Fill the bowl ofthe unitfuel filter withkerosene.
Fastenfuelpurgescrewback in original position.
Handle 0-Ring of fuelpurgescrewcarefully. A damaged 0-Ring can cause
fuel leakage and render unitinoperative. Don't misplace 0-Ring.
f. Wipe all fuelspills off thoroughly.
Fuel purge
screw

3 OPERATIONALPROCEDURES
3-2 INSTALLATION
.
THISUNITMUSTBE INSTALLED IN ACCORDANCE WITHTHESEINSTRUCTIONS. LOCAL CODE, OR-
DINANCE AND/OR INTHE ABSENCE OF LOCAL CODES, THE LATESTEDITION OFTHE NATIONAL
FIRE PROTECTIONASSOCIATION(NFPA31)CODE.
J
SELECTION OFTHE INSTALLATIONSITE:
Choose a suitablesitewithwater and electricalconnectionsreadilyaccessible. The followingshould be taken
into consideration in selecting the installationsite:
1. An indoorplacesheltered from weather.
2. A well-ventilatedplace(airintakeopeningsshould be provided).
3. Side,bottom andtop clearancecomplywith instructions and local codes.
4. A placewherethere areno combustiblematerialsnear the unit.
5. Suitable and non-combustiblefloor.
6. The fueltank is installed according to local codes.
7. The exhaust pipe is installed in accordancewith instructions.
8.If water starts leaking, measures must be taken so that it does not affectotherparts inthe same area
recommendedthat a drain panis placedunderneath the leaking point, until itcanbe repaired.
9.A place accessible for maintenanceafter the installation.
10. Noiseprevention -the unitdoesproducesome low noisewhen operating. Carefullyconsider the location
for the installation, if this is objectionable.
11. Unitmustalways be electrically grounded.
12. If unit istobe installed inan alcove ora closet, its clearanceshouldcomplywithinstructions.
13. Unitmust be level. Unitperformance is maintainedonlywhen itis installed level.
• PROHIBITEDINSTALLATIONS
Do not install the heater inthe followinglocations:
(a) In small, poorly ventilated rooms.
(b) In airtight rooms.
(c) Nearvents for heating or cooling.
(d) In placeswherespecialchemicals are used.
(e) In bathrooms, bedrooms orany occupiedroomsnormallykept closed.
(f) Ina locationwhere itmaybe exposed to freezingtemperatures.
(g) Ina locationwhereheater is subject to vibration.
Note:Checklocalcodes forany specialrequirementsconcerning the location ofa waterheater ina garage.
6

3 OPERATIONAL PROCEDURES
BEFORE THE INSTALLATION
Important safety.
1. Unitshould be raised off floor twoto fourinches to preventcontactwithcombustiblematerial and moisture
damage in case ofwet basements.
Use proper and suitablepatioblock,brick,concreteblock or similarnon-combustible material.
Combustible or
non-combustiblefloor
'/,
Non-combustible
floor only
Bad
FT-
\
2. Clearance from wall,ceilingshall be shown as "Standardclearance for installations."
3. Install an exhaustpipe in accordancewith the instructions.
4. Makesureproper air intake and ventilationopenings are provided.
a. Indoor air intake: 2 air intakeopeningsshould be provided each 150 sq.in.at minimum.
NOTE: Air openingswould be needed if unit is drawing airoutofan areasmallerthen 775 square feet.
STANDARDCLEARANCE FOR INSTALLATION
Make sure to keep a distancefromwalls of combustiblematerial.
From Left Side 7 in (180 mm)
From Right Side 19in. (505 mm)
From Back of Heater 8 in (205 mm)
Heater to ClosetDoor 29in (735 mm)
Flue pipe to CombustibleSurface,VerticallyChimneyInstallation 9 in. (229 mm)
Fluepipe to CombustibleSurface,HorizontallyChimneyInstallation 9 in. (229 mm)
Refer to page 16 for minimumclearance of FluePipe on SideWallVenting.
Pages 19and20forL Type and vertical installations.
Note:Largerspacemakesservice and maintenanceeasier.
Space for service and maintenanceshould be reserved.

3 OPERATIONALPROCEDURES
3-3 OPERATION
• ADJUSTMENT OF HOT WATER TEMPERATURES
a. Thermostat has been setat factory to about 104° F (LOW).
b. Slide "HotWaterTemperature Adjuster" knob up toward
"High" to raise water temperature. Slide knobdown
toward "Low" to reducetemperature.
c. Whenadjusting hot water temperaturewith not-cold water
mixingvalve,control the amount of cold water frommain
supplywithoutchanging the amount ofhot waterbeingsupplied.
if Knob at position "HIGH" provides hot water ata temper-
ature around 167°F.
Knob at position"MED"provides hot water ata temper-
ature around 130° F.
Knob at position"LOW"provides hot water ata temper-
ature around 104°F.
HIGH n
LOW LJ
MED.
WARNING
* Hightemperaturesettingincreases the risk of SCALDinjury.
* Households with small children or invalids may require a 120° For lower thermostat setting (to prevent
accidentalcontactwith"HOT"water.)
NOTE-
* Seasonalchange in temperature of waterfrommainwater supply results in different hot watertemperatures
supplied. Usehot watersupply tapto control hot watertemperature, or readjustthermostatsetting.
UNITSHUT OFF
1. Shut offhot water supply tapand burnerwillautomaticallyextinguish.
(Post purge fan will run approximately 150 secondsaftershutoff.)
2. Press and turn off "Power" whenunit isnot going tobe used foran extendedtime. "Power" lamp gof
8

3 OPERATIONALPROCEDURES
3-4 WARNINGS
BURNS
Don't touch the flue.
The flue reaches a high temperature.Protectyourselffrom potential burns.
WATER FOR DRINKING
The quality of waterfrom unit may changedepending on water being supplied from main, and deterioration of
piping material, scale, etc.
Never use waterthat has remained stagnant in heatexchanger and pipes for long periods as drinking water.Turn
water onfora couple of minutes before drinking.
SHOWER
Feeltemperature ofhot waterwithyourhandbeforeenteringshower stall.
KEEP DRAINVALVESHUTWHILEUNIT IS OPERATING
Openingdrainvalve while unit isin operation will overheat unit andcan result in possible heatexchangerdamage
and blowntemperaturefuses.
LIGHTNING
Lightning may cause a temporarypowersurge,which may damagesome electronic parts.Wherethere is
thunderstormactivity, install a surgeprotector in power circuit.
WHEN UNITWILL NOTBE USED FORAN EXTENDEDPERIOD OF TIME
TAKE THE FOLLOWINGMEASURES:
1. Closefuelsupplyvalve at fuel tank.
2. Turn"Power" switch off.
3. Purgewater from unit (See instructions on Page 10.)
9

4 FREEZE-PROOFING OFTHE PIPING
Freezingmust be anticipated, not only inthe northernstates, butin otherareas as well. Therefore,care must be taken
to ensure the lines,valves and unit donot freeze.
Water should notbe allowed to freeze inthe supply orhot waterpipes in winter. If waterfreezes inthe supply and
hot water supplypipes in winter, frozen pipes could rupture and leak.
Repairs to unitwithrupturedpipescould be costly.Suchdamages arenot covered bythe warranty. The following
preventive measuresshould be followed:
• RUNNING WATER
This methodwillhelp to prevent water from freezingthroughoutunit's systems including pipes for inlet water and
hot watersupplies as well as valves.
1. Turn"Power"switch on controlpanel tooff position.
2. Open ahot water tapand allow a stream to flow continuously at about. 1 gal/min. Be sure to checkthat water
continues torun during the periodthatfreezing may occur.
• PURGINGWATER
Thismethod is usefulwhen unit isnot going tobe used for extended periods of time.
1. Shut off electricalpower.Turn off water supplyvalve at unit.
2. Openfully allhot water faucets (including the shower).
3. Opendrainvalve of heatexchanger.
Open inlet waterscreen and release the pressure relief valve.
Allow water to drainfrominsideheatexchanger.
"CAUTION-
When turning on unit in cold weather,openwaterfaucet and makesurethatwatercomesout. If waterdoes
not run smoothly or does not come outat all,chances are water is frozen.Wait until waterstarts running
smoothly, and thenturnunit on.
10

5 MAINTENANCECHECKLIST
It is recommendedthat the unit is inspected and cleanedonce orsoa year to ensure its longlife,
• FLAMMABLES OR DUST
Keep thetopand vicinity of unit clean.
Keep flammables and dangerousitemsawayfrom unit.
• FUELLEAKAGE,SPILLS AND STAINS
Make sure all fuelconnections are tight andarenot leaking.
Any spills or stains by unitindicate a leak and must be corrected.
• FUELPIPESREPLACEMENT
Checkfuel pipes at least onea year for distortions and/or cracks.Contact authorized servicedealer for re-
placement of defective pipes.
• WATER IN FUELTANK
Water and dust can easily go intofuel tank. Afteraccumulating inthe tank, they may flowintoburner and
cause imperfectcombustion.Check if there isany water inthe tank at leastevery six months by checking
the fuelfiltercanister at tank.Have any waterremoved byan authorizedserviceperson.
• FLUE AND ITS VICINITY
Periodically, make sure thatthere areno flammablesaround and aboveflue.Also,makesureflue is properly
installed and maintained.
• CLEANING HEATEXCHANGER
Drainwaterfromheatexchanger at least onea year.
1. Shutwatersupplyvalve at main.
2. Open hot watersupplyfaucet.
3. Open drain valve at heatexchanger. Also, open inlet waterfilter and pressurereleasevalve.Then,drain
water fromheatexchanger.
• CLEANINGINLET WATER FILTER
Check onceeverythreemonths and removedebris \y/
Cold water intake
gathered in the inletwater filter. [Q/ inlet Water Filter
1. Shutwatersupplyvalve at main. S^T^"?^
2. Open hot watersupplyfaucet.
3. Open drain valve at heatexchanger.
Then,removeinletwater filter and wash and clean it.
CAUTION
If lime has accumulated,remove it with a commercialcompound for dissolvinglime.Check water soften-
ing equipment if lime is found inthe filter.
11

5 MAINTENANCECHECKLIST
CLEANING FUELFILTER
To be done by authorizedserviceperson.Check at least
every six months toseeif debris and/or water has
gathered in fuelfilter.
1. Shutfuelsupplyvalve on fueltank.
Turn cup counterclockwise to remove it from the
assembly. Dumpwater and debrisfromcup.
2. Pull off element. Clean it withkerosene.
3. Reassemblefuelfilter.
Purge air fromfuel fitter.
EXCESSIVE PRESSURERELIEF VALVE
Once a year,makesurethat the pressure relief valve (installed on water supply piping) is functioning.
12

6 VENTINGINSTALLATION
6-1 CHIMNEYINSTALLATION
• FITTING THE FLUE
IMPORTANT'
THISUNITREQUIRES A DRAFT (AT FLUECONNECTION OFTHE UNIT) OF -2mmH20 to -5mmH20 TO
OPERATE NORMALLY.
Use fluepipes of4" inside diameter.
Note: Itmaybe necessary to install a Draft Regulator inthe flue to obtain the recommended operating draft.
\ \ \ \ \\\\\\v\\ \ \ \ \ \ \ V \_ \ A A
9"MIN
FromCombustible
Material
Pitch Flue1/4"
Per FootUpward
9" MIN
10' MAX _
Overall Length
11 Of Flue Pipe
1/2'
MAX
Chimney Installation Example.
13

6 VENTINGINSTALLATION
• GUIDELINE FOR ATTACHING THE FLUE
1. Donot make any changes tothe diameter ofthe flue piping.
2. Use durablematerials forthe fluesuch as doublewall pipes withstainlesssteel.
3. Seal the connections ofthe flue.
4. Ensurethatminimumdistances aremet betweenflue piping and walls and ceiling.
5. Double wall, L-typefluepipes are recommended to preventinjury or bums, if there is contact with flue.
Chimney Connection
Check localcodes and ordinances.
IMPORTANT GUIDELINE>
1. The flue piping ofthe unit should beas short as possible, and pitch 1/4" per foot up towardchimney. Donot
exceed 10 feet overalllength of flue pipe.
2.Donotuse morethan two bends inthe piping.
Chimney penetration isnot considered a bend.
3.The piping, wheninserted into the chimney should not extend1/2"beyond the inside surface ofthe chimnr
The area around of flue piping should be sealedwhere it enters the chimney.Refer tothe drawing belt
Seal
1/2"
14

6 VENTINGINSTALLATION
6-2 SIDEWALL INSTALLATION
IMPORTANT
1. Use only MPI KWH Vent Kitand Accessories for SideWall, Vertical, L-TypeVenting.
2. Thisunitmust be installed in accordancewiththeseinstructions, local code, ordinanceand/or inthe
absence of local codes, the latestedition ofThe National FireProtectionAssociation(NFPA 31) code.
GUIDELINES FOR ATTACHING THE FLUE:
1. Donot make any changes tothe diameter ofthe flue piping.
2. Seal and lock the connections ofthe flue.
3. Useanendcapto protect the flue fromrain and wind coming in.
4. An insulatedwallthimble is required for inserting the fluethrough any combustiblematerial.
5. Ensurethatminimumdistances aremet betweenfluepipes and walls and ceilings.
6. Flue piping usedthrough the wall should be pitched down1/4" per foottoward outside. (SideWallVenting.)
15

6 VENTINGINSTALLATION
SIDEWALL VENTING-FITTING THE FLUE
IMPORTANT
ExtensionLimits ofthe Rue
Length ofthe Rue
10 feet
16 feet
Number of Bends
2
1
Note: Extensionlimits donot includepipeadaptorelbow andend cap.
INSTALLATION EXAMPLE (1) -1 BEND
Use Only MPI Venting Kit
(Model MPI-KWH Vent Kit) Material
3" (MIN)Clearance
From Combustible
9" (MIN)
Clearance
7" (MIN) __
Clearance
9" (MIN)
Clearance
Endcap
(Horizontal VentCap)
Wall thimble
-6"(MIN)Clearance
PitchFlue1/4"downward per foot
NOTE:
• Maintain 3" min. clearancearoundfluepipefrom any combustiblematerial.
• Maintain 9" min.clearancearound endcapand6" min.clearanceoutsidewall.
•Endcapisnot considered a bend. Inthe drawingshown above, the number of bends is one.
16

6 VENTINGINSTALLATION
INSTALLATIONEXAMPLE (2) - 2 BENDS
Vent Cap (Horizontal Vent cap)
Wall Thimble
Top View
Elbow
Elbow
Elbow
Pipe Adapter
Side View
D
Elbow
Wall Thimble
NOTE:
Maintain all min. clearancesstated in installation example (1).
Possible Applications - 2 bends.
(1)Up, across, and back
(2) Up, back, and across
(3) Back and across
(4) Across and back
Length variation may vary depending on place of installation. Length should not exceedextensionlimits and
no morethan 2 bends
17