Honeywell Series 4 Common problems and solutions, Symptom, Common Causes, Possible Corrections

AHE Series 4 Direct Vent Wall-Mounted Boilers — User’s Information Manual

Common problems and solutions

Symptom	Common Causes	Possible Corrections
Rapid cycling —	Thermostat installed where drafts	Locate thermostat on inner wall away from heat sources or cool
boiler turns on and	or heat affect reading	drafts.
off frequently
	Heat anticipator in thermostat	Adjust thermostat per manufacturer's instructions.
	adjusted incorrectly
	Incorrect limit setting	Set limit according to system needs. Maximum setting is 220˚F.
		Increase limit setting to decrease cycling.
	Insufficient water flow through	Check all valves to and from boiler. Return to proper setting.
	boiler
		Confirm circulator size.
Frequent release of	Expansion tank sized too small	Call qualified service technician to check expansion tank
water through relief		operation and size.
valve
	Flooded expansion tank	Call qualified service technician to check expansion tank
		operation.
	Inoperative limit control	Call qualified service technician to replace limit control.
Need to frequently	Leaks in boiler or piping	Have qualified service technician repair leaks at once to avoid
add makeup water		constant use of makeup water. Makeup water can cause
		mineral deposits which, in turn, can cause boiler section failure.
		Do not use petroleum-based stop-leak compounds.
Black water	Oxygen corrosion due to leaks in	Have qualified service technician repair at once. Keep pH of
condition	boiler and piping	water between 7.0 to 8.5.
Popping or	Mineral deposits in sections due	Call qualified service technician to de-lime boiler, if necessary.
percolating noise	to constant use of makeup water	In some cases, deposits will be too heavy to remove with de-
heard in boiler		liming procedures.
		Have qualified service technician repair leaks to eliminate need
		for constant makeup water.
	Incorrect pH of boiler water	Call qualified service technician to check pH level and correct.
		pH should be maintained between 7.0 to 8.5.
	Insufficient water flow through	Check all valves to and from boiler. Return to proper setting.
	boiler
		Confirm circulator size.
Metal flakes found in	Contaminated combustion air	Remove any contaminating products. See page 3 in this
vent outlet or vent —	supply — See page 4 in this	manual.
flueway corrosion	manual.
		Provide outside air for combustion. Kit available through Weil-
		McLain distributor. Have qualified service technician pipe-up kit.
	Condensation of combustion	Have qualified service technician inspect system piping and
	gases in boiler sections	controls to verify proper regulation of return water temperature.
Some radiators or	Air in system	Bleed air from system through air vents in radiators or
baseboard units do		baseboard units.
not heat or are noisy
	Low system pressure	Fill to correct pressure.
		Check for leaks in boiler or piping. Have qualified service
		technician repair at once.
	High limit set too low	Adjust high limit to higher setting.

Part number 550-141-893/0800 11