Coopra trouble shooting manual

EN

TROUBLE SHOOTING

Gas boilers: 80C 40C 30K 30B 30C 15B 15C

COOPRA Advanced Heating Technologies b.v. Vierlinghstraat 14

NL 3316 EL, Dordrecht Tel: +31 (0) 78 – 653 08 30 Fax: +31 (0) 78 – 653 08 33

2008 E000129004

Trouble shooting manual EN - E000129004

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Table of contents 1. Overall information 1.1. Overall view……………………………………..………………. 3 1.2. Hydraulic diagram 1.3. Nomenclature……………………………………….………….. 4 1.4. Cover removal 1.5. Emptying the main circuit 1.6. Emptying the d.h.w. circuit 1.7. Control panel 1.8. Condensate trap route…………………………………….. 5 2. Checks, servicing and replacement of components 2.1. Fan, gas valve and venturi assembly……….…….. 6 2.2. Burner……………………………………………………..………… 7 2.3. Pump 2.4. Main circuit pressure sensor……………………..…….. 8 2.5. Flow water temperature sensor 2.6. Return water temperature sensor……………….…. 9 2.7. D.h.w. heat exchanger sensor 2.8. Three-way diverter valve……………………………..….. 10 2.9. C.h. pressure relief valve…………………………….…… 12 2.10. Electronic control p.c.b. 2.11. Display 2.12. Glow plug and ionisation rod…………………………... 13 2.13. D.h.w. heat exchanger………………………………….... 13 3. FAULT FINDING Burner states Pump test (each boiler start) Temperature test (each boiler start) Pump monitoring (during operation)

System water pressure monitoring (operation) 3.1. Stand-by 3.2. Pre-rinse 3.3. Ignition 3.4. In operation 3.5. Post-rinse 3.6. Pump afterrun 3.7. Burner is on 3.8. Burner is off 3.9. Display 3.10. Blocking 3.11. Lock-out

3.12. STATUS INDICATIONS

All known indications listed: 1 ……………………………….….. flashing 1 ………………………………..…. continuous 1. …..(1+dot) ……...…. continuous 2 …………………...………....… flashing 2 ………………………………..…. continuous 2. …..(2+dot) ……..…. continuous 3 ……………………………………. flashing 4 ……………….…...........…… flashing 4 ………………..……………..…. continuous 4. …..(4+dot) …….….. continuous 5 ……………..…….…………….. flashing 6 ……………..….…………..…… flashing 7 ……………....…..........….. flashing 8 …………….….…………..……. flashing 9 …………….….…………….….. flashing 9 ……….………..…………..…… continuous A …..(large A) ……….… flashing A …..(large A) ……..…. continuous A/C. …..(large A/C+dot) continuous A/d. …..(large A/d+dot) continuous A/b. …..(large A/b+dot) continuous b/r …..(small b/r)…………..… continuous Chimney sweeper function C …..(large C) …….…… flashing C …..(large C) …….…… continuous d …..(small d) …………. continuous b …..(small b) ……...…. continuous J …..(large J) …….….. continuous (TWIN) C …..(large C) ……...... continuous (5x) C. …..(large C+dot) continuous d. …..(small d+dot) continuous b. …..(small b+dot) continuous c …..(small c) ……..….. continuous E …..(large E) ……..….. flashing E …..(large E) …………. continuous (TWIN) F …..(large F) …….…… flashing H …..(large H) ……..….. flashing H …..(large H) ……..….. continuous h …..(small h) ……..….. continuous nc …..(small nc) ……..….. continuous O …..(large O) ……….… flashing O …..(large O) ……….… continuous o …..(small o) ……….… continuous o. .....(small o+dot) ………. continuous P …..(large P) ……...…. continuous P …..(large P+pump test) continuous P …..(large P) …………….... continuous (2x) P/C. …..(large P/large C+dot) continuous P/d. …..(large P/small d+dot) continuous P/b. …..(large P/small b+dot) continuous U …..(large U) ……….… continuous


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Chapter 1: Overall information 1.1. Boiler types 80C, 40C, 30K, 30B, 30C, 15B, 15C Combi boiler 30K TWIN 80C 1.2. Hydraulic diagram of Combi boiler

Heating operation Hot water operation


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1.3. Nomenclature

Fig 2

1 Frame 2 Cover 3 Control panel 4 Control panel cover

1.4. Cover removal

Warning: isolate the boiler from the mains electricity supply before removing any covering or component. For all the checks and maintenance operations it is necessary to remove the cover. To remove the cover: 1. Turn the hexagonal nut F (fig 3) counter-clockwise and free the hook from the boiler frame.

Fig 3

2. Pull the bottom of the cover until the control panel is completely out of the cover, than lift the cover and free it from the hooks G (fig 4) placed on the top of the boiler. 3. Re-assemble in reverse order.

Fig 4 1.5. Emptying the main circuit 1. Open the heating flow and return valves. 2. Open the control valve used for the filling of the heating circuit drain cock and drain the boiler. 3. Drain completely the boiler by turning the knob of the fill and relief valve. 1.6. Emptying the direct hot water circuit Turn off the d.h.w. inlet isolating valve; turn on the hot water taps and any drain cocks. 1.7. Control panel

Warning: isolate the boiler from the mains electricity supply before removing any covering or component. To gain access to the parts located behind the control panel proceed as follows: 1 Remove the cover (section 1.3). 2 Remove the screw H (fig 5) and lower the control panel.

Fig 5

1

2

3

4


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To gain access to the parts located inside the control panel proceed with steps 1 and 2 than: 3 Remove the screws I (fig 6). 4 Remove the lid J 5 Re-assemble in reverse order.

Fig 6 1.8. Condensate trap route The plastic pipe K (fig 7) that connects the condensate collector with the condensate drain pipe has also the function of condensate trap. For this reason, if the pipe K needs to be removed during service operations, it is very important to re-install routing it as shown in figure 7.

Fig 7


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Chapter 2: Checks, servicing and replacement of components 2.1. Fan, gas valve and venturi assembly The function of the fan is to force the mixture of air and gas into the burner. The flow rate of the air-gas mixture and consequently the input power of the boiler is proportional to the speed of the fan that is controlled by the electronic control p.c.b. The venturi assembly A placed on the inlet port of the fan allows the mixing of gas and air in the right proportion. The gas-air ratio can be adjusted by the venturi screw B (fig 8).

Fig 8 F Removal of the assembly

Warning: isolate the boiler from the mains electricity supply before removing any covering or component. 1 Remove the cover (section 1.4. 2 Close the gas inlet valve. 3 Lower the control panel (section 1.7). 4 Disconnect the wirings from the fan C and gas valve D (fig 9). 5 Unscrew the Allen key screws E and separate the gas connection F from the gas valve. 6 Unscrew the Allen key screws G and the bracket H.

Fig 9 7 Remove the fan with the venturi assembly and the gas valve. 8 To separate the fan from the venturi assembly and gas valve unscrew the screws I (fig 10). 9 To separate the gas valve from the venturi assembly unscrew the screws J. 10 Re-assemble the parts following the removal procedures in the reverse order. Replacing the parts replace also the gaskets that ensure the gas circuit tightness. If the venturi assembly has been replaced, before to start the boiler ensure that the venturi screw B (Fig. 8) is completely tighten (clockwise) than carry out a complete adjustment as explained in the installation manual.

Warning: After cleaning or replacement as detailed above refer to section Combustion adjustment check in the chapter Commissioning of the installation instructions manual.

Fig. 10


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2.2. Burner F Removal of the burner assembly

Warning: isolate the boiler from the mains electricity supply before removing any covering or component. 1 Remove the cover (section 1.4 2 Close the gas inlet gas cock. 3 Remove the fan, gas valve and venturi assembly (section 2.1). 4 Remove the condensate connection pipe A (Fig. 11). 5 Unscrew the five Allen key screws B and lower the condensate collector C that holds the burner. 6 To remove the burner from the condensate collector unscrew the Allen Key screws D (Fig. 12). 7 Re- assemble the parts following the removal procedures in the reverse order.

Fig. 11

Fig 12

F Removal of internal turbulators To remove the turbulators placed inside the burner remove the burner as explained in the previous section and unscrew the screw E (Fig. 13).

Fig 13 Follow the indications given in Fig. 13 and Fig. 14 to re-assemble correctly the turbulators.

Fig 14 The disk 6 is thinner than the disk 1. All the spacers (3, 5, 7 and 9 in Fig. 14) have the same length.

Warning: After cleaning or replacement as detailed above refer to section Combustion adjustment check in the chapter Commissioning of the installation instructions manual. 2.3. Pump The pump has the function of making the water in the main circuit circulate through the main heat exchanger and therefore through the heating system (during the heating function) or through the d.h.w. heat exchanger (during the d.h.w. function). F Removal

Warning: isolate the boiler from the mains electricity supply before removing any covering or component. 1 Remove the cover (section 1.4) 2 Empty the main circuit (section 1.5) 3 Lower the control panel (section 1.7) 4 Disconnect the connector A (Fig. 15). 5 Unscrew the Allen screws B and remove the pump. 6 Re- assemble the parts following the removal procedures in the reverse order.

1

1

2

4

6

8

E

9 8 7 6 5 4 3 2 1 E


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Fig. 15 2.4. Main circuit pressure sensor The main circuit pressure sensor is connected to the outlet port of the pump and translates the pressure of the main circuit to an electrical signal. F Removal

Warning: isolate the boiler from the mains electricity supply before removing any covering or component. 1 Remove the cover (section 1.4) 2 Empty the main circuit (section 1.5 3 Lower the control panel (section 1.7 4 Disconnect the connector A (Fig. 16). 5 Unscrew the sensor B. 6 Re-assemble the parts following the removal procedures in the reverse order.

Fig. 16

2.5. Flow water temperature sensor The flow temperature sensor has the function of converting the temperature of the water flowing in the outlet pipe of the main heat exchanger into an electric signal (resistance). F Check

Warning: isolate the boiler from the mains electricity supply before removing any covering or component. 1 Remove the cover (section 1.4). 2 Disconnect the connectors A (Fig. 17). 3 Measure the resistance between the leads of the sensor. At a normal temperature of 25 °C the resistance should be about 12 kOhm. F Removal

Warning: isolate the boiler from the mains electricity supply before removing any covering or component. 1 Remove the cover (section 1.4). 2 Disconnect the connectors A (Fig. 17). 3 Remove the temperature sensor 4 Re-assemble the sensor following the removal procedures in the reverse order.

Fig. 17


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2.6. Return water temperature sensor The return temperature sensor has the function of converting the temperature of the water flowing in the inlet pipe of the main heat exchanger into an electric signal (resistance). F Check

Warning: isolate the boiler from the mains electricity supply before removing any covering or component. 1 Remove the cover (section 1.4). 2 Disconnect the connector A (Fig. 18). 3 Measure the resistance between the leads of the sensor. At a normal temperature of 25 °C the resistance should be about 12 kOhm. F Removal

Warning: isolate the boiler from the mains electricity supply before removing any covering or component. 1 Remove the cover (section 1.4). 2 Empty the main circuit (section 1.5) 3 Lower the control panel (section 1.7) 4 Disconnect the connector A (Fig. 18). 5 Unscrew and remove the temperature sensor. 6 Re-assemble the sensor following the removal procedures in the reverse order.

Fig. 18

2.7. D.h.w. heat exchanger temperature sensor The d.h.w. heat exchanger temperature sensor is placed in the domestic cold water inlet pipe of the exchanger. It has two functions: 1 when there is no d.h.w. draw off it senses the temperature of the exchanger and operates the boiler in order to keep the water at the desired temperature (d.h.w. hold temperature). 2 when there is d.h.w. draw off it senses the temperature change of the exchanger and operates the boiler in d.h.w. mode. F Removal

Warning: isolate the boiler from the mains electricity supply before removing any covering or component. The sensor is not in direct contact with the water so it isn’t necessary to empty the d.h.w. circuit. 1 Remove the cover (section 1.4) 2 Unscrew the screws A and move away the plate B (Fig. 19).

3 Disconnect the sensor from the control panel wiring. 4 Remove the holder spring C (Fig. 20) and extract the sensor. 5 Re-assemble the sensor following the removal procedures in the reverse order.

Fig. 20 Re-assembling the sensor use an adequate quantity of thermal conductive grease and insert the sensor in the jacket until it reaches the top.


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2.8. Three-way diverter valve The three-way valve has the function of modifying the hydraulic circuit of the boiler by means of an electric command given by the electronic control p.c.b. in order to send the water that comes from the heating system or from the d.h.w. heat exchanger towards the pump and the main heat exchanger.

Fig. 21 On the motor body an indicator is visible with which it is possible to know the position of the diverter valve. Fig. 21 and Fig. 22 indicate the relationship between the positions of the indicator A and the consequent hydraulic function.

Fig. 22 F Check of electrical completeness

Warning: isolate the boiler from the mains electricity supply before removing any covering or component. Fig. 23 demonstrates the relationship between the position of the indicator and the electrical resistance of the motor.

Fig. 23 If the valve is complete the resistance measured will be approx. 8 kOhm. F Removal of the motor

Warning: isolate the boiler from the mains electricity supply before removing any covering or component. 1 Remove the cover (section 1.4). 2 Release the electrical connector from the motor body. 3 Press the push-button B placed in the rear side of the motor body (Fig. 24) and rotate the motor anti-clockwise, releasing it from the hydraulic group.

Fig. 24 4 Reassemble the motor carrying out the removal operations in reverse order.

30K

30K

Heating position Hot water position

30K


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F Check the diverter mechanism

Warning: isolate the boiler from the mains electricity supply before removing any covering or component. 1 Remove the cover (section 1.4) and remove the three way valve motor (see section Removal of the motor). 2 Push the stem of the diverter mechanism (Fig. 25) checking that there are no mechanical impediments.

Fig. 25 F Removal of the diverter mechanism

Warning: isolate the boiler from the mains electricity supply before removing any covering or component. 1 Remove the cover (section 1.4) and remove the motor (see section Removal of the motor). 2 Empty the main circuit (section 1.5) 3 Unscrew the diverter mechanism D (Fig. 25) by means of the tool provided with the spare part and replace. 4 Re-assemble the mechanism carrying out the removal operations in reverse order. F Removal of the three way valve body

Warning: isolate the boiler from the mains electricity supply before removing any covering or component. 1 Remove the cover (section 1.4). 2 Empty the main circuit (section 1.5) 3 Lower the control panel (section 1.7) 4 Disconnect the wirings of the diverter valve, pump, return water temperature sensor and main circuit pressure sensor. 5 Disconnect the pipe E (fig 26). 6 Completely unscrew the connections F, G and H (Fig. 26) and remove the complete hydraulic group.

Fig. 26 7 Remove the motor (see section Removal of the motor). 8 Disconnect the pipe I and remove the automatic air vent J (Fig. 27). 9 Remove the pin K and remove the valve body L. 10 Re-assemble the parts carrying out the removal operations in reverse order.

Fig. 27

Type 30K

coopra


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2.9. Pressure relief valve F Removal

Warning: isolate the boiler from the mains electricity supply before removing any covering or component. 1 Remove the cover (section 1.4). 2 Empty the main circuit (section 1.5) 3 Lower the control panel (section 1.7) 4 By means of a suitable spanner unscrew and remove the valve A (Fig. 28). 5 Re-assemble the sensor following the removal procedures in the reverse order.

Fig. 28 2.10. Electronic control p.c.b. The fundamental function of the electronic control p.c.b. is that of controlling the boiler in relation to the external needs (i.e. heating the dwelling or heating the water for d.h.w. use) and operating in order to keep the room temperature and the domestic hot water to the desired value. This is obviously possible within the useful power and maximum working temperature limits foreseen. The electronic control p.c.b. does also a sequence of operations (ignition cycle) which lead to the ignition of the gas at the burner and checks the presence of the flame during the entire period in which it is activated Generally, the electronic control p.c.b. receives inlet in-formation coming from the boiler (the sensors) or from the outside (user settings, room thermostat, etc.), pro-cesses it and consequently acts with outlet commands on other components of the boiler.

F Removal

Warning: isolate the boiler from the mains electricity supply before removing any covering or component. 1 Remove the cover (section 1.4). 2 Lower the control panel (section 1.7) 3 Disconnect all the wirings connected to the p.c.b. 4 Unscrew the screws A (Fig. 29) and remove the electronic control p.c.b. 5 Re-assemble the electronic control p.c.b. carrying out the removal operations in reverse order.

Fig. 29 2.11. Display p.c.b. F Removal

Warning: isolate the boiler from the mains electricity supply before removing any covering or component. 1 Remove the cover (section 1.4). 2 Lower and open the control panel (section 1.7). 3 Remove the electronic control p.c.b. as explained in the section 2.10 4 Unscrew the screws A (Fig. 30) and remove the display p.c.b. 5 Re-assemble the display p.c.b. carrying out the removal operations in reverse order.

Fig. 30


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2.12. Glow plug and ionisation rod F Removal

Warning: isolate the boiler from the mains electricity supply before removing any covering or component. 1 Remove the cover (section 1.4). 2 Disconnect the connector A (glow plug) or B (ionisation rod) (Fig. 31). 3 To remove the glow plug unscrew the screw C. 4 To remove the ionisation rod unscrew the screws D. 5 Re-assemble the component carrying out the removal operations in reverse order.

Fig. 31 2.13. D.h.w. heat exchanger During a d.h.w. draw off the d.h.w heat exchanger allows the instantaneous transfer of heat from the main circuit to the water destined for d.h.w use. When there is no draw off, the exchanger works as a small d.h.w. tank and it is kept at the desired tempera-ture (d.h.w. hold temperature) by means of the electronic control system. F Removal

Warning: isolate the boiler from the mains electricity supply before removing any covering or component. 1 Remove the cover (section 1.4). 2 Empty the main circuit (section 1.5) 3 Empty the d.h.w. circuit (section 1.6) 4 Unscrew the screws A and move away the plate B (Fig. 32). 5 Remove the d.h.w. heat exchanger temperature sensor (section 2.7). 6 Unscrew the inlet and outlet domestic water connections C.

Fig. 32 7 Lower the control panel (section 1.7). 8 Disconnect the wirings of the diverter valve, pump, return water temperature sensor and main circuit pressure sensor. 9 Disconnect the pipe D (Fig. 33). 10 Completely unscrew the connections E, F and G (Fig. 33) and remove the complete hydraulic group. 11 Unscrew and remove the automatic air vent H.

Fig. 33 12 Move the lower part of the exchanger towards the front of the boiler and lower it until its top is free from the frame of the boiler. 13 Move the top of the exchanger towards the front of the boiler, lift and remove it. 14 Re-assemble the exchanger and the other parts carrying out the removal operations in reverse order.

Type 30K

Chapter 3: FAULT FINDING

Burner statestand-by pre-rinse/pre-heat glowpluignition in operation post-rinse pump afterrun stand-by

heat demand

fan

gas valve

glow plug

ionisation

pump0 sec 3 sec 7 sec 12 sec 22 sec end of heat demand

0 sec 6 secPump test program (each boiler start)At each new heat demand the pump is switched, the pre-rinse starts, the glowplug pre-heats, and the static water pressure is measured. After 3 seconds the pump is switched to high speed and the active water pressure is measured and stored in the software.If the difference between the active water pressure and the static water pressure is between 0.05 and 0.54 bar (0.64 bar for type 40 and TWIN) a correct water flow through the primary heat exchanger is present and the ignition time starts.

12 sec 22 secTemperature test (each boiler start)After ignition the water flow through the heat exchanger is secured by a temperature test of flow / return sensor. The temperature rise between flow sensor and return sensor must rise more than 3°C within 10 seconds.If so the regulation is released.

12 sec end of heat demandPressure monitoring (during operation)If the system water pressure changes by more than ± 0.1 bar ( and ± 0,3 bar with changing pump speed) within 4 seconds, the regulation blocks and switches over to the pump test program, with a continuous P on the status display.

12 sec end of heat demandPump speed regulation (high/low during heating operation)When the temperature difference between flow and return is greater than 30°C, the pump switches to high speed. When the temperature difference drops below 10°C, the pump switches back to low speed.

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Static pressure monitoringThe boiler is in working mode when the system water pressure is between 0,5 and 3 bar.With a water pressure between 0,5 and 0,2 bar, the burner is limited to low load.If the water pressure is less than 0.2 bar, the regulation locks with a ‘P’ + ‘pressure’ on the display.If the water pressure is greater than 3.0 bar, the regulation locks with a ‘P’ + ‘pressure’ on the display.

3.1 Stand-by 3.2 Pre-rinse / pre-heat glowplug (Fan off - Gas valve off - Glow plug off - Ionisation off) (Fan on - Gas valve off - Glow plug on - Ionisation off)

Heat demand: During the standby, a check is made to see if there is Fan: The fan switches over to the purging speed (1350 rpm). heat demand. If so the boiler will go over to pre-rise. Glow plug: The glow plug is switched on at full power.

Pump test: After the pump test program is met, ignition state starts.

3.3 Ignition 3.4 In operation(Fan on - Gas valve on - Glow plug on/off - Ionisation off/on) (Fan on - Gas valve on - Glow plug off - Ionisation on)

The ignition sequence of the burner is initiated. conditions burner on: - when the room thermostat is closed (heat demand),

Fan: The fan is running at the ignition speed (2900 rpm). - and when the actual flow temperature is 5°C below the set point,Gas valve: The gas valve coil is activated and opens the safety valves. - and after 3 minutes anti-cycling time, if applicable.Glow plug: The glow plug ignites the gas/air mixture from the burner. Ionisation: As soon as an ionisation signal is measured, the glow plug conditions burner off:is switched off and the boiler will go over to in operation. - when the room thermostat is open (end of heat demand),If there is no ionisation signal at the end of the safety time, a new - or when the actual flow temperature is 3°C above the set point,start attempt is made. - or when the actual flow temperature is 3°C above the After four failed start attempts the boiler runs into lock-out.

3.5 Post-rinse 3.6 Pump afterrun (heating)(Fan on - Gas valve off - Glow plug off - Ionisation off) (Fan off - Gas valve off - Glow plug off - Ionisation off)

Combustion chamber is being post-ventilated with air. The pump continues to run over the heating circuit. At end of heat demand the regulation runs into post-rinse. The time is adjustable (minimum of 1 minute with a maximum of The fan runs at the last demanded speed for 20 seconds. CO=24 hours).

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3.7 Display

The left segment indicates the Status (or the parameter when being in the menu option)A dot on the status display indicates that the burner is on.The two right segments indicate the flow sensor temperature or the system water pressure (or the value of the parameter when being in the menu option).

This boiler is in stand-by mode, waiting for heat demand. The Status shows a continuous 0, no dot (thus the burner is off).The two right segments indicate the actual flow sensor temperature of 19‘C.

3.8 Blocking

The STATUS display shows a continuous indication (not flashing).The boiler operation is stopped due to a minor incorrect operation of the boiler or faulty component.Most blocking actions restore automatically in time when the conditions return within certain requirements.Some blocking operations need a reset of the 230V supply power or must be repaired.Note that each blocking operation will stay at least with 3 minutes anti-cycling time.

3.9 Lock-out

The STATUS display shows a flashing indication.The boiler operation is stopped due to a major incorrect operation of the boiler or faulty componentThe pump runs over the heating circuit (24 hours).At some lock-outs, the fan runs post-rinse for 1 minute.Most lock-out operations can be restored by pressing the ‘Set/Reset’ button once. Note that some lock-out operations need a reset of the 230V supply power.

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A = StatusB = ReadingC = “+” buttonD = “-“ buttonE = Set/ResetF = Flame

3.10 STATUS INDICATIONS

High voltage!The wiring of the pump, the three-way valve, fan and wiring of the gas block can be under a voltage of 230 VAC

each burner start (after the mostly, this lock-out is 1 boiler does check both flow use view option inpump test program), the boiler is related to a water flow flashing not pass and return sensors menu modedoing a temperature test. problem temperature for functionThe flow sensor must rise by 3°C testmore than the return sensor, test sensor replace sensorwithin the first 20 seconds. (R=12 kOhm@25°C)if the difference is not made, theboiler will make a re-start. obstruction in water open (thermostatic)After three failed re-starts, water circuit valves or zone systemswithin one heat demand, (flow or return)boiler runs into lock-out

install a differential Reset the appliance. bypass valve betweenPress the “+” button for 5-10 seconds, the status 8 comes up (water pressure) flow and returnStart demand for heat with the chimney sweeper function. Read the pressures.a). if the delta P is under 0,05 bar, the boiler has no water. check flow ofb). if the delta P is above 0,54 bar (0,64 for type 40 and TWIN), the water does not flow. water throughc). If the delta is between 0,05 and 0,54 (0,64 for type 40 and TWIN), heat exchangerthe water flow is all right, the pump test ends.

flow sensor open circuit 1 flow sensor check flow sensor use view option incontinuous function menu mode

test sensor replace sensorbroken flow sensor, or wiring (R=12 kOhm@25°C)problem

flow sensor short circuit 1. flow sensor check flow sensor use view option incontinuous function menu mode

test sensor replace sensor(R=12 kOhm@25°C)

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if during operation the ionisation during operation, the 2 too many check flame stability display reading can give fails, the gas valve shuts off, and boiler may not have flashing restarts indication of flame functionrestart is made. If this failure ionisation interruption duringcauses a third restart within one operation check ionisation clean ionisation probe withburner demand, the boiler runs current on low load fine sandpaperinto lock-out. (3-13 microAmp DC)

re-adjust gas/air mixture, check gas valve function

check ionisation repair shorted wiring ofwiring ionisation probe to earth

blocked condensation clean siphon and condensatedischarge tray discharge

check gas valve coil replace gas valveresistance on the twooutermost terminals(R = about 4,1 kOhm)

return sensor open 2 return check return sensor use view option incircuit continuous sensor function menu mode

test sensor replace sensorbroken return sensor, or wiring (R=12 kOhm@25°C)problem

return sensor short 2. return check return sensor use view option incircuit continuous sensor function menu mode


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mostly, a printed circuit board - internal 3 internal software interrupt thecomponent is broken. communication error flashing error problem supply power

- internal regulation fault hard-ware replace printed - Analog/Digital component broken circuit boardconversion error - hard-ware component broken

If the flue gas sensor measures extreme low flue gas 4 flue gas software check wiringa temperature below - 25°C, temperature flashing sensor problem and connectionsthe boiler runs into lock-out, (< - 25°C below zero)because the frost protection hard-ware check why frost protectionfailed function. component broken fails and repair this.

check flue gas use view option insensor function menu mode


flue gas sensor 4 flue gas check flue gas use view option inopen circuit continuous sensor sensor function menu mode

test sensor replace sensorbroken flue gas sensor, or wiring (R=12 kOhm@25°C)problem

flue gas sensor 4. flue gas check flue gas use view option inshort circuit continuous sensor sensor function menu mode


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If the measured fan speed, - communication fault, 5 fan speed software push resetduring initialising, exceeds the - heavy running fan flashing malfunction communication buttonmaximum fan speed, the rotor, fault (hall sensor)regulation blocks. - fan motor broken,After 1 minute the boiler runs - PCB failure hard-wareinto lock-out. component brokenIf the measured fan speed,in operation, deviates from the heavy running fan rotor, or replace fandesired fan speed, the burner equal problemwill be switched off, andpost-purge will start. check the fan coil resistance replace fanIf this blocking action PCB power supply to the fan: on the two outermostlasts for more than 1 minute, The voltage supplied by the board onto the two terminalsthe boiler runs into lock-out. outermost contacts of the fan plug varies (modulation). (R =115-120 Ohm)

In chimney sweeper function:high load = approx 230 VAC check the printed circuit board replace PCBlow load = approx 125 VAC for function

If the hot water sensor printed circuit board 6 hot water check internal tank adjust in the menu theis disrupted, the boiler runs into is not recognising continuous sensor sensor connection correct type of appliance,blocking mode the hot water sensor use parameter H

If the gas valve circuit is disrupted, broken gas valve coils, 7 gas valve software check wiringthe boiler runs into lock-out. PCB failure, flashing malfunction problem and connections

interrupted wiringhard-warecomponent broken

check gas valve coil replaceresistance on the two gas valveoutermost terminals

PCB power supply to the gas valve: (R = about 4,1 kOhm) The voltage supplied by the board onto the two outermost contacts to open the gas valve is about check the printed circuit board replace PCB 210 VDC. for function

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If a false flame signal is detected the boiler may not have 8 incorrect software replace printedwith closed gas valve for more an ionisation signal flashing flame problem circuit boardthan 5 seconds, the boiler runs when burner is off. signalinto lock-out.

If a false flame signal is detected during pre-rinse / post-rinse, theregulation blocks. If the false flamesignal lasts for more than 5 sec,the boiler runs into lock-out.

after successful re-programming successful 9 software at the end of the press set/resetof the printed circuit board, the software update flashing updating updating session button oncestatus code shows flashing 9

A sensor with incorrect flow, return, internal 9 sensor find the sensor replace that sensortemperature indication between tank or outdoor sensor continuous malfunction involved97°C and 115°C, while the actual temperature differs. test sensor replace sensor

(R=12 kOhm@25°C)

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If the flue gas sensor exceeds a extreme high flue gas A flue gas Find the cause of this flue gas limiter lock-out,temperature of 105°C, the boiler temperature flashing limiter because previously:runs into lock-out lock-out a). The burner was off at 100°C

( 105°C) b). The burner was on low load at 90°C

interrupt the supplypower

The powering up of the supply voltage makes the flue gas sensor active.

If the flue gas sensor exceeds a extreme high flue gas A burner Find the cause of this flue gas limiter lock-out,temperature of 100°C, the burner temperature continuous blocked, because previously the burner was is blocked. caused by on low load at 90°C

high flue gastemperature burner action restores( 100°C) when the temperature

descends 70°C

If the flue gas sensor exceeds a high flue gas A/C. burner blocking action burner action restorestemperature of 90°C, the burner temperature or limited to restores when the temperatureis blocked. A/d. low load, automatically descends 70°CThe display shows alternately or caused bya code A and the actual A/b. high flue gas check flue gas use view option inboiler status continuous temperature sensor function menu mode

( 90°C)test sensor replace sensor(R=12 kOhm@25°C)

Reset the appliance.Press the “+” button for 5-10 seconds, the status 8 comes up (water pressure) check function ofStart demand for heat with the chimney sweeper function. Read the pressures. burnera). if the delta P is under 0,05 bar, the boiler has no water.b). if the delta P is above 0,54 bar (0,64 for type 40 and TWIN), the water does not flow. check flow ofc). If the delta is between 0,05 and 0,54 (0,64 for type 40 and TWIN), water throughthe water flow is all right, the pump test ends. heat exchanger

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b/r HWScontinuous right unit

TWIN

Chimney sweeper functionStart the chimney sweeper function by pressing the + and - buttons of the display simultaneously for at least 5 to 10 seconds.The status shows a flashing C and the two right segments show the ionisation current in microamperes DC.The chimney sweeper function overruns the heating functions.

temporarily display C chimney press the “+” or “-” chimney sweeper functionfor service purposes flashing sweeper button for high or low removes automatically

function load after 10 minutes orby pressing the "-" button

= high load

Enter the chimney sweeper functionby pressing both the “+” and “-”buttons simultaneously for5 - 10 seconds

= low loadThe two right segmentsshow the actual ionisation currentin micro Amps DC

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C = heat demand heating heat demand C burner is off burner starts Pump is ond = heat demand for hot water combi-boiler or caused by automatically Fan is onb = heat demand for hot water external d 3 minutes Burner is offcylinder or anti-cycling

b counterNo dot indication, burner is off continuous

Jcontinuous

TWIN

If either the flow sensor or return sensor heat demand C high flow or burner is off, block removes automaticallyexceeds a temperature of 93°C, continuous return sensor blocked by maximum when the flow temperaturethe burner is switched off. temperature flow- or return drops 5°C below set point

( 93°C) temperature

If the flow sensor temperature is 3°C above heat demand C flow burner is off, block removes automaticallyset point, the burner is switched off. continuous temperature blocked by set point when the flow temperature

above drops 5°C below set pointset point

if the temperature difference between flow- heat demand C flow/return burner is off, block removes automaticallyand return sensor becomes less than - 5°C, continuous temperature blocked by sensor when the temperaturethe boiler start is blocked. difference is temperatures difference between flow

less than - 5°C and return sensor becomes within - 5°C

if the temperature difference between flow- heat demand C flow/return burner is off, block removes automaticallyand return sensor becomes more than 45°C, continuous temperature blocked by sensor when the temperaturethe boiler start is blocked. difference temperatures difference between flow

is > 45°C and return sensor becomes less than 20°C

at each start the glow plug protection counter heat demand C glow plug glow plug counter is boiler restores automatically is incremented 1 step. If the counter is too high continuous protection decremented 1 step in time( xxx steps), the boiler start is blocked. counter per minute

before each burner start, the differencebetween flow- and return temperaturemust be less than 20°C.

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C. = heat demand heating heat demand C. boiler is in burner modulates, Pump on, Fan on, Burner ond. = heat demand for hot water combi-boiler or heating mode depending the amountb. = heat demand for hot water external d. of heat required.cylinder or

b.The dot indicates the burner is on. continuous

at the end of heat demand, the end of heat demand c pump afterrun post-rinse time is pump stops automaticallycontacts of the green connector, ( Heating) continuous heating adjustable in menu after post-rinse time.ports 1 and 2, are open. ( Letter O)

software or hard-ware problem, internal interlock fault E internal software interrupt thethe boiler runs into lock-out flashing lock-out problem supply powerfor safety reasons

hard-ware replace printedcomponent broken circuit board

E no slavecontinuous recognised

TWIN

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At each burner start, while the fan too many start F boiler does NO GAS SUPPLY open gas cocksruns on the ignition speed of attempts, during one flashing not start gas valve failure in supply line2700 rpm, the gas valve opens heat demand, (four failedand a flammable gas/air mixture successively consecutive gas inlet pressure is too high, reduce gas inletis supplied to the burner. The attempts) (> 60 mbar). The safety valves pressureglow plug ignites the gas/air can not open against highmixture at the surface of the inlet pressureburner. If there is insufficientionisation current at the end of NO IGNITION check resistance glow plugthe safety time, a new start glow plug (1 - 1,4 kOhm)attempt will be made. After fourfailed consecutive start attempts, the life time of the glow plug replace glowthe boiler runs into lock-out. is depending on the number plug

of starts and on high mainsvoltage supply

NO FLAME check ionisation currentgas/air mixture (low load 3-13 micro Amp)

No flame building. adjustmentThe gas/air mixture is not set full / low loadcorrectly for the type of gas

NO IONISATION check wiring, remove shortno current circuit to earth

with high temperature flame, remove dirt withan insulating layer can be fine sandpaperformed on the probe

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If the flow sensor exceeds a high flow temperature H flow sensor test sensor replace flow sensortemperature of 105°C, the flashing limiter (R=12 kOhm@25°C)boiler runs into lock-out ( 105°C)

burner on check water replace pressureburner has to be restored by pressure sensorinterrupting supply power

If the flow sensor exceeds a high flow temperature H flow sensor test sensor replace flow sensortemperature of 105°C, while the continuous high (R=12 kOhm@25°C)burner was off, the boiler blocks. temperature

( 105°C) check water replace pressureburner action restores burner off pressure sensorwhen the actual flow temperaturebecomes 5°C below the set point.

at the end of heat demand of the end of heat demand h pump afterrun post-rinse time pump stops automaticallycombi-boiler, the pump post-rinse ( Hot water) continuous hot water hot water is after 30 secondsfor 30 seconds over the hot water non-adjustablecircuit.

the software was interrupted in the software blocking nc software unexpected interrupt the 230 voltmiddle of a sequence continuous problem failure supply power

open bridge of connector of gas valve circuit has O gas valve check wiring check contact of plug andprinted circuit board causes open bridge flashing connector X4 check bridge terminal of PCBthis lock-out on connector X4

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once per hour is tested the waiting for heat demand O stand-by the difference if not, pump is starteddifference between flow and continuous between flow andreturn temperatures. return temperatures

must be less than 5°C if needed, turn on heating( room thermostat)

Applications with outdoor sensor,the summer/winter switch blocks the heatdemand.

Set in the menu O/t-value to a higher level.

If the flow sensor temperature frost protection 8°C o frost check heat demand repair heat demand on thebecomes below 8°C, the continuous protection ( room thermostat) green connectorregulation starts the pump ( contacts 1 and 2)

frost protection is finished, when the temperature of return sensoris above 15°C.

If the flow sensor temperature frost protection 3°C o. frost check heat demand repair heat demand on thebecomes below 3°C, the continuous protection ( room thermostat) green connectorregulation starts the burner ( contacts 1 and 2)

frost protection is finished, when the temperature of return sensoris above 15°C.

If the pump is not connected the pump wiring open P pump wiring check wiring repair pump wiring,boiler will not start-up. continuous disconnected connector or connection

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after each burner start the boiler is water flow problem P boiler does check water flow have at least one doing a pump test. The boiler is continuous not pass radiator always openstarting and stopping the pump and pump testmeasuring both the dynamic and pump test install a differential bypassstatic system water pressures. repeating valve between flow and

each returnThe two right segments 15 secondsshow the actual flow temperature vent the system vent the air bleed cocks

(boiler/radiators) one at a timePress the “+” button for 5-10 seconds, the status 8 comes up (water pressure)Read the pressures. check pump function vent pump, accelerate pumpa). if the delta P is under 0,05 bar, the boiler has no water. shaftb). if the delta P is above 0,54 bar (0,64 for type 40 and TWIN), the water does not flow.c). If the delta is between 0,05 and 0,54 (0,64 for type 40 and TWIN), check pressure use view option inthe water flow is all right, the pump test ends. sensor function menu mode

high system water, P high water drain water from blocking mode releases afterpressure > 3,0 bar continuous pressure the system draining under 2,9 bar

with water pressure above 3,0 bar (high pressure) or under combo-boiler in hot water open at least one thermostat0,2 bar (low pressure), a combo-boiler makes valve to create contact, viathe regulation blocks. the flow pipe to the returnThe two right segments pipe and expansion vessel.show the actual water pressureThe boiler is operational with a check the expansion pre-pressure depends on thewater pressure between vessel pre-pressure installation height above the0,5 and 3,0 bar. expansion vessel

5 meter - 0,5 barAdvised is to fill the system with 10 meter - 1,0 bara water pressure between 15 meter - 1,5 bar1,5 to 2 bar.

low system water P low water fill the system blocking mode releases pressure < 0,2 bar continuous pressure with water after filling above 1,3 bar

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with water pressure between low system water, P/C. burner fill the system low load releases after0,2 and 0,5 bar, the burner is pressure between or limited to with water filling above 0,5 barreduced to low load. 0,2 and 0,5 bar P/d. low load,The display shows alternately a or caused bycode P with the actual P/b. low wateroperating status. continuous pressure

The two right segmentsshow the actual water pressure

Line and Neutral are exchanged 230 VAC supply U incorrect check supply reverse Line and Neutralor no good Earth is present Line and Neutral continuous electrical

reversed connectioncheck Earth without proper Earth, the

ionisation cannot work

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Troubleshooting manual - E000129004 2008 Coopra Advanced Heating Technologies b.v. All rights reserved. Nothing from this document may be duplicated and/or made public by means of printing, photocopy, microfilm or in any other way without prior written permission from the manufacturer. This also applies to the appropriate drawings and/or diagrams. The information supplied in this document is based on general data with regard to constructions, material characteristics and working methods known at the time of going to print. Therefore, we reserve the right to make changes without notification. For this reason, the instructions given serve only as a guideline for the installation, use and maintenance of the unit shown on the cover of this document. This document is valid for the unit in its standard version. Therefore, the manufacturer cannot be held liable for any damage arising from specifications that deviate from the standard version of the unit delivered to you. This document has been compiled with all possible care. However, the manufacturer cannot be held liable for any mistakes in this document or for any consequences. Take the time to read this document carefully before installing or using the unit. Always keep this document near the unit. COOPRA Advanced Heating Technologies b.v.

Vierlinghstraat 14 NL 3316 EL Dordrecht Tel: +31 (0) 78 – 653 08 30 Fax: +31 (0) 78 – 653 08 33

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