C - Abacus Flame

Transcription

C - Abacus Flame

Appliance Technical Guide
Service Engineer Edition
Neta-tec Combi GA Range
Duo-tec 2 Combi GA Range
Megaflo 2 System GA Range
Gas Fired Wall Mounted Condensing
Combination & System Boilers
© Baxi Heating UK Ltd 2012
Contents
Appliance Technical Guide
This Appliance Technical Guide contains information to enable
diagnosis of faults, interpretation of error codes, identification
of key componets and the performing of commissioining,
calibration and combustion checking.
Models covered:• Baxi Neta-tec Combi
• Baxi Duo-tec 2 Combi
• Baxi Megaflo 2 System
Note: These buttons
inactive on System
models:If only the symbol is
displayed on System
models the boiler will
not operate. Press the
button until the
symbol appears.
2
Page
1.0
Gas Adaptive System
3
2.0
Combi C.H. Sequence of Operation
4
3.0
Combi D.H.W Sequence of Operation 5
4.0
System C.H. Sequence of Operation
6
5.0
Commissioning Function
7
6.0
Service Due Function
9
7.0
Checking the Combustion
10
8.0
Combustion Re-calibration
11
9.0
Gas Type Selection
15
10.0
Information Menu
16
11.0
Error History
17
12.0
Errors & Sub-codes
19
13.0
P.C.B. & R.D.S.
21
14.0
Electronic Gas Valve
22
15.0
Hydraulics
23
16.0
Internal Wiring
26
17.0
Electrical Measurements
29
18.0
Parts Matrix
30
19.0
E133 Flow Chart
31
20.0
Commissiong Procedure & Errors
32
21.0
Additional Information
33
22.0
Pages for Notes
34
1.0 Gas Adaptive System
The Gas Adaptive System
The Baxi GA range of boilers are fully ‘Gas Adaptive’. This means the system automatically monitors the flame and adjusts
the gas valve to achieve the correct combustion at all times.
Explanation of Set Flames on GA
The Set Flame is a value that is used to achieve the desired combustion and is set at either during manufacture or by an
engineer on site. The value of this is different for each model because of fan speeds, mixers, nozzles, heat exchangers etc.
hence each model has different Set Flames.
This value relates to the ionization signal (e.g. 35 = 350 kOhms), and it simply tells the boiler what ionization it should
achieve at that fan speed.
If it is set incorrectly the boiler will always try to achieve that signal. It must be set correctly at manufacture, and by an
engineer if any gas carrying parts or R.D.S. are changed, to achieve 9.0% +-0.2 CO2 on N.G. (10.5% +-0.2 CO2 on N.G. )
The adjustable Set Flames are at three fixed fan speeds:00 (min)
IGN (ignition) Displayed as 33, 41 etc. It is a % of maximum fan speed or ‘power’.
100 (max)
From these three points, a curve is drawn and the values for the entire RPM range are calculated.
When the Set Flame is changed at one of the fan speeds above, the RPM will always stay the same, but the PCB will send a
signal to the valve to open or close the solenoid to alter the gas flow so that the ionization signal matches the Set Flame
value just inputted.
As the ionization signal changes, so does the combustion.
Boiler Cycle: From Factory to Installation
Manufactured & Set
on N.G.
Boiler set
automatically to
achieve 9.0% CO2
Installed
Boiler fitted by installer
Commissioning
Function
Before use boiler must
complete C.F.
Service Due - 1
After 11 months ‘Sd’
shown on boiler
display
Service Due - 2
After 11 months ‘Sd’
shown on boiler
display
‘SD’ function reset at annual service
3
2.0 Combi C.H. Sequence of Operation
Combi Models
C.H. Demand
Pump On
Pump Check by
Water Pressure - OK
No
E430
Yes
Diverter Valve C.H.
Position
Fan On
RPM Check - OK
No
E160
Yes
Gas Valve Start
Sequence
Gas Valve Opens
Spark
Ignition
No Ignition
5 Attempts Ignition
Achieved
No
E133
Reset
Yes
Flame On
Flame Stabilization
5 Seconds
Stabilization
Loss of
Flame
12 Attempts Ignition
Achieved
Yes
Full C.H. Rate
4
Boiler Operating
No
E128
Reset
3.0 Combi D.H.W. Sequence of Operation
Combi Models
D.H.W. Demand
Pump On
Pump Check by
Water Pressure - OK
No
E430
Yes
Diverter Valve
D.H.W. Position
Fan On
RPM Check - OK
No
E160
Yes
Gas Valve Start
Sequence
Gas Valve Opens
Spark
Ignition
No Ignition
5 Attempts Ignition
Achieved
No
E133
Reset
Yes
Flame On
Flame Stabilization
5 Seconds
Stabilization
Loss of
Flame
Achieved
Yes
Full D.H.W Rate
Boiler Operating
No
E128
Reset
5
4.0 System C.H. Sequence of Operation
System Models
C.H. Demand
Pump On
Pump Check by
Water Pressure - OK
No
E430
Yes
Fan On
RPM Check - OK
No
E160
Yes
Gas Valve Start
Sequence
Gas Valve Opens
Spark
Ignition
No Ignition
5 Attempts Ignition
Achieved
No
E133
Reset
Yes
Flame On
Flame Stabilization
5 Seconds
Stabilization
Loss of
Flame
Achieved
Yes
Full Rate
6
Boiler Operating
No
E128
Reset
The Commissioning Function (CF) - Description
5.0 Commissioning Function
The CF is a one off forced function that is activated on the first power up of the boiler after it has left the factory. The boiler
cannot be operated unless the CF has been completed and the CF can be activated only once.
There are two stages to the CF - De-aeration of the system followed by a Gas Type Check.
De-aeration
This function operates the pump and the diverter valve moves from DHW to CH periodically to purge the system of air.
It ensures maximum evacuation of air and prevents damage to the heat exchanger coils at initial fire up. This takes
approximately 7 minutes to complete.
Gas Type Check
This automatically follows the de-aeration function and checks the flame signal to determine if the gas supply is NG or LPG.
It is done by first running at IGN rate, then at full power for the final stage. From these two speeds two values are measured
which are used to recognize the gas type being supplied.
IMPORTANT: When checking at full power, the combustion can go higher than normal for a few seconds, therfore it is not
advisable to insert the analyser probe into the flue sampling point to measure combustion, as saturation may occur and
affect subsequent readings. This stage takes approximately 4 minutes to complete.
The total time for the CF is between 10 and 12 minutes.
Activation of Commissioning Function (CF) from initial Power On
See page 32 for the flow diagram.
Once power is supplied to the boiler the display will show ‘000’ which indicates that the CF needs to be activated.
• Press and hold the ‘CH +ve’ and the ‘ip’ button, together for 6 seconds
• ‘312’ should be displayed and the boiler is now performing the de-aeration cycle
• After approx 7 minutes, the boiler will fire and the Gas Type check cycle will start
• The boiler will remain at a reduced rate for approx 3 minutes, in the final minute it will ramp to ‘100’, during this
time the boiler temp will be displayed. It is advised to open a DHW tap to dump the heat.
• Once the Gas Type check has finished, the display will show what type of gas the boiler is connected to:
• If it is natural gas, it will flash ‘NG’ for a few seconds and then be ready to operate
• If it is LPG, it will flash ‘LPG’ and this will need to be confirmed by pressing the ip button for 6 seconds. All
software values are automatically modified and the boiler is ready to use
If the boiler display shows ‘LPG’ when NG is being supplied, it can be cancelled by pressing the ‘ip’ and reset ‘R’ button
together for 4 seconds.
When there is an error present (e.g. Low Water Pressure – E118) it must be rectified before the CF can be started or
completed.
If there is an interruption to CF it will start again. If de-aeration has been completed, it will start from gas type check.
7
5.0 Commissioning Function (cont.)
Commissioning Function (CF) Mini-Calibration if E133 in Commissioning Mode
If during Commissioning Function the boiler fails to light and goes to E133 then a “mini-calibration” can be performed
within the CF Function (assuming the gas supply has been checked).
• With the display showing ‘000’ and before the Gas Type check, press and hold the reset ‘R’ and ‘CH -ve’ buttons for 6
seconds, followed by the ‘ip’ button.
• The display should now show the ignition speed and calibrate. It will go to ‘100’ briefly then back to ‘000’
Commissioning.
• To activate the Gas Type Check, press and hold the ‘ip’ and ‘CH +ve’, as normal and the boiler will now complete
the Gas Type Check.
IMPORTANT NOTE:
IT IS NOT POSSIBLE TO CALIBRATE A NEW GAS VALVE WHILST IN COMMISSIONING MODE !
Manual De-aeration Function (312)
This function can be activated manually, for example in instances when a radiator or heat exchanger has been changed and
thus the system needs to be purged of air.
• Press and hold the ‘ip’ and ‘CH -ve’ buttons for 6 seconds.
• The display will show ‘312’ and the De-aeration function activated.
• It will be active for 10 minutes.
• To disable, either press and hold the ‘ip’ and ‘CH -ve’ for 6 seconds or isolate the power to the boiler.
8
Service Due Function (SD) - Description
6.0 Service Due Function
When this function is activated ‘Sd’ is displayed after a pre-determined time (Factory Set at 11 months) informing the user
that the 12 month service is due shortly. It is only active whilst there is power to the boiler. If power is interrupted the
counter continues from where it stopped previously.
The boiler continues to work as normal and the display flashes 'Sd' for 3 seconds, every 10 seconds.
It can be reset, disabled and Service Time changed by alteration of parameters.
! IMPORTANT NOTE: DO NOT ADJUST ANY OTHER VALUES OR PARAMETERS AS IT WILL AFFECT THE
OPERATION OF THE BOILER
To reset the SD Function
• Once the annual service is complete the SD Function must be reset so the next service can be indicated.
• Press and hold the ‘CH -ve’ and ‘CH +ve’ buttons together for 6 seconds to enter the ‘TSP Menu’. P01 will be
displayed.
• Use ‘CH +ve’ to scroll to ‘P22’.
• Press the ‘ip’ button to toggle into the ‘P’ value.
• Change ‘00’ to ‘15’ (15 is the SD counter reset code).
• Press the ‘ip’ button to toggle back to to lower parameter menu.
• Press the reset button ‘R’ to exit the ‘TSP’ menu.
The next SD message will be displayed in 11 months.
To disable or change the SD Function Time Period
• Press and hold the ‘CH –ve’ and ‘CH +ve’ buttons together for 6 seconds to enter the ‘TSP Menu’. P01 will be
displayed.
• Press the ‘ip’ button to toggle into the ‘P’ value.
• Change ‘00’ to ‘22’ (22 is the code to access the higher parameters - P41 and above).
• Press the ‘ip’ button to toggle back to lower parameter menu.
• Press the ‘ip’ button to toggle into the value for ‘P50’.
• The value range is 6….25:6….24 = months elapsed before ‘Sd’ is displayed.
25 = function disabled.
• Choose the desired value and press the ‘ip’ button to confirm.
• Press the reset button ‘R’ to exit the ‘TSP’ menu.
9
Checking the Combustion - F304
7.0 Checking the Combustion
At each service the combustion must be checked at three fan speeds:- ‘00’, ‘IGN’ and ‘100’.
00 = Minimum
IGN = Ignition Speed (different for each model)
100 = Maximum Speed (D.H.W. power for Combi)
To check the combustion at these 3 speeds Function 304 must be activated.
To activate, press and hold the ‘ip’ and ‘CH +ve’ buttons together for 6 seconds.
‘304’ should be displayed and then the boiler will run at maximum when ‘100’ will be displayed. Allow a few moments for
the boiler to stabilize then measure the combustion.
To choose the next fan speed, press the ‘CH –ve’ button - the Ignition Speed will be displayed. To set at minimum press the
‘CH –ve’ again. ‘00’ will be displayed.
To de-activate this function, press and hold ‘ip’ and ‘CH +ve’ for 6 seconds or isolate power to the boiler for several seconds.
Note: If at ‘100’ the boiler temperature reaches 85°C, the burner will be extinguish and it will start again. To prevent this
from happening, open one or two D.H.W. taps whilst in F304 and the boiler will automatically dump the heat through the
D.H.W. circuit. In the case of System models it is recommended that any stored hot water is depleted prior to
commencement.
Limited Combustion Adjustment - F304
• A limited adjustment of the combustion can be performed whilst Function 304 is activated.
• By pressing the ‘ip’ button at any of the three fan speeds above an adjustment value is accessed. This adjustment is
limited in that a deviation of only -3 or +3 from the original value of 0 is permitted. The combustion can be
altered by approximately +/- 0.6% in this mode.
• Changing the value by 3 increases or decreases the CO2 value by approximately 0.6%.
• Positive adjustment equates to richer combustion and negative adjustment results in weaker combustion.
• Once the combustion has been changed, press the ‘ip’ button to toggle back to the fan speed and now, by
pressing the ‘CH +ve’ or ‘CH -ve’, the fan speed can be changed.
• Once completed press and hold the ‘ip’ and ‘CH +ve’ buttons for 6 seconds to de-activate Function 304.
10
8.0 Combustion Re-calibration
Combustion Re-calibration
Each boiler is calibrated during manufacture and set during F.F.T. (Final Function Testing). This sets the Fan and E.G.V.
(Electronic Gas Valve) to the rest of the system. Combustion at F.F.T. is set at 9.0% +/- 0.2% on N.G.
The system must be re-calibrated by the engineer to the procedure below if any of the following are changed:• Gas Valve
• R.D.S. (Removable Data Stick)
• Burner
• Fan
IT IS ESSENTIAL THAT THE
CALIBRATION PROCESS IS
STARTED WHEN THERE IS NO
DEMAND !
Combined Analyser/Manometer
Press the ‘CH -ve’ and reset ‘R’
buttons together for 6 seconds.
‘On’ will be displayed and within 2
seconds of this showing press the ‘ip’
button.
If ‘303’ is displayed, the time window
to press the ‘ip’ button has been
missed. Power down at the fused spur
and start again.
DO NOT TURN ON THE
ANALYSER PUMP WHILST THE
BOILER IS CALIBRATING AS THE
INTERNAL CELL MAY BECOME
SATURATED !
To G.V. Inlet
Test Point
Remove the boiler front door and
connect the manometer to the Inlet
Test point on the Gas Valve.
After the ‘ip’ button is pressed the
Ignition Fan Speed (as % of maximum)
will be displayed. Each model is
different (e.g. 33GA is ‘41’).
The boiler software will now search
for the appropriate ignition curve to
light with, usually curve 3 or 4.
To G.V. Inlet
Test Point
After several seconds ‘100’ will be
displayed, indicating that the fan is a
maximum speed. It may be necessary
to put a D.H.W. demand on the
system if the temperature exceeds
85°. Check the gas inlet pressure has
not dropped below 16mb.
The boiler will remain at ‘100’ until
stabilization is achieved - up to 3
minutes.
>16mb
To G.V. Inlet
Test Point
11
After stabilization at maximum (‘100’)
the boiler will revert to ignition fan
speed to stabilize at this rate as well,
taking up to 3 minutes.
To G.V. Inlet
Test Point
After stabilization at ignition fan speed
minimum power will be automatically
selected, ‘00’ being displayed.
Stabilization at this speed will take up
to 2 minutes.
To G.V. Inlet
Test Point
Once calibration is complete the
flame, tap & radiator icons will flash
and the display alternate between ‘00’
and a value. This value is the ‘Set
Flame Value’.
The Set Flame controls the ionization
signal and thus the combustion level.
Each fan speed has an adjustment. The
Set Flame determines what the boiler
can achieve so it is essential to have
correct combustion.
To Flue
Sampling Point
INSERT THE ANALYSER PROBE
INTO THE FLUE SAMPLING POINT
Pressing the ‘CH -ve’ or ‘CH +ve’
buttons changes the Set Flame value.
Increasing the value weakens
combustion, decreasing it makes the
combustion richer.
12
To Flue
Sampling Point
Once combustion is set to 9.0% press
the ‘ip’ button.
°C
The display will alternate between the
fan speed (‘00’ or minimum in this
case) and the boiler temperature.
To Flue
Sampling Point
To select the next fan speed press the
‘CH +ve’ button.
‘33’ will be displayed, indicating
ignition speed.
To Flue
Sampling Point
°C
To view the Set Flame value at that fan
speed press the ‘ip’ button.
The display will alternate between the
ignition fan speed (‘33’) and the Set
Flame value (‘38’ in this example).
To Flue
Sampling Point
Change the Set Flame value to achieve
9.0% CO2 by pressing ‘CH -ve’ or
‘CH +ve’.
Press the ‘ip’ button followed by
‘CH +ve’ to change to maximum fan
speed (‘100’). Press the ‘ip’ button to
display the Set Flame value. The value
can be changed by pressing ‘CH -ve’
or ‘CH +ve’ buttons to achieve
9.0% CO2.
Once combustion has been checked,
adjusted where necessary, and the
readings recorded at each fan speed
press reset ‘R’ button to escape the
calibration function - ‘ESC’ will be
displayed.
To Flue
Sampling Point
13
Remove the pressure tube from the
Gas Valve Inlet Test Point. Tighten the
screw.
To Flue
Sampling Point
Replace the front door, ensuring it is
secured by the screws previously
removed.
Insert the analyser probe in the Air
Sampling Test Point. Replace the plug
in the Flue Sampling Test Point.
Press the ‘ip’ button and ‘CH +ve’ for
6 seconds. ‘304’ will be displayed and
the boiler will operate at maximum fan
speed. ‘100’ will be displayed,
alternating with the boiler temperature.
Pressing ‘CH -ve’ button will change
the fan speed to Ignition, a further
press selecting minimum speed.
Check for recirculation at each fan
speed:- ‘100’, ‘33’* & ‘00’.
°C
* ‘33’ is typical a value
Once the recirculation check is
complete, either press the ‘ip’ and
‘CH +ve’ buttons for 6 seconds or
isolate the power at the used spur and
then re-instate it.
14
To Flue
Sampling Point
Gas Type - L.P.G. & N.G.
9.0 Gas Type Selection
By gaining access to the ‘TSP’ (Transparent Slave Parameters) Menu the Gas Type can be adjusted, for example from L.P.G. to
N.G. in rural areas when mains N.G. is provided subsequent to installation.
Note: If the boiler is to be installed on an L.P.G. supply from new consult the information on page 7.
• Press and hold the ‘CH +ve’ and ‘CH -ve’ buttons together for 6 seconds
• ‘P01’ will be displayed alternating with its value (‘0’).
• Pressing the ‘CH +ve’ and ‘CH -ve’ buttons scrolls through the parameter list.
• Press ‘CH +ve’ until ‘P02’ is displayed.
• Press the ‘ip’ button to view the selected parameter.
• Pressing the ‘CH +ve’ and ‘CH -ve’ buttons modifies the parameter.
• P02 = 0 Boiler set for N.G.
• P02 = 1 Boiler set for L.P.G.
• Press the ‘ip’ button to safe the parameter value.
• Press the reset ‘R’ button to leave the TSP menu. The boiler temperature will be displayed - the boiler is ready
for use.
Once parameter P02 is set to the gas type required no calibration is necessary. The boiler will operate normally with the
new settings automatically adjusted.
Combustion Level & Setting Tolerance
N.G. = 9.0% CO2 +/-0.2%
L.P.G. = 10.5% CO2 +/-0.2%
Note: The tolerance of +/-0.2% is for setting puposes - a tolerance of +/-0.8% can be applied when checking.
The combustion is the same at each fan speed.
15
10.0 Information Menu
Information Menu
By gaining access to the Information Menu a number of values can be viewed. The information can be used to diagnose
faults, e.g. the value of a sensor to check if it is open circuit or closed circuit
Press ‘ip’ for 1 second.
The display will alternate between the ‘0’i code (e.g. i 02) and its value.
To scroll down the list press the ‘ip’ button.
i 00: Error Subcode See table on page 18
i 01: C.H. Temperature
i 02: External Temperature (if present)
i 03: D.H.W. Temperature
i 04: D.H.W. Temperature
i 05: Water Pressure
i 06: Return Temperature
i 07: Flue Temperature
i 08: Heat Exchanger Temperature
i 09: Not used
i 10: Not used
i 11: Not used
i 12: Not used
i 13: Not used
i 14: Not used
i 15: Not used
i 16: Not used
i 17: Fan Speed RPM
i 18: num ic
°C
°C
°C
°C
bar
°C
°C
°C
i 03 & i 04 are the same sensor
RPM
This function operates for 3 minutes, or can be cancelled by pressing the reset ‘R’ button.
16
Reading Errors via the TSP Menu
11.0 Error History
The boiler records the most recent error codes, up to a maximum of 10. These can be viewed via the display.
Whilst the parameter lines are P32 through to P41, the display only shows the ‘C’ codes.
To gain access to the TSP menu:• Press and hold the ‘CH +ve’ and ‘CH -ve’ buttons together for 6 seconds
• ‘P01’ will be displayed.
• Pressing the ‘CH +ve’ to scroll through the parameter list.
• Error codes P32....P38. These errors do not require resetting, for example low system pressure. When the fault is rectified
the code automatically resets.
• Error codes P39....P41. Errors that must be manually reset, for example safety thermostat activated.
Once a parameter has been selected a series of numbers will be displayed. It is advisable to note them down as they
alternate between each other. The order is:• Error Number
• Error Code
• Counter for the same Error
• Days elapsed since Event
• System Status
• Phase Status
• C.H. Flow during Event
‘Counter for the same Error’
Number of times the same error has occurred.
‘Days Elapsed’
Number of days. ‘45’ = 45 days since error.
‘System Status’
Operating Mode before the error.
0
Standby
1
D.H.W. Request
2
Controller Stop Function Active (F304)
3
C.H. Request
4
Preheat active
5
C.H. Frost Protection active
6
D.H.W. Frost Protection active
7
Pump Post circulation active
8
Overheating pump active
‘Phase Status’
Special Operating Mode before the error.
0
Standby
1
Pre-Purging Function active
03 Ignition Load purging between 1st and 2nd attempt
04 Ignition load 1st attempt
05 Operation Active
06 Lock Out
08 2nd Ignition Attempt
11 Ignition Load purging between 2nd and 3rd attempt
14 3rd Ignition attempt
15 Post Purging Function
16 Overheating Post Purging function
17
11.0 Error History (cont.)
Reading Errors via the TSP Menu (cont.)
The display format is such that, for example, P32 will flash then the code, P32 again then the next code and so on.
For example:- P32...C01...P32...E06...P32...02...P32...000...P32...03...P32...05...P32...75°C.
The ‘C’ value is always the start of the sequence.
Error Table for Engineers
Table for recording errors:-
Reset
Errors
Non-reset
Errors
Error Error
Days System
Counter
Number Code
Elapsed Status
18
P32
P33
P34
P35
P36
P37
P38
P39
P40
P41
C01
C09
E06
02
000
03
Phase
Status
C.H.
Flow
05
75°C
12.0 Errors & Sub-codes
List of Errors & Sub-codes
Anomaly
Code
Internal
Code
Anomaly
Action
E09
Gas valve connection fault
Check the cable P.C.B./gas valve and gas valve plug
E10
External probe fault
Check the sensor
E12
Differential water flow switch fault (still open)
Check the water flow switch
E13
Differential water flow switch fault (still closed)
Check the water flow switch
E15
Gas valve comand fault
Check the cable P.C.B./gas valve. Replace P.C.B. if necessary
E18
Water refill activated
Auto-Refill activated – motor energized
E19
Maximum time of water refill
Auto-Refill open too long to fill – check system
E20
1
Central heating NTC sensor fault (s.c.)
Check the sensor
E20
2
Central heating NTC sensor fault (o.c.)
Check the sensor
E40
1
Return central heating NTC sensor fault (s.c.)
Check the sensor
E40
2
Return central heating NTC sensor fault (o.c.)
Check the sensor
E28
539
Flue NTC sensor fault (s.c.)
Check the sensor
E28
540
Flue NTC sensor fault (o.c.)
Check the sensor
E50
1
DHW NTC sensor fault (tank boiler) (s.c.)
Check the sensor
E50
2
DHW NTC sensor fault (tank boiler) (o.c.)
Check the sensor
E53
Incorrect calibration or obstruction in flue pipe
Enable the Calibration Function and check flue for
obstruction
E55
PCB to be set by the “Calibration Function”
Enable the Calibration Function
E71
Fan parameter out of range in autocalibration
Check the fan speed
E72
Combustion test out of range in
autocalibration
Check the correct position and integrity of the sensing
electrode and cable
E77
Current out of range
electrode and for flue recirculation. Enable the automatic
calibration function before replacing components.
E78
Minimum gas valve current
E79
Maximum gas valve current
No communication
Check cable between room unit and P.C.B. or R.F. link.
E92
Combustion test alarm during auto-setting
Failed the self check test during Calibration Function. Check
for re-circulation before changing Gas Valve
E109
Precirculation alarm
Check for correct circulation of water and pump
E83/84/85/86/87
Note: (s.c.) = Short Circuit
(o.c.) = Open Circuit
19
12.0 Errors & Sub-codes (cont.)
E110
437
Boiler max temperature exceeded for gradient
(possible sticking pump or air in the circuit).
Temperature rise too fast. Check correct circulation of the
water and pump.
E110
438
Boiler max temperature exceeded for
overtemperature (possible sticking pump or air
in the circuit).
Temperature overshoots Set Point by 20C. Check correct
circulation of the water and pump.
Safety thermostat sensor tripped.
Check the sensor.
Water pressure HIGH (> 2.9 bar).
Check the water pressure.
Water pressure LOW (< 0.5 bar).
Check the water pressure.
E110
E117
566
E118
E125
500
Water circulation falut (overtemperature).
Check correct circulation of the water and pump.
E125
501
Water circulation fault – Temp not increased
on the flow.
Check correct circulation of the water and pump.
E125
502
Water circulation fault.
Check correct circulation of the water and pump
E128
Safety error for frequent loss of flame (12
times).
Check the sensing electrode and cable and for flue
recirculation. Enable the automatic calibration function
before replacing components.
E129
Safety error for frequent loss of flame with
max correction during the ignition during
Calibration Function.
Check the sensing electrode and cable and for flue
recirculation. Enable the automatic calibration function
before replacing components.
Flue thermostat sensor tripped (lockout).
Check the thermostat, correct circulation of water and
pump.
E133
Gas supply fault.
Check the power supply, sensing electrode, spark electrode
and cable. Check flue recirculation. Enable the automatic
E134
Elapsed time gas valve open without gas (short
request in a short period).
Check the gas pressure, sensing electrode, spark electrode
and cable. Replace the P.C.B. if necessary.
E135
Internal error.
Replace P.C.B.
E154
Plausibility test (flow/return).
Check correct circulation of the water and pump. Check
the correct position of the sensors.
E160
Fan fault.
Check the fan and the cable.
E270
Dry fire.
Check the sensor and the correct circulation of the water
and the pump.
E317
Wrong power supply electrical frequency (Hz)
Check the frequency (Hz) and the power supply.
E130
528
E321
1
Domestic Hot Water NTC sensor fault (s.c.)
Check the sensor.
E321
2
Domestic Hot Water NTC sensor fault (o.c.)
Check the sensor.
E384
Fault flame (parasitic flame).
Check the correct operation of the gas valve.
E385
Under voltage.
Check the power supply (V~).
E430
557
Water pressure temporary test.
Check the correct circulation of the water and the pump.
E430 & flame
505
Water pressure test failed.
Check the correct circulation of the water and the pump.
E431
1
Aluminium sensor fault (s.c.).
Check the sensor.
E431
2
Aluminium sensor fault (o.c.).
Check the sensor.
Note: (s.c.) = Short Circuit
(o.c.) = Open Circuit
20
13.0 P.C.B. & R.D.S.
P.C.B. & R.D.S. (Removable Data Stick)
The same P.C.B. is used for Combi and System models.
The R.D.S. is a removable data stick that determines the model type and also gas valve settings for that particular boiler. The
P.C.B. will not work without the R.D.S. and the display will be blank.
The R.D.S. will store in its memory the Calibration settings for that particular boiler and also the boiler type and output.
If changing a P.C.B., simply swap the existing R.D.S. over to the new P.C.B.
If the R.D.S. is damaged and a new one fitted then a Calibration is required (go to page 11) to calibrate the system.
P.C.B. Changed
Calibration Not
Required
P.C.B. & R.D.S.
Changed
Calibration
Required
R.D.S. Changed
21
Electronic Gas Valve
14.0 Electronic Gas Valve
The Bertelli Electronic Gas Valve (E.G.V.) has no mechanical adjustment of the gas air ratio, however it does have inlet and
burner pressure tapping points.
It is 24vDC and the connection is to the P.C.B. via the front connection. If this connection is faulty E09 will be displayed.
The EGV has two safety valves, the first is an ON/OFF solenoid and the second is used as safety but also to control the
outlet gas flow depending upon the signal from the P.C.B. This second valve also controls the outlet gas pressure.
The outputs on the connector both on the P.C.B. and E.G.V. are extremely difficult to measure with a multi-meter, so it is
advisable not to measure this signal.
Disconnecting the lead and checking the plug will result in an E09 error.
If the boiler keeps going to E133 and you have checked all components and done a re-calibration, then it is possible the gas
valve may not be fully opening upon Ignition.
Change the Valve and do a re-calibration (page 11).
Resistances for the two coils
Pins 1 + 3 = 20 – 30 Ohms
Pins 2 + 4 = 60 – 70 Ohms
Ionization Gap
The ionization electrode is unique to the GA system and it is important to maintain the correct distance from burner to the
parallel section of the electrode.
The distance should be 5mm +- 1mm. If it is out of this tolerance, the combustion may be compromised by the settings of
the E.G.V. so install a new electrode and perform a re-calibration as described on page 11.
22
15.0 Hydraulics
Neta-tec Combi GA
Pressure Sensor
D.H.W. Cartridge
(Turbine Type)
D.H.W. Sensor
Diverter Valve
Cartridge
P.R.V.
D.H.W. Hall
Effect Sensor
Pressure Gauge
Connection
(incorporates
return filter)
Diverter Valve
Head
The Neta-tec GA hydraulics are of a composite construction
• The D.H.W. Flow Switch is a Turbine Type Design
• There is a bypass built into the two bodies connected by a clip on the front.
• Behind the Pressure Gauge there is an inline filter cage.
• The pump is 2 speed operational. In D.H.W. it operates only at Max speed. In C.H. it switches between the two speeds
depending upon temperature loadings to maintain the boiler in condensing mode.
23
15.0 Hydraulics (cont.)
Duo-tec 2 Combi GA
Pressure Gauge
Connection
D.H.W. Hall
Effect Sensor
Pressure Sensor
D.H.W. Cartridge
(Turbine Type)
The Duo-Tec 2 GA hydraulics are of brass construction similar to older products.
• The D.H.W. Flow Switch is a Turbine Type
• The Pressure Sensor measures the pressure and is not a switched type
• The connection for the Pressure Sensor has an adaptor to take the clipped connection
• The capillary pressure gauge connection is on the flow assembly above the D.H.W. sensor position
• The Pressure Vessel connection is on the return assembly above the drain point
• The bypass is integral and utilises the plate heat exchanger
24
Pressure Vessel
Connection
15.0 Hydraulics (cont.)
Megaflo 2 System GA
Pressure Sensor
Pressure Vessel
Connection
Bypass
Pressure Gauge
Connection
The Megaflo 2 GA hydraulics are of a composite construction.
Key components are the same as the Neta-tec Combi GA and the connection points for the pressure gauge and pressure
vessel are the same.
25
16.0 Internal Wiring
Neta-tec Combi GA
Gas
Valve
Hall Effect
Sensor
Fan
M2
Low Voltage
External Control
Connection
Flue Sensor
Hydraulic
Pressure
Switch
Safety
Thermostat
b
b
bk
w
br
From X20
& X31
r
g
b
g
b
b
X3
bk
br
X23
b
b
br bk
Terminal Strip
r
bk
br
X37
w
g br
b
X36
g
r
b r
g
X22
X20
X24
X10
g/y
b
b
br
X13
b
bk
br
To M2
Connection
X31
bk
bk
b
br
br
X11
br
bk
g/y
gr
X12
X1
X2
g/y
g/y
g/y
Pump
Diverter Valve
Motor
26
Heating
Flow
Sensor
DHW
NTC
Sensor
bk
b
Heating
Return
Sensor
Spark
Ignition
Electrode
Flame
Sensing
Electrode
16.0 Internal Wiring (cont.)
Duo-tec 2 Combi GA
Gas
Valve
Fan
Hall Effect
Sensor
M2
Low Voltage
External Control
Connection
Flue Sensor
Hydraulic
Pressure
Switch
Safety
Thermostat
Heating
Return
Sensor
b b
bk
w
Heating
Flow
Sensor
bk
b
br
DHW
NTC
Sensor
bk
br
From X20
& X31
b
X3
bk
br
Terminal Strip
r
r
b
g
br bk
X23
b
b
b
X37
g
w
g br
X36
b
g
r
b r
g
X22
X20
X24
X10
g/y
b
b
br
X13
bk
r
To M2
Connection
b
bk
bk
b
br
br
X11
X31
br
bk
g/y
gr
X12
X1
X2
g/y
g/y
g/y
Pump
Spark
Ignition
Electrode
Flame
Sensing
Electrode
Diverter Valve
Motor
27
16.0 Internal Wiring (cont.)
Megaflo 2 System GA
Gas
Valve
Fan
M2
Low Voltage
External Control
Connection
Flue Sensor
Hydraulic
Pressure
Switch
Safety
Thermostat
Heating
Return
Sensor
b b
b
w
br
bk
X22
r
br
bk
X20
bk
b
b
g
br bk
X31
b
X3
bk
X23
b
b
X37
w
g br
g
b
X36
r
b r
X22
X20
X24
w
Terminal
Strip
br
X10
g/y
b
b
To M2
Connection
b
br
br
br
X13
X31
bk
bk
b
br
X11
bk
g/y
gr
X12
X1
X2
g/y
g/y
g/y
Pump
28
g/y
Spark
Ignition
Electrode
Flame
Sensing
Electrode
Heating
Flow
Sensor
17.0 Electrical Measurements
Useful Electrical Measurements
All voltages for mains A.C. are taken from earth and the stated pin.
Function
PCB Conn.
Voltage
CH Demand
X3
Pin 1 (Blue)
Pump ON
X13
Pin 2 (Brown) 230v
X11
Pin 5 (Black)
225v Lo 260v Hi
(Pump runs at ‘Hi’ speed only in DHW, both speeds in CH)
Pressure Sensor
X22
230v
Between Pins 11 and 12 (red and white) 1 bar = 3v (approx)
Diverter Valve (CH) X13
Diverter Valve (DHW) X13
Pin 4 (Black) 240v
Pin 4 (Black) 0v
Pin 5 (Brown) 0v
Pin 5 (Brown) 240v
Fan ON
X11
X23
240v @ Pin 2
Full Power: Circa 8v DC between Black and Blue
DHW Hall Sensor
X22
ON between Pins 11 and 12 (Red + White) 1v
OFF between Pins 11 and 12 (Red + White) 0v
Between Pins 11 and 13 (Red + Blue)
5v constant
It is not advisable to measure at the smaller P.C.B. connections such as the Electronic Gas Valve as the voltages need to be
taken from the actual edge connector on the board and damage could easily occur.
Water Temperature Sensors
All the sensors use the same resistance/ temperature measurements.
The graph below can be used to establish an approximate measurement, but the important point is to ensure the resistance
reduces as temperature increases.
Temperature Sensors & Resistance
120
Temperature (°C)
100
80
Heat Exchanger
Sensor
60
Water
Sensors
40
20
0
0
2
4
6
8
10
12
14
16
18
20
Resistance (Ohms)
Both C.H. & D.H.W. sensors have the same resistance. The Heat Exchanger sensor has a different curve, but the
temperature/resistance curve is the same.
A further check can be made using the Information Menu as described on page 16. Even if the boiler is not operating the
temperatures can still be read in the Information Menu making it possible to check if a sensor is reading correctly.
29
18.0 Parts Matrix
30
E133
No
Is ‘000’ displayed on
first power up ?
Yes
Yes
Check electrode
gap, gas supply,
etc.
Any components
changed prior to
commissioning ?
No
E55 displayed
Change R.D.S. to
bypass
Commissioning
Function
Calibrate
(‘CH -ve’ &
‘Reset’, then ‘ip’)
Page 11
Mini-Calibrate
(‘CH -ve’ &
Page 8
Check electrode
gap, gas supply,
etc.
Check
combustion
levels whilst in
Calibration
Function (wait
until finished)
Calibrate
(‘CH -ve’ &
Page 11
When ‘000’
displayed start
Commissioning
(‘ip’ & ‘CH +ve’)
Complete
Change the Set
Flame to achieve
9.0% CO2 at all
fan speeds
Complete
312 completed
then Gas Check ?
19.0 E133 Flow Chart
31
32
Start
Press ‘ip’ &
‘CH +ve’ for
6 seconds
‘312’ will be
displayed for
7 minutes
*It is referred to as Mini-Calibration
when activated whilst still in
commissioning mode. Only the
ignition curve is set then
‘000’ displayed.
See page 8
‘000’
displayed
Check
electrode
gap, gas
supply, etc.
E133 or
other gas
error
displayed
No
Gas Type
check
starts
Yes
Yes
Mini-Calibrate
(‘CH -ve’ &
Page 8
In 3 to 4
minutes
‘NG’ or
‘LPG’ is
displayed
No
Boiler will find
an ignition
curve to ignite,
briefly display
‘100’ then stop
Mini-Calibration*
Check electrode
gap, gas supply,
etc.
Check boiler
temp has not
reached 85ºC
When ‘000’
displayed restart
commissioning
(‘ip’ & ‘CH +ve’)
Boiler
commissioned
20.0 Commissioning Procedure & Errors
21.0 Additional Information
Gas Recognition Fault
If the boiler incorrectly identifies the gas type and it cannot be cleared:• Accept the incorrect gas type
• Follow the procedure on page 15
• Select P02 (Gas Type) and change the type back to the correct one (‘00’ = N.G. & ‘01’ = L.P.G.)
• Press reset ‘R’ to escape, power down the electrical supply to the boiler then power up to re-boot and the boiler
will be set to work on the correct gas type
Set Flame Reference Guide - Calibration Mode
Use the values below to assist in setting the flame to the correct combustion leveles:-
Model
24C
28C
33C
40C
Set Flame Values
Fan Speeds
00
IGN
48
38
36
38
37
49
30
35
100
37
32
35
25
18S
24S
28S
33S
60
50
48
34
44
37
40
30
40
40
40
36
These values will closely achieve 9.0% CO2 at all speeds, which is the recommended combustion setting. If the value differs
by more than 10 from those above and the CO2 is not changing it is possible that re-circulation is occurring or there is an
outside influence affecting the combustion.
33
22.0 Notes
34
22.0 Notes
35
All descriptions and illustrations provided in this leaflet have been carefully
prepared but we reserve the right to make changes and improvements in
our products which may affect the accuracy of the information contained in
this leaflet. All goods are sold subject to our standard Conditions of Sale
which are available on request.
BAXI
A Trading Division of Baxi Heating UK Ltd (3879156)
Brooks House, Coventry Road, Warwick. CV34 4LL
After Sales Service 0844 871 1525 Technical Enquiries 0844 871 1555
Website www.baxi.co.uk
e&oe
Comp No. 7210507-01 (5/12)

C - Abacus Flame

Transcription

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