SERVICE SERVICE MANUAL COMPACT 3000 Mod. 3000 92X Mod. 3000 93X Mod.
GB Foreword This service handbook is intended to assist with servicing and fault-finding in caravans and motor caravans equipped with the Alde Compact 3000 92x-94x. The handbook may also be of assistance in ordering spare parts. It also provides general information on how Alde central heating systems are designed, and how they operate. When servicing components designed for LPG and 230 volts, national safety regulations must be adhered to.
GB Contents Page 3 4 5 5 6 6 7 7 7 8 8 8 8 9 9 9 10 10 10 Chap 1:0 1:1 2:0 2:1 3:0 3:1 About the Alde central heating system Care of the heating system About the Compact 3000 Technical data Fault-finding The electrical heating cartridge does not work 3:2 The LPG boiler does not start 3:2:1 The LPG boiler shuts down on start-up 3:2:2 No ignition spark 3:2:3 Ignition spark is generated but the boiler does not start 3:3 The LPG boiler starts but goes out after approx.
GB 1:1 Maintaining the heating system Check the heating system’s fluid level regularly in the expansion vessel. The level should be approximately 10 mm above the ”min” mark when the system is cold. The heating system should be filled with a mixture of water and glycol. For preference, use high quality pre-mixed glycol (with inhibitor) intended for use in aluminium heating systems. If using concentrated glycol, the mixture should consist of 60% water and 40% glycol.
GB 2:0 About the Compact 3000 The set-up of the boiler The boiler consists of three eccentrically-fitted pipes. The innermost pipe is a heat exchanger made from extruded aluminium. This is surrounded by a water jacket containing a 40% glycol mixture which is the fluid for the heating system. The fresh-water heater is located outside the water jacket. The two outer pipes, as well as their ends and connections, are made from stainless steel.
GB Be aware of the risks of 230 V during all service work 3:0 Faultfinding 3:1 The electrical heating cartridge does not work Cause: - Check that the changeover switches on the control panel are in the correct positions (see operating instruction for boiler). - The 12 V fuse has blown. - No or low voltage to the boiler. (< 12 V). - 230 volt not connected. - The overheating protection device has been triggered. - The thermostat is broken/damaged. - Damaged printed circuit board.
GB 3:2 The LPG boiler does not start Initial check: - Disconnect the ignition cable from the electronics box and start the boiler. The electronics box should make a clicking sound for about 10 seconds. If you can hear the clicking, continue to section ”3:2:3 Ignition spark is generated but the boiler fails to start”. 3:2:1 The LPG boiler shuts down on start-up ”Red LED comes on immediately” Cause: - Resetting time too short. - The pressure switch does not cut out. - Fault in electronic ignition unit.
GB 3:2:3 Ignition spark is generated but the boiler does not start Cause: - No or poor gas supply. - No or faulty spark on the spark electrode. - The solenoid valves do not open. - Faulty soft start valve. - Faulty electronic ignition unit. - Nozzle blocked. - Faulty wiring. - Flue blocked. Action: - Check that the gas pressure to the boiler is correct (2850 mbar). - Check that the ignition cable is intact and that there are no short-circuits along the cable.
GB 3:6 Sound from the burner Action: - Whistling sound from the burner on 92x-93x. Change to burner 3000 444. 3:7 Unstable or violent ignition Cause: - The exhaust/intake hoses are too short. - The exhaust/intake hoses are damaged or loose. - The exhaust cowl is blocked. - Incorrect gas pressure. - Blocked or faulty soft start valve. - Faulty nozzle. - Low spark frequency. - The pressure switch does not shut off or has stuck. - The solenoid valves are leaky.
GB 4:0 Replacing components Always switch off the 12 V DC and 230 V ~ power supply, and turn the main gas cock to the ”off” position before starting any servicing. 4:1 Replacing the printed circuit board The seals (marked in red) must NOT be broken unless special permission has been obtained from Alde. 4:2 Replacing fan 1.Remove the cover and service panel on the boiler. 2.Detach the blue (N) (fig. 7 A) and brown (R) (fig.
GB 4:3 Replacing a burner (older model for new model) When a fault occurs in the burner on boiler models no. 3000 921-926, the burner should be replaced with a new model (art nr 3000 385). 1. Remove the cover and end plate from the boiler. 2. Remove the end plate (fig. 10 A) on the burner housing. 3. Detach the spark electrode and sensor cables from the electronic ignition unit. 4. Using two spanners, detach the gas pipe between the burner and the solenoid valve at both connections (fig. 10 B).
GB 4:4 Replacing a burner (new model) 4:5 Replacing the spark electrode Applies to boilers with model no. 3000 927 or higher. 1. Remove the cover and end plate from the boiler. 2. Detach the spark electrode and sensor cables from the electronic ignition circuitry. 3. Using two spanners, unfasten the gas pipe nuts (fig. 14 A) at the burner and the solenoid valve (fig. 14 B). 4. Detach the end plate and burner by slackening the screws (fig. 14 C) on the burner housing. 5.
GB 4:7 Replacing the solenoid valve For boilers where the solenoid valve is fitted to the burner housing (up to serial no. 04444). 1. Remove the cover and end-plate on the boiler. 2. Unfasten the cables (black, brown and yellow/green) on the solenoid valve (fig. 17 A-C). 3. Using two spanners, slacken the nuts on the incoming gas pipe (fig. 18 A) and the gas pipe to the burner (fig. 18 B), and remove the rubber cap from the soft start valve (fig. 17 D). 4.
GB 4:8:1 Replacing a 1 kW heating cartridge 1. Drain the glycol mixture from the heating system. 2. Remove the cover and end plate. 3. Remove the cables from the heating cartridge. 4. Slacken the nut in the centre of the electrical heating cartridge electrode (fig. 21). 5. Give the t-screw on the heating cartridge a one-quarter turn (fig 22). 6. Extract the heating cartridge by pulling straight backwards (fig. 23). 7. Clean around the edges where the old heating cartridge has been located. 8.
GB 4:8:2 Replacing a 2 kW heating cartridge 1. Switch off the 230 V supply. 2. Drain the glycol mixture from the heating system. 3. Remove the cover and end plate. 4. Remove the solenoid valve in accordance with section 4:7. 5. Remove the cables from the heating cartridge. 6. Unscrew the two plate screws and remove the angle bracket (does not apply to boilers with serial numbers of 4445 or higher). 7. Slacken the nut in the centre of the electrical heating cartridge electrode (fig.
GB 4:9 Replacing the operating thermostat 4:10 Replacing the overheating protection device 1. Remove the cover on the boiler. 2. Remove the locking clip (fig. 28 A). Remove the split pin (fig. 24 B) on the immersion pipe. Remove the overheating protection device sensor first (fig. 29), and then the operating thermostat sensor (fig. 30 A). 3. Unscrew the two screws which secure the operating thermostat (fig. 31 A) to the fastening plate, and remove the cables from the flat-pin connections. 4.
GB 4:11 Replacing the pressure switch 1. Remove the cover and end-plate from the boiler. 2. Detach the blue, white and red cables on the pressure switch. 3. Push back the metal securing plate and pull out the pressure switch (fig. 32 A). 4. Detach the rubber hoses (fig. 32 B) from the pressure switch (do not pull the hoses, unscrew them). 5. Refit the hoses to the new pressure switch before pushing it into place. 6.
GB 6:0 Wiring diagram with control panel 3000 266 18
GB 6:1 Wiring diagram with control panel 3000 380 19
GB 6:2 Wiring diagram for 3000 465 A, B A. B.
GB 6:3 Circuit diagram 12 V and 230 V~ 6:4 Control panel 3000 465 6:5 Flow chart 230 V~ 21
GB 7:0 Exploded diagram 1 2 5 47 6 56 2 55 54 7 4 8 7 6 53 3 9 10 11 14 12 8 13 57 52 20 19 17 18 26 24 23 25 45 30 31 32 33 59 44 43 22 29 51 49 48 2 35 42 41 40 34 39 36 37 38 2 22 21 28 50 47 46 15 2 27 47 16
GB 7:1 Article numbers for exploded diagram 1. 3000 133 Metal cover 2. 2900 258 Self-tapping screw B6 x 9.5 3. 3000 195 Fan compl. (for 921) 3000 452 Fan compl. (for 92x and 93x) 3000 409 Fan compl. (for 94x) 4. 3000 247 Insulation 5. 3000 411 Hose connection compl. 6. 3000 372 Double clip 7. 3000 297 Rubber cap 8. 3000 324 Double clip 9. 2930 414 Sleeve 10. 3000 196 Rubber hose, L=190 mm 11. 3000 196 Rubber hose, L=55 mm 12. 3000 196 Rubber hose, L=125 mm 13. 3000 196 Rubber hose, L=110 mm 14.
GB 8:0 Reservdelar 3 3 2 1 1 4 2 1. 3000 195 Fan complete (12 V for 3000 901-921) 2. 3000 452 Fan complete (9 V for 3000 92x-93x) 3. 3000 409 3000 452 Fan complete (9 V for 3000 94x) Packed in cardboard box with Allen key for impeller. 1. 3000 231 2. 3000 168 3. 3000 289 4. 3000 278 3000 385 Burner compl. (for 92x-93x)(Ø 1.8 mm net) 3000 408 Burner compl. (for 94x)(Ø 2.0 mm net) 3000 407 Ignition kit incl.
GB 8:0 Reservdelar 3 2 1 4 2 3 4 5 6 1 7 1. 2. 3. 4. 5. 3000 286 3000 280 3000 367 3000 184 3000 330 3000 333 Mains supply cable Cable Wiring loom Wiring loom Printed circuit board (921) Printed circuit board (92x-94x with 3 kW heating cartridge 3000 334 Printed circuit board (92x-94x with 2 kW heating cartridge 6. 3000 232 Spacer 7. 2762 125 Cable clamp 1. 3000 365 Operating thermostat ”lmit” including retaining clip 2. 3000 327 Spring 3. 4071 011 Retaining clip 4.
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