Advanced Heating Technologies b.v. Wall hung, fan flue, room sealed, high efficiency gas boiler TROUBLE SHOOTING MANUAL EN Models: 15B 15C 30B 30C 30K 40C TWIN80C (partly) COOPRA Advanced Heating Technologies b.v.
Trouble shooting manual EN E000129004 Table of contents 1. Overall information 1.1. 1.2. 1.3. 1.4. 1.5. 1.6. 1.7. 1.8. Overall view……………………………………..………………. 3 Hydraulic diagram Nomenclature……………………………………….………….. 4 Cover removal Emptying the main circuit Emptying the d.h.w. circuit Control panel Condensate trap route…………………………………….. 5 3.12. 1 1 1. 2 2 2. 3 4 4 4. 5 6 7 8 9 9 A A A/C. A/d. A/b. b/r 2. Checks, servicing and replacement of components 2.1. 2.2. 2.3. 2.4. 2.5. 2.6. 2.7. 2.8. 2.9. 2.10. 2.11.
Trouble shooting manual EN E000129004 Chapter 1: Overall information 1.1. Boiler types 80C, 40C, 30K, 30B, 30C, 15B, 15C Combi boiler 30K TWIN80C 1.2.
Trouble shooting manual EN E000129004 1.3. Nomenclature 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. 1 2 4 3 Fig 4 Fig 2 1 2 3 4 1.5. Emptying the main circuit Frame Cover Control panel Control panel cover 1.4. Cover removal 1. Open the c.h. flow and return valves. 2. Open the control valve used for the filling of the c.h.
Service manual E000129004 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.
Service manual E000129004 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.
Service manual E000129004 2.2. Burner 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). F Removal of the burner assembly Warning: isolate the boiler from the mains electricity supply before removing any covering or component. E 1 2 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).
Service manual E000129004 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.
Service manual E000129004 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). 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.
Service manual E000129004 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 c.h. system or from the d.h.w. heat exchanger towards the pump and the main heat exchanger. Heating position Hot water position 30K Fig. 23 If the valve is complete the resistance measured will be approx. 8 kOhm. Fig.
Service manual E000129004 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. Type 30K coopra Fig. 26 7 Remove the motor (see section Removal of the motor).
Service manual E000129004 2.9. C.h. pressure relief valve F Removal F Removal Warning: isolate the boiler from the mains electricity supply before removing any covering or component. 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.
Service manual E000129004 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.
Chapter 3: FAULT FINDING Burner state stand-by pre-rinse/pre-heat glowpluignition in operation 0 sec 12 sec post-rinse pump afterrun stand-by heat demand fan gas valve glow plug ionisation pump 3 sec 7 sec 22 sec end of heat demand 0 sec 6 sec Pump 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.
Static pressure monitoring The 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 (Fan off - Gas valve off - Glow plug off - Ionisation off) 3.
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). A = Status B = Reading C = “+” button D = “-“ button E = Set/Reset F = Flame This boiler is in stand-by mode, waiting for heat demand.
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 pump test program), the boiler is doing a temperature test. The flow sensor must rise by 3°C more than the return sensor, within the first 20 seconds. if the difference is not made, the boiler will make a re-start.
if during operation the ionisation fails, the gas valve shuts off, and restart is made. If this failure causes a third restart within one burner demand, the boiler runs into lock-out.
mostly, a printed circuit board component is broken. internal communication error 3 flashing internal error internal regulation fault software problem interrupt the supply power hard-ware component broken replace printed circuit board software problem check wiring and connections hard-ware component broken check why frost protection fails and repair this.
If the measured fan speed, during initialising, exceeds the maximum fan speed, the regulation blocks. After 1 minute the boiler runs into lock-out. If the measured fan speed, in operation, deviates from the desired fan speed, the burner will be switched off, and post-purge will start. If this blocking action lasts for more than 1 minute, the boiler runs into lock-out.
If a false flame signal is detected with closed gas valve for more than 5 seconds, the boiler runs into lock-out. the boiler may not have an ionisation signal when burner is off.
If the flue gas sensor exceeds a temperature of 105°C, the boiler runs into lock-out extreme high flue gas temperature A flashing flue gas limiter lock-out ( 105°C) Find the cause of this flue gas limiter lock-out, because previously: a). The burner was off at 100°C b). The burner was on low load at 90°C interrupt the supply power The powering up of the supply voltage makes the flue gas sensor active. If the flue gas sensor exceeds a temperature of 100°C, the burner is blocked.
b/r continuous TWIN HWS right unit Chimney sweeper function Start the chimney sweeper fuction by pressing the + and - buttons of the display simultaneously for at least 5 to 10 seconds. The chimney sweeper function overruns the central heating regulation (not hot water regulation). The status shows a flashing C and the two right segments show the ionisation current in microamperes DC.
C = heat demand heating d = heat demand for hot water combi-boiler b = heat demand for hot water external cylinder heat demand No dot indication, burner is off C or d or b continuous burner is off caused by 3 minutes anti-cycling counter burner starts automatically Pump is on Fan is on Burner is off J continuous TWIN heat demand C continuous high flow or return sensor temperature ( 93°C) burner is off, blocked by maximum flow- or return temperature block removes automatically when the flow tempe
C. = heat demand heating d. = heat demand for hot water combi-boiler b. = heat demand for hot water external cylinder heat demand The dot indicates the burner is on. at the end of heat demand, the contacts of the green connector, ports 1 and 2, are open. end of heat demand ( Heating) software or hard-ware problem, the boiler runs into lock-out for safety reasons internal interlock fault C. or d. or b. continuous boiler is in heating mode burner modulates, depending the amount of heat required.
At each burner start, while the fan runs on the ignition speed of 2700 rpm, the gas valve opens and a flammable gas/air mixture is supplied to the burner. The glow plug ignites the gas/air mixture at the surface of the burner. If there is insufficient ionisation current at the end of the safety time, a new start attempt will be made. After four failed consecutive start attempts, the boiler runs into lock-out.
If the flow sensor exceeds a temperature of 105°C, the boiler runs into lock-out high flow temperature H flashing flow sensor limiter ( 105°C) burner on test sensor (R=12 kOhm@25°C) replace flow sensor check water pressure replace pressure sensor flow sensor high temperature ( 105°C) burner off test sensor (R=12 kOhm@25°C) replace flow sensor check water pressure replace pressure sensor burner has to be restored by interrupting supply power If the flow sensor exceeds a temperature of 105°C, whi
once per hour is tested the difference between flow and return temperatures.
after each burner start the boiler is doing a pump test. The boiler is starting and stopping the pump and measuring both the dynamic and static system water pressures. water flow problem P continuous boiler does not pass pump test check water flow pump test repeating each 15 seconds The two right segments show the actual flow temperature install a differential bypass valve between flow and return Press the “+” button for 5-10 seconds, the status 8 comes up (water pressure) Read the pressures. a).
with water pressure between 0,2 and 0,5 bar, the burner is reduced to low load. The display shows alternately a code P with the actual operating status. low system water, pressure between 0,2 and 0,5 bar P/C. or P/d. or P/b.
Trouble shooting manual EN E000129004
Trouble shooting manual EN E000129004 2006 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.
